JP2010131552A - Device for forming functional layer and method for forming functional layer - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for forming a functional layer which restrains a coating liquid for a functional layer both from remaining on the coated surface of a coating film and from injuring the coated surface concerned and forms a functional layer which is controlled in variations of film thickness. <P>SOLUTION: A coating device includes: for example, a coating device 30 which applies a coating liquid for forming a functional layer onto a resin film 10 to form a coating film 11; a first drying-or-hardening device 50A which dries or hardens the coating film 11 to put the coating film 11 under a finger-touch dry state or semihardened dry state; a coating film-removing device 40 which removes both end parts in the width direction of the coating film 11, which is in the finger-touch dry state or semihardened dry state, so that the coated surface of the coating film may partially be exposed, the coating film 11-removing face of the coating film-removing device 40 (for example, a coating film-removing roll 41) being composed of an elastic body; and a second drying-or-hardening device 50B which dries or hardens the coating film 11, whose both end parts in the width direction are removed, to form a functional layer. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a functional layer forming apparatus and a functional layer forming method.

  In recent years, various display media using liquid crystal elements, organic electroluminescence elements, and electro-optical elements such as solar cells have been developed. This electro-optical element is produced, for example, by coating and forming a functional layer (for example, a liquid crystal layer, an optical switching layer, an organic electroluminescence element layer, a photoelectric conversion layer, etc.) on an electrode formed on a resin film. Is done. In addition to the electro-optical element, various developments have been made regarding the coating formation of the functional layer.

  For example, in Patent Document 1, a coating liquid is applied to a belt-like support that is continuously conveyed, and the excessively applied coating liquid is thinned or removed by a film thickness regulating means provided on the downstream side of the coating means. In the coating apparatus, there has been proposed a coating apparatus characterized in that a film that is peeled off and removed together with the coating solution adhering to the coating film after being separated from the coating film is provided at a portion that comes into contact with the coating film of the film thickness regulating means.

Patent Document 2 discloses an absorption in which a coating liquid is applied to an object to be coated, a coating layer is formed on the object to be coated, and the coating layer is heated from the end of the coating layer before drying. A coating layer edge processing method in the production of an electrophotographic photosensitive material has been proposed, which comprises sucking a coating solution with a member and then drying the coating layer.
JP 2002-301417 A Japanese Patent Publication No. 52-038407

  SUMMARY OF THE INVENTION An object of the present invention is to provide a functional layer forming apparatus and a forming method for forming a functional layer in which the coating layer of the coating liquid of the functional layer is prevented from remaining and damaged on the coated surface and the variation in film thickness is suppressed. That is.

The above problem is solved by the following means. That is,
The invention according to claim 1
On the resin film, a coating means for coating the functional layer forming coating liquid to form a coating film,
A first drying or curing means for drying or curing the coating film to bring the coating film into a touch-dried or semi-cured dry state;
A coating film removing means for removing both ends in the width direction of the touch-dried or semi-cured dried film so that a part of the coated surface of the coated film is exposed. A coating film removing means whose surface is made of an elastic body;
A second drying or curing means for drying or curing the coating film from which both ends in the width direction are removed to form a functional layer;
A functional layer forming apparatus comprising:

The invention according to claim 2
The functional layer forming apparatus according to claim 1, wherein the elastic body has a hardness of 10 or more and 40 or less.

The invention according to claim 3
The functional layer forming apparatus according to claim 1, wherein the elastic body is impregnated with a solvent.

The invention according to claim 4
The apparatus for forming a functional layer according to claim 1, wherein the coating film removing unit is disposed by pressing the elastic body against a coated surface side of the coating film.

The invention according to claim 5
The functional layer forming apparatus according to claim 1, wherein a plurality of the coating film removing means are provided.

The invention according to claim 6
The other functional layer is formed on the coated surface of the coating film on the resin film, and a part of the other functional layer is exposed by removing the coating film by the coating film removing means. The functional layer forming apparatus as described.

The invention according to claim 7 provides:
On the resin film, a step of applying a functional layer forming coating solution to form a coating film,
Drying or curing the coating film to bring the coating film into a touch-dried state or a semi-cured dry state;
By the coating film removing means in which the removal surface of the coating film is formed of an elastic body, both ends in the width direction of the coating in the touch-dried state or semi-cured drying state are applied to both ends in the width direction of the coating film. Removing a part of the coated surface of the film so that it is exposed;
The step of drying or curing the coating film from which both ends in the width direction are removed to form a functional layer;
A method for forming a functional layer.

