JP2014188488A - Coating device and coating method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress deterioration of productivity and regulate a forming state of a coating liquid layer.SOLUTION: A coating device 100 adjusts an intermittent coating liquid supply amount to a die head 310, timing of starting and finishing of the intermittent coating liquid supply, and an interval between the die head 310 and a base material K. About a coating liquid layer S which has been formed on the base material K, a target amount, coating length, and coating width are detected, and feedback control of coating liquid supply amount control, timing adjustment control, and interval adjustment control is performed so as to the detected target amount, the detected coating length, and the detected coating width match their allowable range respectively.

Description

  The present invention relates to a coating apparatus and a coating method.

  A coating technique for intermittently forming spray marks, which are sprayed with a coating liquid, on a substrate as a coating liquid layer is widely spread, and it has been proposed to improve the formation position accuracy of the coating liquid layer ( For example, Patent Document 1).

Japanese Patent Laid-Open No. 9-19654

  Although the above-mentioned coating method improves the formation position accuracy of the coating liquid layer, consideration is given to the formation status other than the formation position of the coating liquid layer formed repeatedly, for example, the vertical and horizontal dimensions and the basis weight. Is lacking. That is, even if the formation position of the coating liquid layer is adapted to a predetermined pitch, these are not necessarily adapted to the basis weight of the coating liquid layer and the vertical and horizontal dimensions. Therefore, it is not enough to set the coating position of the coating liquid layer with the sensor.For example, use a gauge that defines the vertical and horizontal dimensions or a gauge that estimates the basis weight, and compare these gauges with the formed coating liquid layer. The actual situation is that the apparatus is appropriately adjusted to form the coating liquid layer formation. It is desirable to avoid equipment adjustment as much as possible because it causes a decrease in productivity with a temporary stop of the coating line. For these reasons, it has been requested that the formation of the coating liquid layer be standardized while suppressing the decrease in productivity. In addition, it is also required to simplify the coating method for intermittently forming the coating liquid layer and to reduce the number of steps.

  In order to achieve at least a part of the problems described above, the present invention can be implemented as the following forms.

  (1) According to one aspect of the present invention, a coating apparatus is provided. This coating apparatus is a coating apparatus that intermittently forms a spray mark sprayed with a coating liquid on a base material as a coating liquid layer, and a die head that sprays the coating liquid against the base material; First control for adjusting the supply amount of the coating liquid when the intermittent supply of the coating liquid to the die head is set as a first control amount, and start and stop of the intermittent coating liquid supply The second control for adjusting the timing of the second control amount as the second control amount and the third control for adjusting the distance between the die head and the substrate as the third control amount are used in combination, and relative to the die head. A coating control unit that intermittently forms the coating liquid layer on the base material to be driven, and a formation state detection unit that detects a formation state of the coating liquid layer already formed on the base material The coating control unit detects the formation status detection unit for the formed coating liquid layer. The coating solution layer shaped situation to match the coating solution layer shaped allowable range, the feedback control of the at least one of the third control amount from the first. In the coating apparatus of the said form, if the formation condition of the coating liquid layer already formed in the base material is detected and the detected coating liquid layer shape deviates from the allowable range, the first to third Through the feedback control of the control amount, the coating liquid layer already formed on the base material can be matched with the coating liquid layer shape within the allowable range, and at this time, the apparatus does not need to be stopped. Therefore, according to the coating apparatus of the said form, the formation state of a coating liquid layer can be standardized, after suppressing the fall of productivity. Moreover, the cost reduction and quality improvement of the product in which the coating liquid layer has been intermittently formed on the substrate can be achieved by suppressing the decrease in productivity.

  (2) In the coating apparatus of the above-described form, the formation state detection unit detects the basis weight of the formed coating liquid layer as the coating liquid layer shape state, and the coating control unit The first control amount can be feedback-controlled according to the degree of difference in basis weight between the detected basis weight and the allowable basis weight in the coating liquid layer shape within the allowable range. In addition, the formation state detection unit detects the coating length along the relative driving direction of the base material with respect to the die head as the coating liquid layer shape state for the formed coating liquid layer, The coating control unit feedback-controls the second control amount in accordance with a layer length difference between the detected coating length and an allowable coating length in the allowable coating liquid layer shape. Can be. Further, the formation state detection unit detects, as the coating liquid layer shape state, a coating width that intersects a relative driving direction of the base material with respect to the die head for the formed coating liquid layer. The process control unit feedback-controls the third control amount in accordance with a difference in the layer width between the detected coating liquid width and the allowable coating liquid width in the allowable coating liquid layer shape. Can be. The amount of coating liquid supplied to the die head is related to the weight of the coating liquid layer, and the timing of starting and stopping the coating liquid feeding is related to the coating length of the coating liquid layer. The distance from the material is related to the coating width. Therefore, according to the coating apparatus of any one of the above forms, the basis weight, the coating length, and the coating width as the formation state of the coating liquid layer can be stabilized.

