JP2006272128A - 塗布方法及び防眩性フィルムの製造方法 - Google Patents
塗布方法及び防眩性フィルムの製造方法 Download PDFInfo
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- JP2006272128A JP2006272128A JP2005094274A JP2005094274A JP2006272128A JP 2006272128 A JP2006272128 A JP 2006272128A JP 2005094274 A JP2005094274 A JP 2005094274A JP 2005094274 A JP2005094274 A JP 2005094274A JP 2006272128 A JP2006272128 A JP 2006272128A
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Images
Abstract
【解決手段】粒径1μm以上の粒子を0.5重量%以上含み、粒子の比重が塗布液より0.01g/cm3 以上大きく、粘度が10mPa・s以下の塗布液Fを、スロット16へ供給するマニホールド14とマニホールドと連通し塗布液を外部に吐出させるスロットとを内部に備えたスロットダイ12を使用して連続走行する可撓性支持体上に塗布する塗布方法である。塗布中は液供給口とット以外の開口を全て閉じて送液量の全量を可撓性支持体上に塗布し、塗布を一時中断させ、その間にマニホールド内の塗布液中の沈降粒子を除去し、その後、塗布を再開させる。
【選択図】 図2
Description
この際、マニホールド14へ塗布液Fを供給する液供給量と、マニホールド14から塗布液Fを引き抜く液引き抜き量とは、マニホールド14内全域の塗布液Fの流速が0.1mm/秒以上になるようにする必要がある。
次に、塗布液Fを塗布する工程における、粒子沈降への対処以外の留意点について説明する。光学フィルムの製造においては、上記の粒子沈降以外に、塗布液F中の微細な気泡により、スジ状欠陥、点状欠陥などの面状欠陥を生じやすい。以下の説明は、主に塗布液F中の気泡に対処するための留意点である。
更に、この溶液を孔径30μmのポリプロピレン製フィルタ(PPE−30、富士写真フイルム(株)製)でろ過してハードコート層の塗布液を調製した。
更に、この溶液に個数平均粒径1.99μm、粒径の標準偏差0.32μm(個数平均粒径の16%)の架橋ポリスチレン粒子(SX−200HS、綜研化学(株)製、比重1.05)を20g、80gのメチルエチルケトン100%溶媒に高速ディスパにて5000rpmで1時間攪拌分散し、孔径10μm、3μm、1μmのポリプロピレン製フィルタ(それぞれPPE−10、PPE−03、PPE−01、いずれも富士写真フイルム(株)製)にて順に濾過して得られた分散液29gを添加し、攪拌した後、孔径30μmのポリプロピレン製フィルタで濾過して防眩層用の塗布液を得た。
粒子濃度を3重量%、液粘度を5mPa・s、粒子材質をポリスチレン( 比重1.05、粒径1〜10μmの綜研化学(株)製SXシリーズ、粒径0.1μmと0.5μmのモリテックス(株)製粒子径標準粒子3000シリーズを使用。) の条件で行ったテスト結果を以下に示す。
粒子径が3μm、液粘度が5mPa・s、粒子材質がポリスチレン( 比重1.05) 、液と粒子との比重差が0.2g/cm3 の条件で、粒子濃度を変化させ、送液開始1時間後の塗布面状の点状欠陥数を確認した。結果を図8の表に示す。
粒子径が3μm、粒子濃度が3%、粒子材質がポリスチレン( 比重1.05) 、液と粒子との比重差が0.2g/cm3 の条件で、溶媒組成比とハードコート組成物の濃度を変化させることによって液粘度を変え、送液開始1時間後の塗布面状の点状欠陥数を確認した。結果を図9の表に示す。
粒子径が3μm、粒子濃度が3%、液粘度が5mPa・sの条件を固定して、溶媒組成比( メチルエチルケトン、シクロヘキサノン) と粒子材質( シリカ、PMMA、ポリスチレン) とハードコート組成物量を変化させることによって液と粒子との比重差を変え、送液開始1時間後の塗布面状の点状欠陥数を確認した。結果を図10の表に示す。
粒子径が3μm、粒子濃度が3重量%、液粘度が5mPa・s、粒子材質がポリスチレン( 比重1.05) 、液と粒子との比重差が0.2g/cm3 の条件で、3時間連続送液後に液排出口のコックを開いて液を排出した。その後コックを閉じて再送液・塗布を1時間行い、塗布面状の点状欠陥数を確認した。結果を図11の表に示す。
既述のハードコート層の上に、粒子径が3μm、粒子濃度が3重量%、液粘度が5mPa・s、粒子材質がポリスチレン( 比重1.05) 、液と粒子との比重差が0.2g/cm3 の液を、図2に示される反給液口から液を引き抜くスロットダイ12及び全量塗布型のスロットダイをそれぞれ使用して、24時間連続塗布を行い、塗布面状の点状欠陥数を比較した。