The invention according to claim 8 provides:
The method for forming a functional layer according to claim 7, wherein the elastic body has a hardness of 10 or more and 40 or less.

The invention according to claim 9 is:
The method for forming a functional layer according to claim 7, wherein the elastic body is impregnated with a solvent.

The invention according to claim 10 is:
The method for forming a functional layer according to claim 7, wherein an elastic body of the coating film removing unit is pressed against a coated surface side of the coating film to remove both end portions in the width direction of the coating film.

The invention according to claim 11 is:
The method for forming a functional layer according to claim 7, wherein both end portions in the width direction of the coating film are removed by a plurality of the coating film removing means.

The invention according to claim 12
The other functional layer is formed on the coated surface of the coating film on the resin film, and a part of the other functional layer is exposed by removing the coating film by the coating film removing means. The formation method of the functional layer of description.

According to the first aspect of the invention, compared to the case without this configuration, the remaining and damage to the coated surface of the coating film of the functional layer coating liquid is suppressed, and the variation in film thickness is suppressed. A functional layer is formed.
According to the invention which concerns on Claim 2, the damage with respect to the to-be-coated surface of the coating film of the coating liquid for functional layers is suppressed compared with the case where the hardness of an elastic body is not considered.
According to the invention which concerns on Claim 3, compared with the case where an elastic body does not impregnate a solvent, the residual and damage with respect to the to-be-coated surface of the coating liquid of the coating liquid for functional layers are suppressed.
According to the fourth aspect of the present invention, compared to the case where the elastic body of the coating film removing means is not pressed against the coated surface side, the remaining of the coating film of the coating liquid for the functional layer on the coated surface is suppressed.
According to the invention which concerns on Claim 5, compared with the case where multiple coating film removal means are not provided, the residual with respect to the to-be-coated surface of the coating film of the coating liquid for functional layers is suppressed.
According to the invention which concerns on Claim 6, even if another functional layer exists in the to-be-coated surface of the coating film of the coating liquid for functional layers, the remaining and damage with respect to another functional layer are suppressed.
According to the invention of claim 7, compared to the case without this configuration, the remaining and damage to the coated surface of the coating film of the functional layer coating liquid is suppressed, and the variation in film thickness is suppressed. A functional layer is formed.
According to the invention which concerns on Claim 8, the damage with respect to the to-be-coated surface of the coating film of the coating liquid for functional layers is suppressed compared with the case where the hardness of an elastic body is not considered.
According to the ninth aspect of the present invention, compared to the case where the elastic body is not impregnated with the solvent, the remaining and damage to the coated surface of the coating film of the functional layer coating liquid is suppressed.
According to the invention which concerns on Claim 10, compared with the case where the elastic body of a coating-film removal means is not pressed on the to-be-coated surface side, the residual with respect to the to-be-coated surface of the coating liquid of a functional layer is suppressed.
According to the invention which concerns on Claim 11, the residual | survival with respect to the to-be-coated surface of the coating liquid of the coating liquid for functional layers is suppressed compared with the case where multiple coating film removal means are not provided.
According to the invention which concerns on Claim 12, even if another functional layer exists in the to-be-coated surface of the coating film of the coating liquid for functional layers, the remaining and damage with respect to another functional layer are suppressed.

  Embodiments of the present invention will be described below with reference to the drawings. In addition, the same code | symbol is provided to the member which has the substantially same function and effect | action through all the drawings, and the overlapping description may be abbreviate | omitted.

  FIG. 1 is a schematic configuration diagram showing a main part of the functional layer forming apparatus according to the present embodiment. 2 and 3 are process diagrams showing the functional layer forming apparatus according to the present embodiment. FIG. 2 is a process diagram in plan view. FIG. 3 is a cross-sectional process diagram.

  The functional layer forming apparatus 101 according to the present embodiment includes support rolls 20 and 21 for transporting the resin film 10 while supporting it, and a coating apparatus 30 disposed to face the support roll 20 via the resin film 10. And a coating film removing device 40 disposed to face the support roll 21 with the resin film 10 interposed therebetween. Further, a first drying or curing device 50A is disposed between the coating device 30 and the coating film removing device 40. In addition, a second drying or curing device 50B is provided.

  The coating device 30 is a coating means for coating a functional layer forming coating liquid on a resin film. Examples of the coating apparatus 30 include known coating heads used for bar coating, die coating, slide hopper coating, roll coating, curtain coating, air knife coating, or gravure coating. It is done.

