JP2007222723A - Coating film thickness control process of beltlike object by roll coater - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coating film thickness control process of a belt-like object by a roll coater which is capable of accurately calculating the application conditions when the thickness of a rubber lining of an applicator roll is 5-50 mm. <P>SOLUTION: The coating film thickness control process of the belt-like object comprises a step of controlling the coating film thickness in continuously applying the coating onto the transferring belt-like object 2 using the roll coater 1. The initial setting is conducted by calculating the application conditions that the coating film thickness M becomes the range of tolerance of the target film thickness using model formula including the relationship of the coating film thickness M, the spacing hma between the applicator roll 12 and the metering roll and the spacing has between the applicator roll 12 and the belt-like object 2. The application conditions are calculated by obtaining the value of h'ma and h's and then substituting the values of h'ma and h'as for hma and has in the model formula. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a coating film thickness control method when a coating material is continuously coated on a strip using a roll coater.

As a coating film thickness control method, for example, Patent Documents 1 to 3 show a method of simultaneously controlling a nip load and a touch load, and Patent Documents 4 and 5 control a nip load based on a past database. However, there is no description based on a specific control method or model formula.
Patent Document 6 reports a method in which model equations are described in detail. However, there are problems such as the thickness of the rubber lining of the applicator roll and the case where a mesh roll is used as the meter roll are not taken into consideration.

Patent Document 7 reports a method of controlling the film thickness by feeding back the value of the radiation film thickness meter and adjusting the push-in amount (nip load), but what is the condition of the roll coater? There is no way of thinking.
Patent Documents 8 and 9 report a method in which the influence of the rubber lining thickness is taken into account. However, since the coating model is based on an empirical formula, it is necessary to perform many experiments and is difficult to apply. There's a problem.
And in these prior art, when the thickness of the rubber lining of an applicator roll is 5-50 mm, there exists a malfunction that the conditions for coating with high precision cannot be calculated.

JP 58-6268 A Japanese Patent Publication No. 60-56553 Japanese Patent Publication No.62-41077 JP 58-166959 A Japanese Patent Publication No. 3-23225 Japanese Patent Laid-Open No. 5-220441 JP-A-9-99271 Japanese Patent Laid-Open No. 10-34067 JP-A-11-90310

  The present invention has been made in view of such a conventional problem. When the thickness of the rubber lining of the applicator roll is 5 to 50 mm, the coating condition can be accurately calculated. It is intended to provide a method for controlling the coating film thickness.

The present invention has an applicator roll for transferring the coating material to the belt-like body, and a meter roll for supplying the coating material to the applicator roll, and a rubber having a thickness b (5 mm ≦ b ≦ 50 mm) on the outer periphery of the applicator roll. In a method of controlling the coating film thickness when continuously coating a moving strip using a roll coater provided with a lining,
A model formula consisting of the following formula 1 including at least the relationship between the coating film thickness M, the distance hma between the applicator roll and the meter roll, and the distance has between the applicator roll and the belt-like body When using the above-mentioned coating film thickness M to calculate the coating conditions within the tolerance range of the target film thickness M ₀ and performing the initial setting,
The above hma and has are obtained using the following formulas 2 and 3,
H'ma and h'as are obtained using the following equations 4 to 6,
A method for controlling the coating thickness of a roll coater, characterized in that h'ma is substituted for hma in the model equation and h'as is substituted for hs to calculate the coating conditions. (Claim 1).
Formula 1: M = (ρ · C / LS) · {[α (Va / Vm) ^β / (1 + α (Va / Vm) ^β )] · hma · (Va + Vm) / 2−λ · has · (Va−LS )}
Formula 2: hma = 3.10 · μ ^0.6 · Ema ^−0.4 · Rma ^0.6 · (Nma / L) ^−0.2 · [(Va + Vm) / 2] ^0.6
Formula 3: has = 3.10 · μ ^0.6 · Eas ^-0.4 · Ras ^0.6 · (Nas / W) ^-0.2 · [(Va-LS) / 2] ^0.6
Formula 4: h′ma = f (hma / 2b) · hma
Formula 5: h′as = f (has / 2b) · has
Formula 6: f (X) = A ₀ + A ₁ · X + A ₂ · X ² + A ₃ · X ³ +... + A _n · X ⁿ