Claims (10)
- 粒径1μm以上の粒子を0.5重量%以上含み、該粒子の比重が塗布液より0.01g/cm3 以上大きく、粘度が10mPa・s以下の塗布液を、スロットへ供給するマニホールドと該マニホールドと連通し前記塗布液を外部に吐出させる前記スロットとを内部に備えたスロットダイを使用して連続走行する可撓性支持体上に塗布する塗布方法において、
塗布中は液供給口と前記スロット以外の開口を全て閉じて送液量の全量を前記可撓性支持体上に塗布し、
塗布を一時中断させ、その間に前記マニホールド内の前記塗布液中の沈降粒子を除去し、
その後、塗布を再開させることを特徴とする塗布方法。 - 塗布一時中断中に、前記スロット以外の開口から前記マニホールド内の前記塗布液を排出させ、前記マニホールド内の前記塗布液の線流速を10mm/s以上で10秒以上保持させる工程を含む請求項1に記載の塗布方法。
- 1時間以上、前記液供給口及び前記スロット以外の開口を閉じて前記マニホールド内に前記塗布液を存在させる請求項1又は2に記載の塗布方法。
- 前記ダイを塗布位置と異なる位置に置いて前記塗布液の流量を増加させる工程を含む請求項1〜3のいずれか1項に記載の塗布方法。
- 粒径1μm以上の粒子を0.5重量%以上含み、該粒子の比重が塗布液より0.01g/cm3 以上大きく、粘度が10mPa・s以下の塗布液を、スロットへ供給するマニホールドと該マニホールドと連通し前記塗布液を外部に吐出させる前記スロットとを内部に備えるスロットダイを使用して連続走行する可撓性支持体上に塗布する塗布方法において、
前記スロットダイの塗布液供給口と別位置に設けられた塗布液排出口より前記マニホールドに供給された前記塗布液の一部を引き抜くことにより前記マニホールド全域で前記塗布液の幅方向線流速を1mm/s以上にすることを特徴とする塗布方法。 - 前記可撓性支持体を塗布位置において回転部材に巻き掛けて支持するとともに、前記可撓性支持体の走行方向上流側の塗布ビードを減圧する、又は、下流側の塗布ビードを加圧する請求項1〜5のいずれか1項に記載の塗布方法。
- 前記スロットダイがエクストルージョンダイである請求項1〜6のいずれか1項に記載の塗布方法。
- 送液ポンプ以外の液排出手段を用いる請求項1〜7のいずれか1項に記載の塗布方法。
- 前記塗布液が防眩性粒子を含む請求項1〜8のいずれか1項に記載の塗布方法。
- 請求項9に記載の塗布方法を用いた防眩性フィルムの製造方法。
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JP2010005616A (ja) * | 2008-05-30 | 2010-01-14 | Toppan Printing Co Ltd | 塗布装置および塗布方法 |
JPWO2009001911A1 (ja) | 2007-06-28 | 2010-08-26 | ソニー株式会社 | 光学フィルムおよびその製造方法、並びにそれを用いた防眩性偏光子および表示装置 |
JP2012120980A (ja) * | 2010-12-08 | 2012-06-28 | Nitto Denko Corp | 塗布物の製造方法及び製造装置 |
JP2013127520A (ja) * | 2011-12-16 | 2013-06-27 | Dainippon Printing Co Ltd | 光学フィルムの製造装置及び光学フィルムの製造方法 |
JP2016504177A (ja) * | 2012-11-09 | 2016-02-12 | イリノイ トゥール ワークス インコーポレイティド | ナノファイバーを基体に塗布するシステム及び方法 |
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JPWO2009001911A1 (ja) | 2007-06-28 | 2010-08-26 | ソニー株式会社 | 光学フィルムおよびその製造方法、並びにそれを用いた防眩性偏光子および表示装置 |
JP2010005616A (ja) * | 2008-05-30 | 2010-01-14 | Toppan Printing Co Ltd | 塗布装置および塗布方法 |
JP2012120980A (ja) * | 2010-12-08 | 2012-06-28 | Nitto Denko Corp | 塗布物の製造方法及び製造装置 |
JP2013127520A (ja) * | 2011-12-16 | 2013-06-27 | Dainippon Printing Co Ltd | 光学フィルムの製造装置及び光学フィルムの製造方法 |
JP2016504177A (ja) * | 2012-11-09 | 2016-02-12 | イリノイ トゥール ワークス インコーポレイティド | ナノファイバーを基体に塗布するシステム及び方法 |
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