JP2008246417A - Manufacturing apparatus and method of coated article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing apparatus of a coating film capable of more rapidly keeping at least a drying speed than a natural drying speed while suppressing even the slight occurrence of drying irregularity and capable of also enhancing surface properties and productivity, and a manufacturing method of the coating film. <P>SOLUTION: The coating film feed distance from the coating part of a coating apparatus is set to 0.2-0.8 m. A drying oven is internally divided into a plurality of drying zones and has air supply and discharge means at every drying zone and a distance regulating means for uniformizing the distance between the top of the drying oven and the coating film. Further, the distance of the top and base of the drying oven is set to 10-100 mm and the relation between the height L1 of the gap on the side of the top between the top and coating film and the height L2 of the gap on the side of the base between the base and a base material is L1≤L2. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an apparatus and a method for manufacturing a coated product. In particular, it is used in the production of an optical film or the like in which an organic solvent is included in the coating liquid and a film thickness unevenness with an error of 1% or less is recognized as a defect on the product.

  In recent years, optical film products manufactured using wet coating technology are increasingly required to have an error of 1% or less in terms of film thickness accuracy. In the production of such an optical film, an organic solvent is generally used as a solvent for a coating solution. However, an organic solvent has a higher evaporation rate than water and must be accurately dried in the drying process after coating. It is known to cause wind-like unevenness.

  Conventionally, there are many techniques aimed at increasing the drying efficiency of a coating film. For example, Patent Document 1 proposes a method in which hot air is applied to both surfaces of a traveling substrate. In this method, hot air is applied to the surface of the coating film. As a result, the film is uneven and cannot be used in products that require high film thickness accuracy.

On the other hand, a technique that emphasizes drying more precisely than drying efficiency for the formation of a precise coating film has also been proposed. For example, in Patent Document 2, it is proposed to lower the wind speed of the drying air on the film surface in the initial stage of drying.
Patent Document 3 also proposes that precise drying is performed as a result of suppressing the drying speed as much as possible by saturating the atmosphere solvent concentration during drying.
However, these methods are intended to achieve a uniform surface shape by slowing the drying speed, and have a drawback that productivity is lowered.

Therefore, as a method of drying while efficiently removing the evaporated solvent in order to increase the drying speed as much as possible, Patent Document 4 discloses a solvent that is evaporated by dividing a traveling base material into a base material transport section and a solvent removal section. There has been proposed a method of drying while always removing with a cross wind of the solvent removal section. This method is characterized in that the substrate transport section is narrowly divided in the vicinity of the substrate.
Further, Patent Document 5 proposes a method in which the solvent evaporated on the condensing plate is condensed and removed instead of being removed by cross wind.
In order to increase the drying speed, there has also been proposed a method in which a cross wind is directly applied to a base material while straightening the dry air. However, for example, the method described in Patent Document 6 is based on the premise that no wind is applied until the coating liquid viscosity in the initial stage of drying rises to 1.5 times, and the drying speed cannot be dramatically improved. .
These methods have a problem that the drying rate cannot be increased more than the drying rate of so-called natural drying in which the drying rate is left in the atmosphere, and the productivity cannot be dramatically improved.

JP 2002-59074 A JP 2003-126768 A JP 2002-320898 A JP 2003-93954 A JP 2002-515585 A JP 2005-81256 A

  An object of the present invention is to provide an apparatus and a method for manufacturing a coated product that can maintain a drying speed faster than at least natural drying while suppressing generation of slight drying unevenness, and can improve surface properties and productivity. That is.

The invention described in claim 1 is a coating apparatus that forms a coating film by applying a coating solution containing an organic solvent to a belt-shaped substrate being transported, and drying that transports the coating film formed on the substrate. In an apparatus for producing a coated product having a device,
In the drying apparatus, at least the top plate, the bottom plate, the right side plate, the left side plate, and the coating film are carried in, and the coating film transport distance from the coating unit of the coating apparatus is 0.2 m or more to 0.00. A drying furnace having a carry-in port in a range of 8 m or less and a carry-out port for carrying out the coating film;
A plurality of drying zones formed by dividing the drying furnace and disposed along the transport direction of the coating film;
An air supply means for supplying air into each drying zone;
Exhaust means for exhausting air in each drying zone;
Control means for controlling the amount of air supplied by the air supply means into each drying zone, or the amount of air discharged by the exhaust means from within each drying zone, or both;
At least one zone of the plurality of drying zones is provided with a distance adjusting means for adjusting the distance between the facing surfaces of the top plate and the base material to be uniform. is there.