  In the coating film thickness control method of the present invention, when the coating film thickness of the roll coater is controlled in consideration of the thickness of the rubber lining of the applicator roll, as described above, hma and has in the model formula consisting of Formula 1 above. These are replaced with h′ma and h′as shown in the above formulas 4 and 5. As a result, as shown in the examples to be described later, when the thickness of the rubber lining of the applicator roll is 5 to 50 mm, the coating conditions can be calculated with high accuracy. You can get the method.

  An applicator roll for transferring the coating material to the belt-like body and a meter roll for supplying the coating material to the applicator roll, and a rubber lining having a thickness b (5 mm ≦ b ≦ 50 mm) are provided on the outer periphery of the applicator roll. A roll coater is used. Further, a pickup roll may be combined before the meter roll. In this case as well, the present invention can be applied. In the present invention, when the thickness b of the rubber lining is less than 5 mm or more than 50 mm, the practical range is not considered.

A model formula consisting of Formula 1 above, including at least the relationship between the coating film thickness M, the spacing hma between the applicator roll and the meter roll, and the spacing has between the applicator roll and the strip. using, when the initial setting by calculating the coating conditions of the coating thickness M is within the tolerance range of the target thickness M _0, the hma, hAS is determined using equation 2 and equation 3 below. h'ma and h'as are obtained using the above equations 4 to 6, and h'ma is substituted for hma in the model equation and h'as is substituted for the above as well as the above coating. Calculate the conditions.

Since Equation 1 is used as the model equation, in the roll coater 1 composed of a meter roll 11, an applicator roll 12, and a backup roll 13, as shown in FIG. A method for controlling the coating film thickness in the reverse roll coating in which the talol 12 rotates can be derived.
The roll coater 1 is assumed to be uniform with no flow or distribution of the paint 3 in the band width direction.

The above formula 1 is obtained as follows.
First, the adhesion amount M after baking of the paint adhering to the surface of the belt-like body is expressed by the following formula 7.
Formula 7: M = qs · ρ · C / LS
here,
qs: Flow rate of paint adhering to the surface of the belt-like body per unit width [m ² / s]

On the applicator roll, qa is the flow rate of the paint flowing into the interface between the applicator roll and the strip, and qL is the flow rate of the paint remaining on the applicator roll through the applicator roll and the strip. Then, the qs becomes qs = qa-qL. Therefore, the above formula 7 becomes the following formula 8.
Formula 8: M = (qa−qL) · ρ · C / LS
here,
qa: paint flow rate [m ² / s] flowing into the interface between the applicator roll and the belt
qL: Flow rate of paint remaining on the applicator roll after passing between the applicator roll and the strip [m ² / s]

In addition, it is known that the flow rate qma [m ² / s] of the paint passing between the meter roll and the applicator roll (hereinafter referred to as the nip portion) is proportional to the average peripheral speed of both rolls according to the lubrication theory. . Therefore, qma is expressed by the following formula 9.
Formula 9: qma = hma · (Va + Vm) / 2

Since the paint that has passed through the nip portion is distributed to the meter roll and applicator roll, the relationship between the qma and the paint flow rate distributed to each of the meter roll and applicator roll is expressed by the following equation (10).
Formula 10: qma = qm + qa
here,
qm: Flow rate of paint remaining on the meter roll through the nip [m ² / s]

Also, the distribution of the paint to the meter roll and applicator roll at the nip portion is as described in H.C. It is known from the experiment of Benkreira et al. That the relationship of the following equation 11 holds.
Formula 11: qa / qm = α · (Va / Vm) ^β
From the above formula 10 and the above formula 11, the following formula 12 can be obtained.
Formula 12: qa = [α (Va / Vm) ^β / (1 + α (Va / Vm) ^β ] · qma

Substituting the above equation 9 into the above equation 12, the following equation 13 is obtained for qa.
Formula 13: qa = [α (Va / Vm) ^β / (1 + α (Va / Vm) ^β ] · hma · (Va + Vm) / 2

On the other hand, the qL is expressed by the following formula 14 from the “Lubrication Handbook” edited by the Japan Lubrication Society.
Formula 14: qL = λ · has (V−LS)
By substituting Equation 13 and Equation 14 into Equation 8, Equation 4 can be obtained, which is a model equation including the relationship between the coating film thickness M, the hma, and the has.