  Although not shown, the coating device 30 is provided with a moving mechanism so as to face the resin film 10 so that the coating solution contacts the resin film 10 at the time of coating, and away from the resin film 10 when not coated. Is good.

  The coating film removing apparatus 40 is an apparatus for removing both ends in the width direction of the coating film 11 of the coating liquid for forming a functional layer (both ends in the direction orthogonal to the conveying direction of the resin film 10), for example, a pair of coating film removing rolls. 41. The coating film removing apparatus 40 removes the coating film 11 in the dry-to-touch or semi-cured drying state so that a part of the coated surface of the coating film 11 is exposed. And as for the coating film removal apparatus 40, the removal surface of the coating film 11 is comprised with the elastic body. That is, the coating film removing apparatus 40 removes both end portions in the width direction of the coating film 11 by scraping the coating film 11 with the elastic body constituting the removal surface of the coating film 11.

  Specifically, the coating film removing roll 41 as the coating film removing apparatus 40 includes, for example, a shaft 41A and an elastic layer 41B (elastic body) disposed on the outer peripheral surface of the shaft 41A. Two coating film removing rolls 41 are disposed so that both ends of the coating film 11 in the width direction are removed. Thus, as for the coating film removal roll 41, the removal surface of the coating film of the functional layer forming coating liquid is composed of an elastic body, that is, an elastic layer 41B. The coating film removal roll 41 is not limited to a pair, and the elastic layer 41B is positioned at both ends in the width direction of the coating film 11 with respect to the outer peripheral surface of one shaft 41A (that is, the width of the coating film 11). A single roll disposed in two places may be applied so that both ends in the direction are removed.

  As the shaft 41A, for example, a rod-like member generally made of iron, copper, brass, stainless steel, aluminum, nickel, or the like can be given.

  The elastic layer 41B (elastic body) has a hardness of preferably 10 or more and 40 or less, preferably 15 or more and 35 or less, and more preferably 20 or more and 30 or less. By making this hardness into the above range, damage to the coated surface of the coating film 11 of the functional layer forming coating liquid is suppressed.

  Here, the hardness of the elastic layer 41B is a value measured by an Asker C hardness meter which is a standard of the Japan Rubber Association (SRIS0101).

  Examples of the material constituting the elastic layer 41B (elastic body) include polyurethane resin, polystyrene resin, polyethylene, polypropylene resin, nylon resin, melamine resin, polyethylene terephthalate resin, ethylene-vinyl acetate copolymer, butyl rubber, nitrile rubber, poly Examples include isoprene rubber, polybutadiene rubber, silicone rubber, natural rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, styrene-butadiene rubber, acrylic rubber, and chloroprene rubber.

  The material constituting the elastic layer 41B (elastic body) may be a non-foamed elastic body or a foamed elastic body, but is preferably a foamed elastic body. Since the elastic layer 41B (elastic body) is formed of a foamed elastic body, damage to the coated surface of the coating film of the functional layer coating liquid is suppressed.

  The elastic layer 41B (elastic body) is preferably formed by impregnating a solvent. Thereby, the residual and damage with respect to the to-be-coated surface of the coating film 11 of the coating liquid for functional layers are suppressed.

  A solvent that dissolves or swells components other than the solvent component in the functional layer forming coating solution (the coating film 11) is applied. The solvent is preferably composed mainly of a component that dissolves.

  The coating film removing roll 41 is preferably disposed by pressing the elastic layer 41 </ b> B (elastic body) against the coated surface side of the coating film 11. Thereby, when removing the width direction both ends of a coating film, the remaining with respect to the to-be-coated surface of the coating film of the coating liquid for functional layers is suppressed. Of course, the coating film removing roll 41 may be disposed only in contact with the coated surface of the elastic layer 41B (elastic body) coating film 11 (without pressing).

  The coating film removing roll 41 may be arranged non-rotatingly or may be arranged to be driven to rotate. In the case of rotational driving, the coating film removing roll 41 is preferably driven to rotate in the direction opposite to the conveying direction of the resin film 10 to remove the coating film 11.

  For example, two coating film removal rolls 41 may be arranged at a specific interval along the conveyance direction of the resin film 10. Thereby, the width direction both ends of the coating film 11 are removed twice. The number of coating film removing rolls 41 as the coating film removing means is not limited to two, and may be one or may be three or more. By providing a plurality of coating film removing rolls 41 as coating film removing means, the remaining of the coating film of the functional layer coating liquid on the electrode is suppressed.