  According to a second aspect of the present invention, there is provided an apparatus for producing a coated product according to the first aspect, wherein a gap between the top plate and the bottom plate is in a range of 10 mm to 100 mm.

The invention according to claim 3 is a drying furnace top plate installed on the side of the substrate on which the coating film is formed,
A gap L1 between the top plate and the coating film;
A bottom plate of a drying furnace installed on the side opposite to the side on which the coating film of the substrate is formed;
A gap L2 between the bottom plate and the substrate;
Have
L1 and L2 satisfy | fill the relationship of L1 <= L2, The manufacturing apparatus of the coating material of Claim 2 characterized by the above-mentioned.

The invention according to claim 4 is an air supply port arranged on either the right side plate or the left side plate of each drying zone;
An air supply means for supplying air into each drying zone through the air supply port;
An exhaust port disposed on either the left side plate or the right side plate of each of the drying zones facing the air supply port;
Exhaust means for exhausting air from within each drying zone through the exhaust port;
Have
A flow of air generated in each drying zone using the air supply means, the exhaust means, or both flows in both the top plate side gap and the bottom plate side gap of each drying zone. It is the manufacturing apparatus of the coating material in any one of Claims 1-3.

  According to a fifth aspect of the present invention, the height of the openings of the air supply port and the exhaust port substantially coincides with the gap between the top plate and the bottom plate. It is an apparatus for manufacturing goods.

  In the invention described in claim 6, as the distance adjusting means, a grid-like section is set on a surface of the top plate facing the base material, a distance adjusting element is arranged for each section, and each distance adjusting section is set. It is a manufacturing apparatus of the coating material of Claims 1-5 provided with the distance adjustment element drive means which expands / contracts an element separately.

  The invention according to claim 7 is an optical film formed using the manufacturing apparatus according to any one of claims 1 to 6.

The invention according to claim 8 is a coating step in which a coating liquid containing an organic solvent is applied to a belt-shaped substrate being conveyed to form a coating film, and then the coating film formed on the substrate is placed in a drying furnace. In the manufacturing method of the coated product having a drying step of drying while transported in,
The drying furnace has a top plate, a bottom plate, a right side plate, a left side plate, a carry-in port into which the coating film is carried in, and a carry-out port through which the coating film is carried out,
And the drying furnace is divided into a plurality of drying zones along the transport direction of the coating film,
An application step of applying a coating liquid containing an organic solvent to the belt-shaped substrate being transported to form a coating film;
Next, a transporting process for transporting the coating film to a carry-in port of the drying furnace disposed in a range of 0.2 m to 0.8 m from a position where the coating liquid is applied to the base material to form a coating film;
Next, a carry-in process of carrying the coating film from the carry-in port of the drying furnace,
Next, the air supply means for supplying air into each of the drying zones, and the exhaust means for exhausting the air in each of the drying zones, the air supply means supplies air into each of the drying zones. The amount of air supplied or the amount of air exhausted from the inside of each drying zone by the exhausting means, or both are controlled by the control means, and in at least one of the plurality of drying zones, A drying step of drying while conveying the coating film formed on the substrate by adjusting the distance between the opposing surfaces of the substrate in the drying zone;
Next, a step of carrying out the coating film from the outlet of the drying furnace,
It is a manufacturing method of the coated material characterized by having.

  The invention according to claim 9 is the method for producing a coated product according to claim 8, wherein a gap between the top plate and the bottom plate is in a range of 10 mm to 100 mm.

The invention according to claim 10 is a drying furnace top plate installed on the side of the substrate on which the coating film is formed,
A height L1 of a top plate side gap between the top plate and the coating film;
A bottom plate of a drying furnace installed on the side opposite to the side on which the coating film of the substrate is formed;
A height L2 of a bottom plate side gap between the bottom plate and the base material;
Have
The method for producing a coated product according to claim 9, wherein the height L1 and the height L2 satisfy a relationship of height L1 ≦ height L2.