The hma and the has are obtained by using the above formula 2 and the above formula 3.
In this case, the elastic deformation of the lubrication contact surface, which cannot be ignored when using a roll made of rubber for roll coating, reflects the distance hma between the applicator roll and the meter roll, and the applicator roll and the belt shape. An interval hass between the body and the body can be determined.

When a roll made of rubber is used for roll coating, it is a region called elastohydro-dynamic lubrication (EHL) in which the influence of elastic deformation of the lubricating contact surface appears, and the viscosity accompanying an increase in pressure Since the increase is considered to be a negligible region, it is treated as a soft EHL region of an isoviscous-elastic region. The formula for calculating the minimum film thickness of the line contact lubricated surface in the soft EHL region is expressed by the following formula 15 by Herrebrough using a dimensionless display group of Dowson-Higginson.
Formula 15: H = 3.10 · U ^0.6 · W ^−0.2
H is the film thickness, U is the speed, W is the dimensionless display of the load, and is dimensionless by the following equations 16-18.
Formula 16: H = h / R
Expression 17: U = (η · u) / (E · R)
Formula 18: W = w / (E · R)
here,
h: Film thickness [kg / m ² ]
w: Load per unit width [N]
u: Average flow velocity [m / s]
R: Equivalent radius [m]
η: Viscosity at atmospheric pressure [N · s / m ² ]
E: Equivalent elastic modulus [N / m ² ]

Substituting the above parameters into Equation 15 yields Equation 19 below.
Formula 19: h = 3.10 · η ^0.6 · u ^0.6 · E ^−0.4 · R ^0.6 · w ^−0.2
For this reason, the equations for obtaining hma and has become Equation 2 and Equation 3.

  The distance hma between the meter roll and the applicator roll and the distance has between the applicator roll and the belt-shaped body are values when the applicator roll is handled as a roll made of rubber. Therefore, the rubber lining thickness b of the applicator roll is not taken into consideration, and the hma and the has have an error from the actual values. Therefore, in consideration of the rubber lining thickness b of the applicator roll, the thickness of the rubber lining of the applicator roll is 5 to 50 mm by using equations 4 to 6 and substituting h'ma and h'as. In addition, appropriate coating conditions can be obtained with high accuracy.

Equation 6 shows the influence of the rubber lining b on the contact width. In a contact state between a rubber roll (roll composed only of rubber) and a metal roll, a contact width when a force is applied between the rolls with a load W is defined as w ₀ . The contact width w ₀ is expressed by Equation 20 below.
Expression 20: w ₀ = {16 · W · Rma · (1−ν _m )} ^1/2
Rolls obtained by coating several rolls of rubber with thickness b _i on metal rolls are prepared, and the respective contact widths w _i are measured. From the measured contact width w _i , the relationship of (w ₀ / 2b _i , w _i / w ₀ ) is obtained, and polynomial approximation is performed using the following equation (21).
Equation _{21: (wi / w 0)} = f (w 0 / 2b i) = A 0 + A 1 · (w 0 / 2b i) + A 2 · (w 0 / 2b i) 2 + ···· + A n · (W ₀ / 2b _i ) ⁿ
This method is described in G.H. J. et al. This is the same method as the experimental result (1957) conducted by Parish et al.
Coefficients A _0, A _1, A ₂ of the formula 21, ..., determine the A _n.
Since the contact width (nip width) changes due to the elasticity of the rubber, when the width w _i increases, the surface pressure decreases, so the gap between the rolls also increases. Accordingly, the same correction is performed by replacing the contact width w _i with the gap between the rolls. That is, h'ma = h (hma / 2b) and h'as / has = f (has / 2b) are replaced with h'ma = f (hma / 2b) · hma and h'as = f ( The gap between the rolls is corrected by elastic rubber deformation as has / 2b) .has.