  In addition, although this embodiment demonstrated the form which applied the coating-film removal roll 41 as the coating-film removal apparatus 40, it will not restrict | limit especially if the removal surface of the coating film 11 is comprised with the elastic body. For example, a blade whose removal surface of the coating film 11 is made of an elastic body may be used.

The first drying or curing device 50A is a means for drying or curing the coating film 11 to bring the coating film 11 into a touch-dried state or a semi-cured and dried state. For example, when a functional layer forming coating liquid in which a functional layer is formed only by drying is applied to the first drying or curing device 50A, a drying device is applied. For example, the functional layer is formed using a resin curing reaction. When the functional layer forming coating liquid to be formed is applied, a curing device is applied.
As the drying device, for example, a heating device and a blower device are applied.
The curing device is selected according to the stimulus for curing the functional layer forming coating solution. For example, when the functional layer forming coating solution is thermosetting, a heating device is applied as the curing device, and when it is photocurable, a light irradiation device is applied.

The second drying or curing device 50B dries or cures the coating film 11 to make the coating film 11 a functional layer 11A, that is, completely dry or cure the coating film 11 in a dry-to-touch or semi-cured dry state. It is a means to make the functional layer 11A. In addition, completely dry or hardened means to be in a state as the functional layer 11A that is usually required, and the functional layer 11A may be slightly dry or uncured.
Specific examples of the second drying or curing device 50B are the same as those of the first drying or curing device 50A.

  Next, a coating method to which the functional layer forming apparatus 101 according to this embodiment is applied will be described.

  In the coating method according to the present embodiment, first, as shown in FIGS. 2A and 3A, the functional layer is applied by the coating device 30 to the surface of the resin film 10 conveyed by the support rolls 20 and 21. Apply the forming coating solution. Thereby, the coating film 11 of the functional layer forming coating solution is formed. The resin film 10 may be transported and applied as a sheet-shaped resin film, or may be transported and applied while pulling out a roll-shaped resin film.

  Here, in the present embodiment, another functional layer 12 is formed in advance on a part of the coated surface of the functional layer forming coating solution on the resin film 10. Specifically, for example, another functional layer 12 is formed at the center in the width direction of the resin film 10, and a plurality of the functional layers 12 are formed with a specific gap along the transport direction of the resin film 10. Then, for example, the functional layer forming coating solution is applied so as to completely cover the other functional layer 12 to form the coating film 11.

  Next, as shown in FIG. 2 (B) and FIG. 3 (B), the coating film 11 is brought into the touch-dried state or the semi-cured dry state by the first drying or curing device 50A. Here, the dry touch state of the coating film 11 means a state in which the fingertip is not soiled by lightly touching the center of the coating film 11 (coating surface) with a fingertip (JIS K 5600-1-1 4.3. 5 See a)). The semi-cured and dried state of the coating film 11 means a state in which the central portion of the coating film 11 (coating surface) is gently rubbed gently with a fingertip so that no mark is left on the coating film 11 (coating surface) (JIS K 5600). -1-1 See 4.3.5 b)).

  In the case where the functional layer forming coating solution is a layer in which the functional layer 11A is formed by applying a non-curing material and only drying the coating film, as the drying state proceeds, the undried state, the touch-dried state, The cured and dried state and the completely cured and dried state change.

  Next, as shown in FIG. 2 (C) and FIG. 3 (C), both ends in the width direction of the coating film 11 of the coating liquid for functional layer formation (in the direction orthogonal to the resin film 10 conveying direction) by the coating film removing roll 41. At both ends). The coating film 11 of the functional layer forming coating solution is removed so that a part of the coated surface of the coating film 11 is exposed when the coating film 11 is in a dry-to-touch state or a semi-cured dry state. Specifically, for example, both ends in the width direction of the coating film 11 are removed so that a part of the surface of the other functional layer 12 is exposed together with the surface of the resin film 10 covered with both ends in the width direction of the coating film 11. . Specifically, for example, both end portions in the width direction of the coating film 11 are removed so that one end portion in the width direction of the other functional layer 12 is exposed. In addition, the coating film 11 removes the width direction both ends of the area | region within 50 mm by the length along the width direction from the width direction edge.

  Thereafter, as shown in FIG. 2D and FIG. 3D, the coating film 11 of the functional layer forming coating liquid from which both ends in the width direction are removed is dried or cured by the second drying or curing apparatus 50B. Thus, the functional layer 11A is formed. In this way, the functional layer 11 </ b> A is formed on the resin film 10.