The invention according to claim 11 is an air supply port arranged on either the right side plate or the left side plate of each drying zone;
An air supply means for supplying air into each drying zone through the air supply port;
An exhaust port disposed on either the left side plate or the right side plate of each of the drying zones facing the air supply port;
Exhaust means for exhausting air from within each drying zone through the exhaust port;
Have
A flow of air generated in each drying zone using the air supply means, the exhaust means, or both flows in both the top plate side gap and the bottom plate side gap of each drying zone. It is the manufacturing method of the coating material in any one of Claims 8-10.

  The invention according to claim 12 is characterized in that the heights of the openings of the air supply port and the exhaust port substantially coincide with the gap between the top plate and the bottom plate. It is a manufacturing method of a thing.

  In the invention described in claim 13, as the distance adjusting means, a grid-like section is set on the surface of the top plate facing the base material, a distance adjusting element is arranged for each section, and each distance adjusting section is set. It is a manufacturing method of the coating material of Claim 8-12 provided with the distance adjustment element drive means which expands / contracts an element separately.

  The invention according to claim 14 is an optical film formed by using the manufacturing method according to any one of claims 8 to 13.

  By using the production apparatus and production method of the coated product in the present invention, it is possible to maintain a drying speed faster than at least natural drying while suppressing slight drying unevenness, and to improve surface and productivity. it can.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic side view of a coated product manufacturing apparatus according to the present invention as viewed from the side. The coating film 9b is coated on the base material 9a in the coating unit 1b of the coating apparatus 1a. The base material 9a on which the coating film 9b is formed is conveyed into the drying furnace 5 of the drying device 2.

  The inside of the drying furnace 5 is divided into a plurality of drying zones 18 in the conveyance direction of the base material 9a. Each drying zone is partitioned by a partition plate provided outside the drying furnace 5 or between adjacent drying zones. Each adjacent drying zone may be arranged linearly or may be arranged refracted. Each drying zone includes an air supply port, an exhaust port, an air supply unit, an exhaust unit, and a control unit that controls an air supply amount, an exhaust amount, or both.

  In FIG. 1, four drying zones 18 are linearly arranged in the drying furnace 5 in the conveying direction of the substrate 9a, and each of the drying zones 18 is opposed to the air supply port 6a and the air supply port 6a. An exhaust port 6b that is installed at a position and that is not shown is installed one by one, and although not shown, an air supply unit that supplies air into the drying zone 18 through the air supply port 6a is also illustrated. Although not shown, exhaust means for exhausting air from the inside of the drying zone 18 through the exhaust port 6b are provided one by one. Moreover, the internal pressure measuring means 7a may be installed one by one in each drying zone 18, and the external pressure measuring means 7b may be installed in the vicinity of the carry-in entrance 3. This represents one embodiment of the present invention, and the present invention is not limited to this.

  The coating film 9b formed on the base material 9a is carried into the drying furnace 5 from the carry-in port 3 formed in the partition plate 31, and sequentially passes through each drying zone 18 partitioned by the partition plates 32-34. Then, it is carried out of the drying furnace 5 from the carry-out port 4 formed in the partition plate 35.

  At this time, when the internal pressure measuring means 7a and the external pressure measuring means 7b are installed, the differential pressure between the drying furnace 5 and the outside, or the differential pressure in the adjacent drying zone 18 is preferably within a predetermined range. The air supply means and the exhaust means of each drying zone may be adjusted so that the pressure is in the range of −2 Pa to 2 Pa. When the internal pressure measuring means 7a and the external pressure measuring means 7b are not installed, the air supply means and the exhaust means in each drying zone are adjusted to have a predetermined supply / exhaust amount.