  After obtaining hma and has using the above formulas 2 and 3, h'ma and h'as are obtained by the above formulas 4 to 6, and then these values are replaced with hma and has in the model formula of formula 1. Thus, the present invention can be implemented.

In calculating the coating conditions using the above equations 1 to 6, the value of M is changed while sequentially changing the values of Vm and Nma on the assumption that initial fixed values are input to values other than Vm and Nma. An appropriate combination selection step for calculating and finding an appropriate combination of Vm and Nma in which the value of M is within the tolerance of the target film thickness M ₀ ;
It is preferable to include a condition determining step of selecting an optimum combination including the maximum Nma from the appropriate combination and setting the condition including the Vm and Nma as the coating condition.

First, the selection step will be described.
As described above, values other than Vm and Nma are set as initial fixed values.
Vm and Nma are operation amounts. For example, Nma is a main operation amount, and Vm having high operation sensitivity is appropriately used as a secondary operation amount.
The initial fixed value includes various names such as a fixed condition value, a fixed set value, an initial value of Va, a paint viscosity, and an actually measured value of the concentration, as will be described later in Examples.
Among the above-mentioned initial fixed values, those using measured values can be measured and reflected at any time even after the start of painting by applying a densitometer, viscometer, etc. to the paint circulation system. It is.
The fixed condition values include M ₀ , LS, Ra, W, and the like, and the fixed set values include Rm, Vcc, Vm _max , Vm _min , ΔVm, ΔNma, and the like.

First, initial fixed values other than the above Vm and Nma are input to Equations 1 to 6, and Nma is increased or decreased for each Vm _i (i = 1 to n) obtained by dividing n between Vm _{max and} Vm _min. Then, the value of the coating film thickness M is calculated. Until the value of M asymptotically approaches the target film thickness M ₀ , Nma is sequentially increased or decreased to converge the value of M to M ₀ , and an appropriate combination of Vm and Nma giving the target film thickness M ₀ is obtained. Ask.

Next, the condition determining step will be described.
Vm has a restriction that a value obtained by adding a safety margin to the maximum speed at which the paint scatters due to centrifugal force is set as a limit speed Vm _max . Further, the above Nma has a restriction that a value obtained by multiplying the maximum load of the apparatus performance by the safety factor is the limit load Nma _max . Further, there is a restriction that a value at which a load can be safely applied is a minimum load Nma _min .
Under the constraints of the Vm and Nma, from among appropriate combinations of Vm and Nma exhibiting target thickness M ₀ obtained by the above selection steps, obtaining coating conditions including the optimum combination Nma is maximized.

In addition, when all appropriate combinations of Vm and Nma exhibiting the target film thickness M ₀ do not satisfy the constraints of Vm and Nma, Va is incremented and the appropriate combination of Vm and Nma is similarly calculated. The process is repeated until the appropriate combination of Vm and Nma that exhibits the target film thickness M ₀ falls within the appropriate range of Vm and Nma. Thereafter, similarly, the coating conditions including the optimum combination that maximizes Nma are obtained.

  In the condition determining step, a curve with Vm and Nma on the horizontal and vertical axes is obtained based on the conditions of the appropriate combination, and the coating conditions are determined from the relationship between the curve and the appropriate range of Vm and the appropriate range of Nma. It is preferable to determine (Claim 3).

In this case, the appropriate combination of Vm and Nma can be quickly changed according to the situation by using the above curve.
The Nma penetrates the larger value of air bubbles and, because it is effective in removing, desirable, to obtain the target thickness M ₀ is always Nma does not need a maximum, a combination that is on the curve I just need it. Therefore, when there is a problem in quality, the target film thickness M ₀ can be obtained by using a condition that changes the curve.
The above curve is shown in FIG. The horizontal axis is Vm, and the vertical axis is Nma.