  Here, the coating film 11 of the functional layer forming coating solution has a tendency that the film thickness at the end in the width direction is thicker than other parts (see FIG. 4), and the function of drying or curing the coating film 11 The end in the width direction of the layer often becomes a region that cannot be used as a functional layer because the performance as a functional layer exhibits different performance from other portions. FIG. 4 is a schematic diagram showing a film thickness profile in the width direction of the coating film of the coating liquid before removing both ends in the width direction of the coating film.

  Therefore, in the functional layer forming apparatus (functional layer forming method) according to the present embodiment, the coating film removing apparatus 40 (coating film) is brought into a dry state or semi-cured drying state by using the first drying or curing device 50A. The removal roll 41) removes both ends in the width direction of the coating film 11 having a film thickness larger than that of the other parts so that a part of the coated surface of the coating film 11 is exposed. That is, both ends in the width direction of the coating film 11 are removed. And the removal of the both ends of the width direction of the coating film 11 is performed in the touch-contact dry state or a semi-hardened dry state. Thereby, since the removal of the both ends of the width direction of a coating film is performed in the state solidified to some extent, the film thickness fluctuation | variation of the width direction both ends of the coating film 11 after removal is suppressed (refer FIG. 5). FIG. 5 is a schematic diagram showing film thickness profiles at both ends in the width direction of the coating film after removing both ends in the width direction of the coating film in the present embodiment.

  On the other hand, the removal of both ends in the width direction of the coating film 11 is performed by a coating film removing apparatus 40 (coating film removing roll 41) in which the removal surface of the coating film 11 is formed of an elastic body. Thereby, even if the said elastic body (elastic layer 41B of the coating-film removal roll 41) contacts with the to-be-coated surface of the coating film 11, since an elastic body elastically deforms, damage to the to-be-coated surface of the coating film 11 is suppressed. In addition, the remaining of the coating film 11 is also suppressed.

  Therefore, in the functional layer forming apparatus (functional layer forming method) according to the present embodiment, the function of the coating liquid of the functional layer with respect to the surface to be coated and the damage to the coated surface are suppressed and the variation in the film thickness is suppressed. A layer is formed.

  Moreover, in the functional layer forming apparatus (functional layer forming method) according to the present embodiment, even if another functional layer 12 is formed on the coated surface of the coating film 11 on the resin film 10, for the same reason as described above, Damage to other functional layers 12 is suppressed. As a result, performance deterioration due to damage to the resin film 10 and other functional layers 12 is suppressed. This is particularly effective when the other functional layer 12 covered with the coating film 11 of the functional layer forming coating solution is exposed by removing both end portions in the width direction of the coating film 11. Specifically, for example, when the electrode is formed on the resin film 10 as the other functional layer 12 and is exposed by removing both end portions in the width direction of the coating film 11 for the purpose of conduction of the electrode, the electrode is damaged. While the conduction failure is suppressed and the remaining of the coating film 11 is suppressed, the conduction failure due to the remaining is also suppressed. This is effective when an indium tin oxide (ITO) electrode that is relatively weak against external impacts (for example, rubbing) as compared with other types is applied as an electrode.

  The functional layer forming apparatus (functional layer forming method) according to the present embodiment is applied to the fields of electro-optical elements, printable electronics for manufacturing these, and the like. Examples of the electro-optical element include a display medium (a liquid crystal element, an optical switching element, an organic electroluminescence element, etc.), a solar cell, and the like.

Specifically, as the functional layer 11A to be formed, for example, a liquid crystal layer, an organic electroluminescence element layer, a photoelectric conversion layer, a light switching layer (for example, a light composed of a laminated body such as a charge generation layer and a charge transport layer) Conductive layer: Note that each layer corresponds to the functional layer 11A). As the functional layer coating liquid for forming these functional layers 11A, well-known liquids corresponding to the types of the functional layers 11A are applied, and non-curable materials or curable materials may be used. May be. That is, the functional layer coating liquid may be either one in which the functional layer 11A is formed only by drying the coating film or one in which the functional layer 11A is formed by causing a curing reaction of the coating film.
Moreover, as another functional layer 12 formed as a lower layer (surface to be coated) of the functional layer 11A, for example, an electrode (for example, an ITO electrode, a gold electrode, a copper electrode, a silver electrode, etc.) or the functional layer 11A itself Also mentioned.
Further, as the resin film 10, for example, a film made of a resin material (for example, polyethylene terephthalate, polysulfone, polyethersulfone, polycarbonate, polyethylene naphthalate, etc.) is used. Moreover, if the resin film 10 uses a plastic thing, it is good from a flexible display medium and a solar cell being obtained. Moreover, when applying to the display medium and a solar cell, the resin film 10 is good to use a transparent film. In addition, although the thickness of the resin film 10 is not specifically limited, For example, it is good to set it as the range of 0.01 mm or more and 0.5 mm or less.