  FIG. 2 is a schematic cross-sectional view taken along the line A-A ′ of the drying device 2 shown in FIG. 1. An air supply opening 6 a having an air supply opening 14 is provided on the right side plate of the drying furnace 5, and an exhaust opening 15 is provided at a position facing the air supply opening 6 a of the left side plate of the drying furnace 5. An exhaust port 6b is provided. In the present invention, air is supplied into the drying furnace 5 from the air supply port 6a using the air supply means, and air is exhausted from the inside of the drying furnace 5 using the exhaust means from the exhaust port 6b. That is, an air flow 17 is generated from the air supply port 6a toward the exhaust port 6b in a direction perpendicular to the conveying direction of the base material 9a, and the evaporated friendly solvent 25 is discharged to the outside of the drying furnace 5.

  In FIG. 1 and FIG. 2, an air flow 17 is generated from the right side to the left side in the conveyance direction of the base material 9, and this represents one embodiment of the present invention. An air flow may be generated from the left side to the right side in the transport direction. That is, the air supply port may be provided on the left side plate of the drying furnace 5, and the exhaust port may be provided at a position facing the air supply port on the right side plate of the drying oven 5.

  Since the drying apparatus 2 of the present invention is intended to dry evenly to a semi-solid state where the coating film does not move, it is desirable that the air flow 17 is a uniform one close to a laminar flow. For this reason, it is desirable that the distance L1 from the coating film 9b to the top plate of the drying furnace 5 is on the order of several mm to several cm, and variation in the distance L1 is suppressed to within ± 5%.

  Especially in the case of a wide drying furnace, the top plate is likely to bend. When the top plate is bent, the distance L1 is often smaller at the center portion than at both end portions in the width direction. At a location where the distance L1 is reduced, the speed of the air flow 17 is higher than that of the surroundings, so that uneven drying occurs in the coating film 9b. In order to make the distance L1 uniform, a flat plate having a material and a thickness that allows the deflection of the top plate to fall within an allowable range, and the occurrence of deflection are taken into account and assembled as a drying furnace 5. A plate having a shape adjusted so that the distribution of the distance L1 to the coating film 9b is within an allowable range may be used as the top plate.

  Further, a plurality of distance adjusting elements 27 are two-dimensionally arranged in a lattice-like section on the surface of the top plate facing the coating film 9b, and the distance L1 to the coating film 9b is adjusted to be uniform. You may do it. FIG. 3 is a schematic plan view of the coated product manufacturing apparatus of FIG. 1 as viewed from the coating film side, and schematically shows a case where a plurality of distance adjusting elements 27 are arranged in the first drying zone 18a. It is. Each distance adjusting element 27 can be individually operated by a distance adjusting element driving means (not shown). Even when the top plate is deformed by bending or the like, each distance adjusting element 27 is a distance L1 to the coating film 9b. Can be adjusted to be uniform.

  As the distance adjusting element 27, a piezoelectric material such as PZT or PVDF having a flat plate shape and electrodes formed on both surfaces can be used. The smaller the size of the distance adjusting element 27, that is, the unit of the section where the distance can be adjusted, is, the more precise distance adjustment is possible. Further, in FIG. 3, for the sake of simplicity, the distance adjusting element 27 is disposed only in the drying zone 18a closest to the carry-in port 3, but it is desirable to dispose it over the necessary drying zone.

  It is to be noted that the air supply means and the exhaust means in each drying zone can individually set the flow rate, and a certain drying zone can be in a state where there is no air flow 17 in the width direction. In the initial drying stage immediately after coating, the coating film 9b still contains a large amount of solvent components, so that it has high fluidity and is particularly susceptible to airflow. Therefore, the supply and exhaust of the first zone or several zones from the beginning are stopped, and the coating film 9b is semi-cured to such an extent that it is dried very slowly only with the accompanying air generated depending on the conveying direction of the base material 9a, and no flow occurs. Further, it may be transported into a drying zone that is supplying and exhausting air.

  It is important to adjust the distance L1 between the top plate of the drying furnace 5 and the coating film 9b to be uniform even in the drying zone where the supply and exhaust are stopped. As in the case of air supply / exhaust, the speed of the accompanying air generated by the transport direction of the base material 9a is higher than the surroundings at the location where the distance L1 is small, and therefore, the coating film 9b has uneven drying. This is because.

  The coating apparatus 1 in the present invention can use a gravure, a wire bar, a die or the like, but is not limited to these.