When using a mesh roll provided with a square pyramid or square pyramid-shaped depression having a diagonal of 0.2 to 1.0 mm and a depth of 50 to 500 μm on the surface as the above-mentioned meter roll, 1 m of the depression The volume per ² is Vcc [m ³ / m ² ],
Hma · (Va + Vm) / 2 in the above equation 4 is
It is preferable to replace with hma · (Va + Vm) / 2 + [1-kd · exp (kc · P)] · Vcc · Vm.
In this case, it is possible to accurately obtain the coating amount when a mesh roll is used as the meter roll.

  In the meter roll having a mesh, when the pressure applied to the nip portion between the meter roll and the applicator roll, the paint accumulated in the mesh groove is affected by the paint flow at the interface of the nip portion and decreases. Therefore, the term relating to the paint accumulated in the mesh groove is a function of the load. From the empirical rule that the effect becomes significant when the load exceeds a certain load due to the shape and rigidity of the rubber and metal mesh roll of the applicator roll, [1-kd · exp (kc · P)] Can be expressed as

Vcc is obtained by multiplying the number of meshes per unit volume by the volume per mesh, and corresponds to the average film thickness when the paint is filled in all the grooves.
That is, the paint flow rate that accumulates in the mesh groove applied to the meter roll and passes between the applicator roll and the meter roll can be expressed as [1-kd · exp (kc · P)] · Vcc · Vm. it can.
When this is corrected by adding to the paint flow rate hma · (Va + Vm) / 2 passing through the distance hma between the applicator roll and the meter roll in the model formula (1), the mesh roll is used as the meter roll. The coating conditions can be determined with high accuracy.

(Example)
The Example concerning the coating film thickness control method of this invention is described.
For the roll coater having the configuration shown in FIG. 1, two different types of paints are prepared, and the coating conditions for the target film thickness M ₀ are calculated according to the flowchart shown in FIG. Note that the flowchart shown in the figure is not a flowchart in a strict sense, but shows a simplified and rough flow.

  As shown in FIG. 1, the roll coater 1 in this example includes an applicator roll 12 that transfers the paint 3 to an aluminum alloy plate as a band 2, and a meter roll 11 that supplies the paint 3 to the applicator roll 12. Furthermore, the roll coater 1 of the present example includes a backup roll 13 that has a pickup roll 10 in front of the meter roll 11 and supports the band 2. In the model formula, the presence or absence of the pickup roll 10 is irrelevant.

In this example, the meter roll 11 has a Poisson's ratio ν _m = 0.29 and a longitudinal elastic modulus Em = 2.1 × 10 ¹¹ N / m ² .
The applicator roll 12 has a rubber lining b = 20 mm, a peripheral speed Va = 2.0 m / s, a Poisson's ratio ν _a = 0.48, and a longitudinal elastic modulus Ea = 7 × 10 ⁶ N / m ² .
The band 2 has a width W = 1 m, a line speed LS = 1.83 m / s, a Poisson's ratio ν _s = 0.33, and a longitudinal elastic modulus Es = 6.9 × 10 ¹⁰ N / m ² .
Further, the total touch load Nas is 2000 N, and the applicator roll / meter roll surface length L is 1.8 m.
Table 1 shows the type, viscosity, concentration, and specific gravity of the paint used for coating.

In calculating coating conditions, assuming that initial fixed values are input to values other than Vm and Nma, the coating film thickness M is calculated while sequentially changing the values of Vm and Nma, and the value of M is the target film. An appropriate combination selection step for obtaining an appropriate combination of Vm and Nma within the tolerance of the thickness M ₀ is performed. Thereafter, an optimum combination including the maximum Nma is obtained on the basis of the appropriate combination, and a condition determining step is performed in which the conditions including the Vm and Nma are set as the coating conditions.

Specifically, as shown in FIG. 2, first, in the selection step S1, in step S101, the fixed condition value, the fixed set value, and the Va initial value are input to Equations 1 to 6. As the Va initial value, a past actual value is set. As will be described later, the Va initial value is appropriately changed according to the result. ΔVm, which is the initial setting value, is (Vm _max −Vm) when Vm _i (i = 1 to n + 1) is given by dividing n between the limit speed Vm _max and the minimum speed Vm _{min. min} ) / n = ΔVm. Further, ΔNma that is the initial setting value may be set to 1/20 to 1/50 of the maximum capacity of the machine. In this example, it is about 200N. The value may be changed according to the calculation convergence accuracy.
Furthermore, in step S102, the paint viscosity μ and the concentration C are input from the actually measured values.