  (3) In the coating apparatus of the above-described form, when the feedback control according to the degree of difference in basis weight is required simultaneously with other feedback, the coating control unit feedback according to the degree of difference in basis weight. Control can be executed preferentially. The thickness of the coating liquid layer is regarded as important in defining the quality of a product in which the coating liquid layer has been intermittently formed on the substrate, and is defined by the basis weight of the coating liquid layer. Therefore, according to this form of the coating apparatus, stabilization of the basis weight is preferentially achieved, thereby preferentially stabilizing and uniforming the thickness of the coating liquid layer which is important in terms of product quality regulations. You can Thus, after stabilizing the basis weight, the coating length and coating width can also be stabilized.

  (4) In any one of the above-described coating apparatuses, the coating control unit performs the feedback control of the first to third control amounts, and the detected basis weight and the coating length. And when the detection item of any one of the coating liquid width deviates continuously from the corresponding allowable weight per unit area, the allowable coating length, or the allowable coating liquid width a plurality of times, the deviating detection Feedback control corresponding to the item can be performed. By so doing, it is possible to stabilize the basis weight, the coating length, and the coating width while limiting the execution of feedback control.

  (5) According to another aspect of the present invention, a coating method is provided. This coating method is a coating method that intermittently forms a spray mark sprayed with a coating liquid on a substrate as a coating liquid layer, and is directed to a die head that sprays the coating liquid facing the substrate. The first control for adjusting the coating liquid supply amount when the intermittent supply of the coating liquid as the first control amount is adjusted, and the timing of the start and stop of the intermittent coating liquid supply are The second control that is adjusted as the control amount of 2 and the third control that adjusts the distance between the die head and the base material as the third control amount are used in combination, and are driven relative to the die head. A coating process for intermittently forming the coating liquid layer on the base material, and a detection process for detecting the formation status of the coating liquid layer already formed on the base material, The coating liquid layer shape detected in the detection step is acceptable for the formed coating liquid layer To match the coating solution layer shape circumference, the feedback control of the at least one of the third control amount from the first. According to the coating method of the said form, after the fall of productivity can be suppressed, the formation of the formation state of a coating liquid layer can be aimed at. Moreover, the cost reduction and quality improvement of the product in which the coating liquid layer has been intermittently formed on the substrate can be achieved by suppressing the decrease in productivity.

  The present invention can be realized in various forms. For example, a manufacturing apparatus and a manufacturing method of a membrane electrode assembly in which a base material is an electrolyte membrane and a coating liquid layer is an anode or cathode electrode catalyst layer. Or the like.

It is explanatory drawing which shows schematic structure of the coating apparatus 100 as embodiment of this invention. It is explanatory drawing which shows the relationship between the die head 310 and the coating guide roller 302, after enlarging the A section in FIG. It is explanatory drawing which shows a mode that the coating liquid layer S was formed in the base material K intermittently. 3 is an explanatory diagram showing an outline of control performed by a control device 102. FIG. 4 is a flowchart showing processing contents of coating control performed by a control device 102.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an explanatory diagram showing a schematic configuration of a coating apparatus 100 according to an embodiment of the present invention. FIG. 2 is a schematic enlarged view of a portion A in FIG. 1 and then a die head 310 and a coating guide roller 302. It is explanatory drawing which shows the relationship.

  As shown in the figure, the coating device 100 includes a control device 102, a base material delivery zone 200, a coating zone 300, a shape measurement zone 400, a drying zone 500, a basis weight measurement zone 600, and a take-up housing. Zone 700. The substrate feeding zone 200 includes upstream guide rollers 202 to 204, a tension roller 205, and downstream guide rollers 206 to 207 in addition to the substrate supply roller 201. The base material supply roller 201 winds and stores the film-like base material K in a roll shape, rotates under the drive control of the control device 102 described later, and sends out the base material K. The upstream guide rollers 202 to 204 convey the base material K sent out from the base material supply roller 201 to the downstream side while guiding the base material K while maintaining the conveyance trajectory. The tension roller 205 can move up and down in the drawing and rotates by itself to convey the substrate K downstream while applying tension. The raising and lowering and rotation of the tension roller 205 are controlled by the control device 102. The downstream guide rollers 206 to 207 convey the fed substrate K to the downstream coating zone 300 while guiding the substrate K while maintaining its conveyance locus.