  The drying device 2 in the present invention is installed in a range of 0.2 m to 0.8 m at a coating film transport distance 8 from the coating unit 1b of the coating device 1a. Here, the coating film transport distance 8 refers to the length along the transported base material 9a, not the linear distance between the coating section 1a and the carry-in port 3. Although the conveyance speed of the base material 9a is not a restriction | limiting matter, the drying apparatus 2 which has a general speed of about 20 m / min or more and 60 m / min or less is used. If the coating film conveyance distance 8 is longer than 0.8 m, the naturally drying region cannot be ignored, and unevenness due to natural drying occurs, which is not preferable. Also, if it is less than 0.2 m, the outside air is blocked at the carry-in entrance 3 for carrying in the base material 9a, which is not preferable.

  The drying furnace 5 has a box shape surrounding the base material 9, and includes a carry-in port 3 for carrying in the base material 9 a, and a carry-out port 4 installed so as to face the carry-out port 3. The top plate 12 installed on the side on which the coating film 9b of the base material 9a is formed, the bottom plate 13 installed facing the top plate 12 across the base material 9a, and the transport direction of the base material 9a It is the right side, and is composed of a right side plate installed in the width direction of the base material 9a and a left side plate installed facing the right side plate. Here, it does not matter whether the coating film 9b is formed on the upper surface side in the gravity direction or the coating film 9b is formed on the lower surface side of the substrate 9a to be conveyed.

  As the air supply means and exhaust means in the present invention, a blower is generally used. However, the blower is not limited to the blower as long as the air supply amount and the exhaust amount can be adjusted.

  As the control means in the present invention, when the internal pressure measuring means 7a and the external pressure measuring means 7b are installed, the differential pressure between the inside and outside of the drying furnace 5 and the differential pressure in the adjacent drying zone 18 are predetermined. Of the air supplied into the drying furnace 5 by the air supply means and the air exhausted from the drying furnace 5 by the exhaust means so as to be in the range of −2 Pa to 2 Pa. There is no particular limitation as long as it can control the displacement. Further, when the internal pressure measuring means 7a and the external pressure measuring means 7b are not installed, the air supply means and the exhaust means in each drying zone can be controlled to have a predetermined supply / exhaust amount. I just need it.

  During coating, fluctuations in the atmospheric pressure outside the drying apparatus 2 are unavoidable due to entering and leaving the coating chamber. When the change is made, the control means is used to change the amount of air supplied to the drying furnace 5 and the amount of air exhausted from the drying furnace 5. The airflow inside becomes turbulent and causes unevenness. Therefore, the control means may be used for controlling the static air supply amount before starting the application and / or the exhaust amount. However, the base material 9 may be transported or stopped at the time of pressure measurement or control of the air supply amount and the exhaust amount.

  The distance 11 between the top plate and the bottom plate in the present invention indicates the distance in the direction perpendicular to the base material surfaces of the top plate 12 and the bottom plate 13. In order to keep the air supply amount at the air supply port 6a and the exhaust amount at the exhaust port 6b small and to increase the drying speed, it is necessary to restrict the space in which the air flow 17 is generated to some extent. Therefore, the distance 11 between the top plate and the bottom plate is preferably in the range of 10 mm to 100 mm. If it is less than 10 mm, it causes a trouble such as contact with the top plate 12 or the bottom plate 13 when the substrate 9a is conveyed, which is not preferable. On the other hand, if it is higher than 100 mm, it is necessary to increase the air supply amount and the exhaust amount in order to increase the drying speed.

  The height of the opening of the air supply port installed on the right side plate of the drying furnace 5 and the exhaust port installed on the left side plate is perpendicular to the base material surface of the opening 14 of the air supply port and the opening 15 of the exhaust port. The aperture is shown. Here, it is preferable that the distance 11 between the top plate and the bottom plate and the height 16 of the opening of the air supply port and the exhaust port substantially coincide. By doing so, an air flow 17 generated between the air supply port 6a and the exhaust port 6b is uniformly generated between the top plate 12 and the bottom plate 13 of the drying furnace 5, and the coating film 9b of the base material 9a. An air flow 17 is generated on the side opposite to the side on which the coating film 9b is formed on the substrate 9a. Thereby, it becomes difficult to produce blur in the height which conveys the base material 9a, stability is ensured, and generation | occurrence | production of a nonuniformity can be prevented.