Next, in step S103, i = 1. Also, Vm _i = Vm _max + ΔVm is given as the initial value of Vm, and Nma _i = 0 is given as the initial value of Nma, which is input to Equations 1 to 6. In step S104, calculates a paint film thickness M using the equations 1 to 6, in step S105, the value of the painting thickness M it is determined whether there are more than the upper limit of the tolerance range of the target thickness M _0.

If paint thickness M is greater than or equal to the upper limit of the tolerance range of the target thickness M ₀ in step S106, the value of the Nma _i type by replacing the Nma _i + ΔNma, tolerance of the M, the target thickness M ₀ Steps S104 to S106 are repeated until the upper limit of the range is reached. When the value of the coating thickness M is determined to be less than the upper limit of the tolerance range of the target thickness M ₀ in S105, in step S107, whether the coating thickness M is within the tolerance range of the target thickness M ₀ Judging.

If the coating film thickness M is outside the tolerance range of the target film thickness M ₀ , Nma _i is replaced with Nma _i · ΔNma / 4 in step S108 and input, and in step S109, equations 1 to 6 are used. The value of M is calculated. Until the coating thickness M is within the tolerance range of the target thickness M _0, repeat steps S107 to S109. When paint thickness M in the step S107 is determined to be within the tolerance range of the target thickness M _0, in step S110, it is stored in the table the value of Vm _i and Nma _i as a proper combination.

Next, in step S111, it is determined whether i is larger than n + 1. If i ≦ n + 1, i is replaced with i + 1 in step S112, and Vm _i = Vm _i−1 −ΔVm and Nma _i = 0 are set. Input, and repeat steps S104 to S112 until i exceeds n + 1. If it is determined in step S111 that i> n + 1 (Vm _i = Vm _min ), in step S113, based on a plurality of appropriate combinations stored in the table, as shown in FIG. Is a Vm-Nma curve based on n + 2 points a in an appropriate combination (hereinafter referred to as an appropriate combination curve).

Then, in the condition determination step 2, it is determined in steps S201 and S202 whether there is a region of the obtained appropriate combination curve in the appropriate range of Vm and Nma (specifically, determination is made using FIG. 4 described later). can do). In step S202, if there is no shared area between the appropriate range area and the appropriate combination curve, Va is replaced with Va + ΔVa in step S203, and the selection steps S103 to S203 are performed in step S202. And until the curve has a shared area. The ΔVa may be about 1/4 to 1/10 of the difference between LS and Va given empirically. In this example, it was set to 0.01 m / s. The value may be changed according to the calculation convergence accuracy.
If it is determined in step S202 that there is a shared area of the appropriate range area and the appropriate combination curve, in steps S204 and S205, the combination of Vm and Nma that maximizes Nma is determined and set as the optimum combination. Thereafter, in step S206, the condition including the optimum combination is automatically set as the coating condition.

According to the above procedure, the optimum combination when the target film thickness M ₀ = 13 μm was obtained for two different types of paints (paint A and paint B). The results for paint A are shown in FIG. 4, and the results for paint B are shown in FIG.

First, the paint A will be described.
In FIG. 4, the horizontal axis represents the meter roll peripheral speed Vm, and the vertical axis represents the applicator roll / meter roll load Nma. _A region S _A indicates a region that is an appropriate range of Vm for the coating material A and an appropriate range of Nma. Curve K shows the proper combination of paint A.
As is known from FIG. 4, the paint A has a minimum load Nma _min and a minimum speed Vm that are below the limit load Nma _max and the limit speed Vm _max among the points on the curve K obtained at the empirical standard value Va. in _min or more regions S _a, a point Nma is maximum is determined as the optimum combination.