  Hereinafter, the present invention will be described more specifically with reference to examples. However, these examples do not limit the present invention.

Example 1
-Resin film-
A PET film (width 180 mm) having a thickness of 125 μm on which an ITO electrode (width direction 125 mm × conveyance direction 250 mm) having a thickness of 0.08 μm was formed so as to be arranged with a specific gap along the film conveyance direction was prepared. (See the arrangement in Figure A).

-Functional layer forming coating solution-
74.8 parts by mass of nematic liquid crystal E8 (manufactured by Merck) having positive dielectric anisotropy, 21 parts by mass of chiral agent CB15 (manufactured by BDH), and 4.2 parts by mass of chiral agent R1011 (manufactured by Merck) Was heated and dissolved, and then returned to room temperature to obtain a chiral nematic liquid crystal that selectively reflects blue-green color light.
To 10 parts by weight of this blue green chiral nematic liquid crystal, 3 parts by weight of an adduct of 3 moles of xylene diisocyanate and 1 mole of trimethylolpropane (D-110N manufactured by Takeda Pharmaceutical Co., Ltd.) and 100 parts by weight of ethyl acetate are added to obtain a homogeneous solution. A liquid to be an oil phase was prepared.
On the other hand, 10 parts by mass of polyvinyl alcohol (Poval 217EE manufactured by Kuraray Co., Ltd.) was added to 1000 parts by mass of heated ion-exchanged water, stirred, and then allowed to cool to prepare a liquid that became an aqueous phase.
Next, an oil-in-water solution in which 10 parts by mass of the oil phase was emulsified and dispersed in 100 parts by mass of the aqueous phase for 1 minute by a household mixer provided with 30 V alternating current by a slidac, and oil phase droplets were dispersed in the aqueous phase. An emulsion was prepared. The oil-in-water emulsion was stirred for 2 hours while being heated in a water bath at 60 ° C. to complete the interfacial polymerization to form liquid crystal microcapsules. When the average particle diameter of the obtained liquid crystal microcapsule was measured by a laser particle size distribution meter, it was estimated to be about 12 μm.
The obtained liquid crystal microcapsule dispersion was filtered through a 38 μm mesh stainless steel mesh and allowed to stand overnight, and the milky white supernatant was removed to obtain a slurry having a solid component of about 40% by mass consisting of liquid crystal microcapsules.
A functional layer-forming coating solution was prepared by adding a solution of 12% by mass of polyvinyl alcohol containing polyvinyl alcohol in an amount of 2/3 with respect to the mass of the solid component to the obtained slurry.

-Coating film removal device-
A shaft made of SUS303 having an outer diameter of 20 mm and a length of 200 mm was prepared, and a rubber sponge layer (elastic layer) was formed on the outer peripheral surface thereof to prepare two coating film removing rolls.

  The functional layer coating solution and each member were applied to the functional layer forming apparatus according to the present embodiment (see FIG. 1), and the functional layer was formed as follows according to the functional layer forming method according to the present embodiment ( 2 and 3).

First, while transporting the resin film, the functional layer coating liquid is applied to the surface of the resin film by a coating device (a die coating device equipped with a die head and capable of transporting a roll-shaped film), and the functional film after passing through the second drying device. A coating film was formed so that the film thickness of the film was 40 μm. This coating film was formed with a width (160 mm) so as to cover the ITO electrode formed on the resin film.
Next, a hot air slit blowing device was used as the first drying device, and the coating film was dried so that warm air at a temperature of 40 ° C. hits the coating film surface at a wind speed of 0.2 m / s or less. When this coating film was examined, it was in a touch-and-dry state.
Next, both end portions in the width direction of the coating film in a dry-to-touch state were removed while pressing the two coating film removing rolls toward the resin film with a pressure of 0.05 MPa. The removal of the coating film was performed so that each of the 20 mm wide regions at both ends in the width direction of the coating film was removed and one end in the width direction of the ITO electrode was exposed at a width of 10 mm.
Next, a hot air slit blower is used as the second drying device so that 100 ° C. hot air hits the coating surface at a wind speed of 2.0 to 3.0 m / s, and both ends in the width direction are removed. The functional layer (liquid crystal layer) was formed by drying the coated film.