If an air flow is generated only on either the side of the base material 9a where the coating film 9b is formed or the side of the base material 9a opposite to the side where the coating film 9b is formed, the height of the transport of the base material 9a is increased. It must be strictly determined. However, in reality, when the base material 9a is transported, the height at which the base material 9a is transported is blurred, which causes unevenness.
In order to more stably generate the air flow 17 generated between the air supply port 6a and the exhaust port 6b, it is preferable to match the air supply amount at the air supply port 6a with the exhaust amount at the exhaust port 6b. .

  Furthermore, it is preferable to manage the air supply amount and the exhaust amount. The amount can be controlled by the height L1 of the top plate side gap between the coating film 9b and the top plate 12 formed on the base material 9a and the height L2 of the bottom plate side gap between the base material 9a and the bottom plate 13. At this time, it is preferable that the height L1 and the height L2 have a relationship of height L1 ≦ height L2. When the distance 11 between the top plate and the bottom plate is in the range of 10 to 100 mm and the relationship of height L1 ≦ height L2 is satisfied, surface properties and productivity can be improved most.

  The length of the drying device 2 (the conveyance direction of the base material) is not particularly limited. The length of the drying device 2 is determined by whether or not the coating film is dried, and varies depending on the product. However, in the present invention, the drying apparatus 2 having a general length of about 5 m to 100 m is used.

  The drying apparatus 2 according to the present invention can maintain the drying speed faster than at least natural drying while suppressing the occurrence of slight drying unevenness, and thus the effect is most apparent in the initial stage of drying. The entire length of the drying apparatus does not depend on the drying apparatus 2 of the present invention, and the drying apparatus 2 of the present invention can be introduced only in the initial stage of drying including the carry-in port 3. In that case, as shown in FIG. 1, the drying apparatus 2 of the present invention may be introduced as the first drying apparatus in the first half, and a known drying apparatus may be introduced as the second drying apparatus 10 in the second half.

  As the second drying device 10, a method of applying a jet flow with a raised temperature to a coating film formed on a base material from a slit nozzle or punching metal may be introduced, or a quick return type nozzle or base material A system in which hot air is ejected from a nozzle of a system in which a parallel flow is made in the transport direction may be used. Moreover, you may provide a heating means not only from one side but from both sides. The use of any commercially available drying apparatus does not interfere with the effects of the present invention.

  Further, FIGS. 1 and 3 show a case where the drying device 2 of the present invention and the known second drying device 10 are made independent of each other, but the first half of the drying device is the present invention. The effect of the present invention does not change even when the method based on the drying apparatus is used and the latter half is based on a known drying apparatus.

  The apparatus and method for producing a coated product of the present invention can be used for various products, and is particularly effective for coating a dispersion using an organic solvent as a solvent. Among them, it is effective for a product with less tolerance for unevenness, such as an optical film, which has been in increasing demand in recent years.

  Here, the optical film is a film used mainly on or on the outermost surface of a display device such as a liquid crystal or a plasma display, and is a hard coat film, an antireflection film, an antiglare film, an optical compensation film, a light diffusion film. A film etc. are mentioned.

  Examples of the organic solvent used in the present invention include alcohols such as methanol, ethanol, isopropanol, butanol and 2-methoxyethanol, ketones such as acetone, methyl ethyl ketone and methyl isobutyl, methyl acetate, ethyl acetate and butyl acetate. Esters, ethers such as diisopropyl ether, glycols such as ethylene glycol, propylene glycol, hexylene glycol, glycol ethers such as ethyl cellosolve, butyl cellosolve, ethyl carbitol / butyl carbitol, fats such as hexane, heptane / octane Aromatic hydrocarbons such as aromatic hydrocarbons, halogenated hydrocarbons, benzene, toluene and xylene, N-methylpyrrolidone, dimethylformamide and the like, and one kind or a mixture of two or more kinds It may be used as an object, but is not limited thereto.

  Examples of the binder used in the coating liquid of the present invention include ionizing radiation curable resins and thermosetting resins such as ultraviolet curable resins and electron beam curable resins. Agent is included.