Next, the paint B will be described.
In FIG. 5, the horizontal axis represents the meter roll peripheral speed Vm, and the vertical axis represents the applicator roll / meter roll load Nma. Regions S _B denotes a region that is appropriate range and proper range of Nma of Vm for coating B. A curve L indicates an appropriate combination of the paint B.
As can be seen from FIG. 5, the paint B has a minimum load Nma _min and a minimum speed Vm that are below the limit load Nma _max and the limit speed Vm _max among the points on the curve L obtained at the empirical standard value Va. in _min or more regions S _B, B point Nma is maximum is determined as the optimum combination.

  Next, coating conditions including the optimum combination determined by the above procedure were applied, and the strip 2 was coated using the roll coater 1 shown in FIG. The paint A was used as the paint 3, the paint 3 was supplied to the applicator roll 12 by the meter roll 11, and the paint 3 was transferred to the strip 2 by the applicator roll 12. And the actual coating film thickness after baking was measured.

In addition, the coating conditions were similarly calculated and measured for a plurality of target film thicknesses.
In addition, FIG. 6 shows the relationship between the target film thickness and the actual coating film thickness measurement value for the measurement results obtained by applying the calculated coating conditions. The horizontal axis is the target film thickness, and the vertical axis is the measured coating film thickness.

The coating B was also carried out in the same manner as the coating A. The results are shown in FIG. The horizontal axis is the target film thickness, and the vertical axis is the measured coating film thickness.
As known from FIGS. 6 and 7, in this example, the coating conditions can be calculated with high accuracy, and the coating film thickness of the belt-like body by the roll coater can be controlled.

(Comparative example)
In this example, the coating conditions calculated using the model formula described in Japanese Patent Laid-Open No. 5-220441 were applied using the coating material A prepared in the above example. Specifically, the thickness of the rubber lining at the outer peripheral portion of the applicator roll is not taken into consideration, and the process of replacing hma and has with the h′ma and h′as as in the present invention is not performed.
The result of the comparative example is shown in FIG. The horizontal axis is the target film thickness, and the vertical axis is the measured coating film thickness. As can be seen from FIG. 8, it can be seen that the target film thickness and the actually measured coating film thickness are not only absolutely deviated, but also have large variations.

The schematic block diagram of the roll coater in an Example. The flowchart which shows the condition calculation procedure in an Example. Explanatory drawing which shows the Vm-Nma curve of an appropriate combination. Explanatory drawing which shows the optimal combination of the coating material A in an Example. Explanatory drawing which shows the optimal combination of the coating material B in an Example. Explanatory drawing which shows the relationship between the target film thickness at the time of using the coating material A in an Example, and a film thickness actual value. Explanatory drawing which shows the relationship between the target film thickness at the time of using the coating material B in an Example, and film thickness actual value. Explanatory drawing which shows the relationship between the target film thickness and film thickness actual value in a comparative example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Roll coater 10 Pickup roll 11 Mitter roll 12 Applicator roll 13 Backup roll 14 Nip part 2 Band-shaped body 3 Paint

Claims (4)