The film thickness of the obtained functional layer was evaluated as follows. Using Nikon Digimicro MF-501, the difference in thickness of the substrate from the measured value was taken as the film thickness. The film thickness distribution in the width direction at the center position in the conveyance direction of the ITO electrode pattern was evaluated. The width direction was measured at intervals of 5 mm, and the measurement was started and ended at positions 5 mm from the width side end of the coating film on the ITO pattern. The total number of measurement points was 22 as shown in FIG. And it computed as film thickness nonuniformity based on the following formula | equation.
Unevenness of film thickness = | (average of 6 points for each of 3 points on both ends)-(average value at all measurement points) | / (average value at all measurement points). The evaluation criteria are as follows. The results are shown in Table 1.
○: Less than 0.15 Δ: 0.15 or more and less than 0.4 ×: 0.4 or more

Moreover, the surface of the resin film and ITO electrode exposed after removing the coating film for forming the functional layer was evaluated as follows. The remaining of the coating film and damage to the ITO electrode were determined based on whether the liquid crystal was driven by applying a voltage after creating the device as follows.
First, the resin film on which the ITO electrode and the functional layer (liquid crystal layer) were formed as described above was cut into a width of 130 mm and a conveyance direction length of 260 mm (see FIG. 7). In FIG. 7, the other functional layer 12 corresponds to an ITO electrode.
Next, a resin film (PET film) on which the same ITO electrode as that described above was formed was prepared, and a double-sided adhesive film having a thickness of 5 μm was pasted on the ITO electrode with a laminating apparatus.
Next, the resin film on which the ITO electrode and the functional layer (liquid crystal layer) are formed and the resin film on which the ITO electrode is formed face each other on the ITO electrode formation surface side (see FIG. 8A), and these After bonding, pressure bonding was performed with a press device (see FIG. 8B: however, two 0 resin films were pressure bonded so that some of the ITO electrodes were not in contact with each other). This produced the liquid crystal display element. In FIG. 8, 110 indicates a resin film, 120 indicates an ITO electrode, and 121 indicates a double-sided tape.
First, a voltage of 800 V is applied at 10 Hz and 2 pulses between the exposed ITO electrodes of the obtained liquid crystal display element, and then a voltage of 10 Hz, 2 pulses and 400 V is applied to visually check whether the display is switched by driving the liquid crystal. It was confirmed that the film remained and the ITO electrode was damaged. This was carried out 50 sheets. The evaluation criteria are as follows. The results are shown in Table 1.
◎: No drive failure (damage or paint film remaining) ◎: Drive failure less than 5% ○: Drive failure less than 10% △: Drive failure less than 30% ×: Drive failure exceeding 30%

(Examples 2 to 5)
According to Table 1, a functional layer was formed and evaluated in the same manner as in Example 1 except that the constituent material type of the coating film removal surface (elastic layer) of the coating film removal apparatus (coating film removal roll) was changed. . The results are shown in Table 1.

(Example 6)
The above coating solution is used as the functional layer forming coating solution, and the conditions of the first drying apparatus are such that warm air at a temperature of 40 ° C. hits the coating surface at a wind speed of 1.0 m / s to 2.0 m / s, and second drying is performed. A functional layer was formed and evaluated in the same manner as in Example 1 except that the conditions of the apparatus were the same as in Example 1. The results are shown in Table 1.
In addition, when the state of the said coating film after drying the coating film of a functional layer formation coating liquid with the 1st drying apparatus was investigated, it was a semi-hardened dry state.

(Example 7)
A functional layer was formed and evaluated in the same manner as in Example 1 except that a coating film removing roll obtained by impregnating the elastic layer (rubber sponge layer) with water was applied. The results are shown in Table 1.

(Comparative Example 1)
A functional layer was formed and evaluated in the same manner as in Example 1 except that a metal blade (metal blade made of SUS304) was applied as the coating film removing apparatus. The results are shown in Table 2.

(Comparative Example 2)
The same as in Example 2 except that both ends of the coating film were removed by the coating film removing roll before the coating film of the functional layer forming coating solution was brought into the dry-to-touch state without any treatment by the first drying apparatus. The functional layer was formed and evaluated. The results are shown in Table 2.