  Examples of the ionizing radiation curable resin include polyfunctional acrylate resins such as polyhydric alcohol acrylic acid or methacrylic ester, diisocyanate, polyhydric alcohol and acrylic acid or methacrylic hydroxy ester. Examples include functional urethane acrylate resins. Besides these, polyether resins having an acrylate functional group, polyester resins, epoxy resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, and the like can also be used.

  Examples of the thermosetting resin include thermosetting urethane resins, phenol resins, urea melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins.

  Any photopolymerization initiator may be used as long as it generates radicals when irradiated with active energy rays. For example, 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropane-1- ON, 2-methyl [4- (methylthio) phenyl] morpholinopropan-1-one, 2,2-dimethoxy-1,2-diphenylethane-1-one, benzophenone, 1- [4- (2-hydroxyethoxy) ) Phenyl] -2-hydroxy-2-methyl-1-propan-1-one, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) butan-1-one, bis (2,6- And dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxide. 0.1-10 mass parts is preferable with respect to 10-80 mass parts of active energy ray hardening monomers, and, as for the addition amount of a photoinitiator, 1-7 mass parts is more preferable, and 1-5 mass parts is. Further preferred.

As the base material 9 used in the present invention, various materials can be used depending on applications. Examples of components constituting the substrate 9 include cellulose films such as acetyl cellulose and triacetyl cellulose, polyester films such as polyethylene terephthalate and polyethylene naphthalate, and acrylic films such as polymethyl methacrylate. It is not limited to these. Moreover, the base material 9 may consist of a single layer, or may consist of multiple layers. In addition, the thickness of the base material 9 is generally 10 to 500 μm.

The side schematic diagram when the manufacturing apparatus of the coating film of this invention is seen from the side. FIG. 2 is a schematic cross-sectional view of the drying apparatus shown in FIG. 1. The plane schematic when the manufacturing apparatus of the coating film of this invention is seen from the coating film side.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coating device 2 Drying device 3 Carrying-in port 4 Carrying-out port 5 Drying furnace 6a Air supply port 6b Exhaust port 7a Internal pressure measuring means 7b External pressure measuring means 8 Coating film conveyance distance 9a Base material 9b Coating film 10 Second drying apparatus 11 Top The distance between the plate and the bottom plate 12 Top plate 13 Bottom plate 14 Opening portion 15 of the air supply opening 16 Opening portion of the exhaust port 17 Height of the opening portion of the air supply port and the exhaust port 17, 17 a Air flow 18, 18 a Drying zone 25 Evaporation Organic solvent 27 Distance adjusting element 31-35 Partition plate

Claims (14)