An applicator roll for transferring the paint to the belt-like body and a meter roll for supplying the applicator roll with the paint, and a rubber lining having a thickness b (5 mm ≦ b ≦ 50 mm) are provided on the outer periphery of the applicator roll. In the method of controlling the coating film thickness when continuously coating the moving strip using a roll coater,
A model formula consisting of the following formula 1 including at least the relationship between the coating film thickness M, the distance hma between the applicator roll and the meter roll, and the distance has between the applicator roll and the belt-like body When using the above-mentioned coating film thickness M to calculate the coating conditions within the tolerance range of the target film thickness M ₀ and performing the initial setting,
The above hma and has are obtained using the following formulas 2 and 3,
H'ma and h'as are obtained using the following equations 4 to 6,
A method for controlling a coating film thickness of a roll coater, wherein the coating condition is calculated by substituting h'ma in place of the hma in the model formula and substituting the h'as in place of the has.
Formula 1: M = (ρ · C / LS) · {[α (Va / Vm) ^β / (1 + α (Va / Vm) ^β )] · hma · (Va + Vm) / 2−λ · has · (Va−LS )}
Formula 2: hma = 3.10 · μ ^0.6 · Ema ^−0.4 · Rma ^0.6 · (Nma / L) ^−0.2 · [(Va + Vm) / 2] ^0.6
Formula 3: has = 3.10 · μ ^0.6 · Eas ^-0.4 · Ras ^0.6 · (Nas / W) ^-0.2 · [(Va-LS) / 2] ^0.6
Formula 4: h′ma = f (hma / 2b) · hma
Formula 5: h′as = f (has / 2b) · has
Formula 6: f (X) = A ₀ + A ₁ · X + A ₂ · X ² + A ₃ · X ³ +... + A _n · X ⁿ
here,
M: Amount of paint applied per unit area of strip (after baking) [kg / m ² ]
ρ: Coating film density [kg / m ³ ]
C: Concentration LS: Line speed [m / s]
Va: Applicator roll peripheral speed [m / s]
Vm: Mitaroll peripheral speed [m / s]
hma: Distance between the meter roll and applicator roll [m]
has: distance between the applicator roll and the belt [m]
α: partition coefficient [= 0.87 (Newtonian fluid), = 0.99 (non-Newtonian fluid)]
β: partition coefficient [= 1.65 (Newtonian fluid), = 1.54 (non-Newtonian fluid)]
λ: leak coefficient [= 0.63 (Newtonian fluid), = 0.69 (non-Newtonian fluid)]
μ: Paint viscosity [N · s / m ² ]
Ema: Equivalent longitudinal elastic modulus [N / m ² , 2 / Ema = (1−ν _m ² ) / Em + (1−ν _a ² ) / Ea]
Rma: Applicator roll / Metaroll equivalent radius of curvature [m]
Nma: Load between applicator roll / meter roll (hereinafter referred to as total nip load) [N]
Nas: Applicator roll / band-to-band load (hereinafter referred to as total touch load) [N]
L: Applicator roll / meter roll surface length [m]
Eas: Equivalent longitudinal elastic modulus [N / m ² , 2 / Eas = (1−ν _a ² ) / Ea + (1−ν _s ² ) / Es]
Ras: Applicator roll / band-like body equivalent radius of curvature [m]
W: Band width [m]
ν _m : Poisson's ratio Em of the meter roll material Em: Longitudinal elastic modulus of the meter roll material [N / m ² ]
ν _a : Poisson's ratio of applicator roll rubber material Ea: Longitudinal elastic modulus of applicator roll rubber material [N / m ² ]
ν _s : Poisson's ratio of the belt-like body Es: Longitudinal elastic modulus [N / m ² ] of the belt-like body In claim 1, in calculating the coating conditions using the above equations 1 to 6, the values of Vm and Nma are sequentially changed on the assumption that an initial fixed value is input to a value other than Vm and Nma. Calculating a value of M, and selecting an appropriate combination for obtaining an appropriate combination of Vm and Nma in which the value of M is within the tolerance of the target film thickness M ₀ ;
A coating film thickness control for a roll coater, comprising: selecting an optimum combination including the maximum Nma from the appropriate combinations, and a condition determining step using the conditions including the Vm and Nma as the coating conditions. Method.   3. The condition determining step according to claim 2, wherein a curve having Vm and Nma on the horizontal and vertical axes is obtained based on the conditions of the appropriate combination, and the relationship between the curve and the appropriate range of Vm and the appropriate range of Nma. A coating film thickness control method for a roll coater, characterized in that the coating conditions are determined from: The mesh according to any one of claims 1 to 3, wherein the metha roll is provided with a square pyramid or square pyramid-shaped depression having a diagonal of 0.2 to 1.0 mm and a depth of 50 to 500 µm on the surface thereof. In the case of using a roll, the volume per 1 m ^{2 of the} dent is Vcc [m ³ / m ² ],
Hma · (Va + Vm) / 2 in the model formula 1 above,
hma · (Va + Vm) / 2 + [1-kd · exp (kc · P)] · Vcc · Vm (where P is the surface pressure per unit width; P = Nma / L [N / m], A method of controlling the coating film thickness of a roll coater, wherein kc and kd are replaced with coefficients).

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