(Comparative Example 3)
Except that the functional layer coating solution was applied with a width of 120 mm so that one end in the width direction of the ITO electrode exposed a 10 mm wide region and covered the ITO electrode in the other region, the same as in Example 2 A functional layer was formed and evaluated. The results are shown in Table 2.

(Comparative Example 4)
The conditions of the first drying apparatus were such that hot air at a temperature of 100 ° C. hits the coating film surface at a wind speed of 1.0 m / s to 2.0 m / s, and the second drying apparatus was the same as in Example 1. Were evaluated by forming a functional layer in the same manner as in Example 1. The results are shown in Table 2.

  From the above results, it can be seen that in this example, the variation in the film thickness of the functional layer is suppressed, and the remaining of the coating liquid and the suppression of damage are suppressed on the surfaces of the resin film and the ITO electrode, as compared with the comparative example. .

It is a schematic block diagram which shows the principal part of the functional layer forming apparatus which concerns on this embodiment. It is process drawing which shows the functional layer forming apparatus which concerns on this embodiment. It is process drawing which shows the functional layer forming apparatus which concerns on this embodiment. It is a schematic diagram which shows the film thickness profile of the width direction of the coating film of the coating liquid before removing the width direction both ends of a coating film. In this embodiment, it is a schematic diagram which shows the film thickness profile of the width direction both ends of a coating film after removing the width direction both ends of a coating film. In an Example, it is a schematic diagram which shows the measuring point of the film thickness of a functional layer. In an Example, it is a schematic diagram which shows a mode that the resin film in which the ITO electrode and the functional layer (liquid crystal layer) were formed was cut | disconnected. In an Example, it is a schematic diagram which shows a mode that the resin film in which the ITO electrode and the functional layer (liquid crystal layer) were formed, and the resin film in which the ITO electrode and the double-sided tape were formed were bonded together.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Resin film 11A Functional layer 11 Coating film 12 Other functional layers 20, 21 Support roll 30 Coating apparatus 40 Coating film removal apparatus 41 Coating film removal roll 41A Shaft 41B Elastic layer 50A 1st drying or hardening apparatus 50B 2nd drying or hardening Device 101 Functional layer forming device 110 Resin film 120 ITO electrode 121 Double-sided tape

Claims (12)

On the resin film, a coating means for coating the functional layer forming coating liquid to form a coating film,
A first drying or curing means for drying or curing the coating film to bring the coating film into a touch-dried or semi-cured dry state;
A coating film removing means for removing both ends in the width direction of the touch-dried or semi-cured dried film so that a part of the coated surface of the coated film is exposed. A coating film removing means whose surface is made of an elastic body;
A second drying or curing means for drying or curing the coating film from which both ends in the width direction are removed to form a functional layer;
A functional layer forming apparatus comprising:   The functional layer forming apparatus according to claim 1, wherein the elastic body has a hardness of 10 or more and 40 or less.   The functional layer forming apparatus according to claim 1, wherein the elastic body is impregnated with a solvent.   The functional layer forming apparatus according to claim 1, wherein the coating film removing unit is disposed by pressing the elastic body against a coated surface side of the coating film.   The functional layer forming apparatus according to claim 1, wherein a plurality of the coating film removing means are provided.     The other functional layer is formed on the coated surface of the coating film on the resin film, and a part of the other functional layer is exposed by removing the coating film by the coating film removing means. The functional layer forming apparatus as described. On the resin film, a step of applying a functional layer forming coating solution to form a coating film,
Drying or curing the coating film to bring the coating film into a touch-dried state or a semi-cured dry state;
By the coating film removing means in which the removal surface of the coating film is formed of an elastic body, both ends in the width direction of the coating in the touch-dried state or semi-cured drying state are applied to both ends in the width direction of the coating film. Removing to expose a part of the coated surface of the film;
The step of drying or curing the coating film from which both ends in the width direction are removed to form a functional layer;
A method for forming a functional layer.   The method for forming a functional layer according to claim 7, wherein the elastic body has a hardness of 10 or more and 40 or less.   The method for forming a functional layer according to claim 7, wherein the elastic body is impregnated with a solvent.   The method for forming a functional layer according to claim 7, wherein an elastic body of the coating film removing unit is pressed against a coated surface side of the coating film to remove both end portions in the width direction of the coating film.   The method for forming a functional layer according to claim 7, wherein both end portions in the width direction of the coating film are removed by a plurality of the coating film removing means.   The other functional layer is formed on the coated surface of the coating film on the resin film, and a part of the other functional layer is exposed by removing the coating film by the coating film removing means. The formation method of the functional layer of description.

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