An apparatus for producing a coated product, comprising: a coating apparatus that forms a coating film by applying a coating solution containing an organic solvent to a belt-shaped substrate being transported; and a drying apparatus that dries while transporting the coating film formed on the substrate. In
In the drying apparatus, at least the top plate, the bottom plate, the right side plate, the left side plate, and the coating film are carried in, and the coating film transport distance from the coating unit of the coating apparatus is 0.2 m or more to 0.00. A drying furnace having a carry-in port in a range of 8 m or less and a carry-out port for carrying out the coating film;
A plurality of drying zones formed by dividing the drying furnace and disposed along the transport direction of the coating film;
An air supply means for supplying air into each drying zone;
Exhaust means for exhausting air in each drying zone;
Control means for controlling the amount of air supplied by the air supply means into each drying zone, or the amount of air discharged by the exhaust means from within each drying zone, or both;
At least one zone of the plurality of drying zones is provided with a distance adjusting means for adjusting the distance between the facing surfaces of the top plate and the base material to be uniform.   The distance between the top plate and the bottom plate is in the range of 10 mm to 100 mm. A top plate of a drying oven installed on the side on which the coating film of the substrate is formed,
A height L1 of a top plate side gap between the top plate and the coating film;
A bottom plate of a drying furnace installed on the side opposite to the side on which the coating film of the substrate is formed;
A height L2 of a bottom plate side gap between the bottom plate and the base material;
Have
The apparatus for producing a coated product according to claim 2, wherein the height L1 and the height L2 satisfy a relationship of height L1 ≦ height L2. An air supply port arranged on either the right side plate or the left side plate of each drying zone;
An air supply means for supplying air into each drying zone through the air supply port;
An exhaust port disposed on either the left side plate or the right side plate of each of the drying zones facing the air supply port;
Exhaust means for exhausting air from within each drying zone through the exhaust port;
Have
A flow of air generated in each drying zone using the air supply means, the exhaust means, or both flows in both the top plate side gap and the bottom plate side gap of each drying zone. The apparatus for producing a coated product according to any one of claims 1 to 3.   The apparatus for manufacturing a coated product according to claim 4, wherein the height of the opening of the air supply port and the exhaust port is substantially equal to the distance between the top plate and the bottom plate.   As the distance adjusting means, a grid-like section is set on the surface of the top plate facing the base material, a distance adjusting element is arranged for each section, and the distance adjusting elements are individually expanded and contracted. The apparatus for producing a coated product according to claim 1, further comprising a driving unit.   An optical film formed using the manufacturing apparatus according to claim 1. A coating step in which a coating solution containing an organic solvent is applied to the belt-shaped substrate being transported to form a coating film; and a drying step in which the coating film formed on the substrate is then dried while being transported in a drying furnace; In a method for producing a coated product having
The drying furnace has a top plate, a bottom plate, a right side plate, a left side plate, a carry-in port into which the coating film is carried in, and a carry-out port through which the coating film is carried out,
And the drying furnace is divided into a plurality of drying zones along the transport direction of the coating film,
An application step of applying a coating liquid containing an organic solvent to the belt-shaped substrate being transported to form a coating film;
Next, a transporting process for transporting the coating film to a carry-in port of the drying furnace disposed in a range of 0.2 m to 0.8 m from a position where the coating liquid is applied to the base material to form a coating film;
Next, a carry-in process of carrying the coating film from the carry-in port of the drying furnace,
Next, the air supply means for supplying air into each of the drying zones, and the exhaust means for exhausting the air in each of the drying zones, the air supply means supplies air into each of the drying zones. The amount of air supplied or the amount of air exhausted from the inside of each drying zone by the exhausting means, or both are controlled by the control means, and in at least one of the plurality of drying zones, A distance adjusting means for adjusting a distance between the opposing surfaces of the base material; and a coating film formed on the base material so that a distance between the top plate and the opposing surface of the base material is uniform. A drying process for drying while transporting in the drying zone;
Next, a step of carrying out the coating film from the outlet of the drying furnace,
The manufacturing method of the coating material characterized by having.   The method for producing a coated product according to claim 8, wherein a distance between the top plate and the bottom plate is in a range of 10 mm to 100 mm. A top plate of a drying oven installed on the side on which the coating film of the substrate is formed,
A height L1 of a top plate side gap between the top plate and the coating film;
A bottom plate of a drying furnace installed on the side opposite to the side on which the coating film of the substrate is formed;
A height L2 of a bottom plate side gap between the bottom plate and the base material;
Have
The method for producing a coated product according to claim 9, wherein the height L1 and the height L2 satisfy a relationship of height L1 ≦ height L2. An air supply port arranged on either the right side plate or the left side plate of each drying zone;
An air supply means for supplying air into each drying zone through the air supply port;
An exhaust port disposed on either the left side plate or the right side plate of each of the drying zones facing the air supply port;
Exhaust means for exhausting air from within each drying zone through the exhaust port;
Have
A flow of air generated in each drying zone using the air supply means, the exhaust means, or both flows in both the top plate side gap and the bottom plate side gap of each drying zone. The manufacturing method of the coating material in any one of Claims 8-10 to do.   The method for producing a coated product according to claim 11, wherein the height of the opening of the air supply port and the exhaust port is substantially equal to the distance between the top plate and the bottom plate.   As the distance adjusting means, a grid-like section is set on the surface of the top plate facing the base material, a distance adjusting element is arranged for each section, and the distance adjusting elements are individually expanded and contracted. It has a drive means, The manufacturing method of the coating material of Claims 8-12 characterized by the above-mentioned.   An optical film formed using the manufacturing method according to claim 8.

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