  The coating zone 300 includes an upstream guide roller 301, a coating guide roller 302, a die head 310, a coating liquid pressure feeding mechanism 320, and a die head position adjusting mechanism 330 from the upstream side of the substrate conveyance path. The upstream guide roller 301 guides the base material K conveyed from the base material feed zone 200 along the surface of the coating guide roller 302. The coating guide roller 302 brings the base material K into contact with the roller surface, rotates under the control of the control device 102, transports the base material K downstream, and applies the coating liquid applied from the die head 310. Take coating pressure. The die head 310 opposes the base material K held in contact with the coating guide roller 302, and sprays and applies the coating liquid intermittently fed from the coating liquid pressure feeding mechanism 320 to the base material K. As shown in detail in FIG. 2, the die head 310 includes a coating hole 312 opened in a rectangular shape at the tip of the head, and the long side direction of the coating hole 312 is aligned with the width direction of the base material K. Opposite to. Then, the die head 310 sprays the coating liquid from the coating hole 312 to the base material K in the spray form Sr as shown in the drawing Dd from the surface of the coating guide roller 302. The spraying of the coating liquid from the die head 310 is performed in cooperation with a coating liquid pumping mechanism 320 described later.

  The coating liquid pressure feeding mechanism 320 includes a coating liquid tank 321, a stirring motor 322, a coating liquid pressure feeding motor 324, a coating liquid delivery valve 325, a die supply path 326, a return flow path 327, and an electromagnetic actuator. 328. The coating liquid tank 321 stores the coating liquid, and the stirring motor 322 rotates the fins at the lower end of the shaft under the drive control of the control device 102 to stir the coating liquid in the coating liquid tank 321. The coating liquid pumping motor 324 is driven to rotate under the control of the control device 102, and pumps the supply amount of coating liquid commanded from the control device 102 to the die head 310 via the coating liquid delivery valve 325. The supply amount at this time has a correlation with the basis weight of the coating liquid layer S described later. The coating liquid delivery valve 325 switches the flow between the die supply path 326 and the return flow path 327 and opens / closes the die supply path 326 and returns the flow by an electromagnetic actuator 328 that is driven backward by the control of the control device 102. The path 327 is opened and closed. The coating liquid delivery valve 325 opens and closes the die supply path 326 connected to the in-head flow path of the die head 310, thereby starting and stopping the feeding of the coating liquid to the die head 310, that is, The timing for starting and stopping the application (spraying) of the coating liquid from the die head 310 toward the substrate K is determined. The coating liquid delivery valve 325 opens and closes the return flow path 327 after closing the die supply path 326 by the electromagnetic actuator 328, and the coating liquid fed from the coating liquid pressure feed motor 324 after the die supply path 326 is closed. Is returned to the coating liquid tank 321. The coating liquid pressure feeding mechanism 320 intermittently repeats the driving of the coating liquid pressure feeding motor 324 and the electromagnetic actuator 328 under the control of the control device 102 to intermittently apply the coating liquid from the die head 310 to the substrate K. The coating liquid layer S is intermittently formed on the substrate K by spraying.

  Here, the relationship between the coating liquid layer S applied by the die head position adjusting mechanism 330 and the substrate K, and the timing of supplying / stopping the coating liquid will be described. FIG. 3 is an explanatory view showing a state where the coating liquid layer S is intermittently formed on the substrate K. FIG. As shown in the figure, the coating liquid layer S is formed on the base material K intermittently on the base material K with the coating length MD and the coating width TD, and is conveyed to the right in the drawing. The coating start and the coating stop of the coating liquid are repeated for the material K. Each timing of the start and stop of the coating is determined by the coating length MD of the coating liquid layer S and the conveyance speed of the substrate K, and is adjusted and controlled by the control device 102. The coating width TD of the coating liquid layer S is determined by the dimension in the long side direction of the coating hole 312 of the die head 310 shown in FIG. 2, and the spread of the skirt of the spray form Sr differs depending on the distance Dd. It is determined by the influence of the distance Dd. The coating length MD is also affected by the distance Dd and the short side dimension of the coating hole 312, but the short side dimension of the coating hole 312 is shorter in each step than the long side dimension. The influence of the distance Dd on the long MD is small. As shown in the figure, the front end side and the rear end side of the coating liquid layer S receive the start and stop of spraying of the coating liquid from the coating hole 312 and are different from the rectangular linear long and short side locus. The control device 102 calculates the coating length MD and the coating width TD of the coating liquid layer S through image analysis.

  As shown in FIG. 1, the die head position adjustment mechanism 330 includes a die head drive table 332 and a drive motor 334. The die head drive table 332 includes a ball screw and a linear rail (not shown), and the die head 310 is slidably engaged with the rail. The drive motor 334 is configured as a pulse motor that can rotate forward and backward, and rotates under the control of the control device 102 to drive the ball screw of the stirring motor 322. Thereby, the die head position adjusting mechanism 330 adjusts the distance Dd (see FIG. 2) between the die head 310 and the coating guide roller 302 in a wide and narrow manner. The wide and narrow adjustment of the distance Dd is performed by controlling the rotation direction of the drive motor 334 and the drive amount (number of pulses) by the control device 102.

  The shape measurement zone 400 includes a first sensor 410, a second sensor 420, and a dry delivery guide roller 430. The drying delivery guide roller 430 rotates under the control of the control device 102, and guides the base material K to and from the coating guide roller 302 in the coating zone 300 and conveys the base material K to the drying zone 500. Bear. The first sensor 410 is configured as a transmissive optical sensor if the substrate K has translucency, and is configured as a reflective optical sensor if the substrate K is non-translucent. As shown in FIG. 2, the front end position (coating start position) and the rear end position (coating stop position) of the coating liquid layer S applied to the substrate K are detected. This detection signal is transmitted to the control device 102 and used for timing adjustment in the control device 102. The second sensor 420 is configured as a CCD (Charge Coupled Device) camera, captures a planar view image of the coating liquid layer S already formed on the substrate K, and transmits the captured image to the control device 102. The captured image includes a coating liquid layer S having a coating length MD and a coating width TD superimposed on the base material K, and the control device 102 reads the coating length MD and the coating width TD from the captured image. . Then, the control device 102 uses the read coating length MD and coating width TD to start and stop the spraying of the coating liquid from the die head 310, that is, start the feeding of the coating liquid to the die head 310 and The drive timing of the electromagnetic actuator 328 of the coating liquid delivery valve 325 to be stopped is adjusted.

  In the drying zone 500, the coating liquid layer S is dried by a heater 502 that generates heat under the control of the control device 102 while horizontally transporting the substrate K using a roller (not shown). The basis weight measurement zone 600 includes an upstream roller 601, a downstream roller 602, and a basis weight sensor 610. The upstream roller 601 and the downstream roller 602 rotate under the control of the control device 102 and hold the substrate K conveyed from the drying zone 500 horizontally and convey it downstream. The basis weight sensor 610 has an X-ray transmission type sensor structure, and inputs X-rays irradiated from the upper side of the coating liquid layer S formed on the base material K on the lower side of the base material K. Based on the input amount, the basis weight of the coating liquid layer S formed on the substrate K, that is, the mass of the coating liquid layer S per unit area is measured, and the measurement result is transmitted to the control device 102. The control device 102 uses the received basis weight (detected basis weight) for controlling the amount of coating liquid supplied to the die head 310, that is, the rotational driving amount of the coating liquid pumping motor 324.

  In addition to the base material collection roller 701, the take-up accommodation zone 700 includes upstream guide rollers 702 to 706, a tension roller 707, an appearance sensor 710, and a marking device 720. The base material collection roller 701 rotates under the control of the control device 102 described later, and winds and collects the base material K on which the coating liquid layer S has been formed in a roll shape. The base material collection roller 701 that has collected and wound up the base material K is conveyed to a post-process line (not shown) for the base material K. The upstream side guide rollers 702 to 706 convey the base material K fed from the basis weight measurement zone 600 to the downstream side while guiding the base material K while maintaining its conveyance path. The tension roller 707 conveys downstream while applying a tension necessary for winding the substrate by the substrate collection roller 701 to the substrate K. The appearance sensor 710 is configured as a CCD camera, captures a planar image of the coating liquid layer S already formed on the base material K, and transmits the captured image to the control device 102. The control device 102 determines the quality of the appearance of the coating liquid layer S from the received captured image, and the marking device 720 performs defective marking on the coating liquid layer S with a poor appearance. The imaging by the appearance sensor 710 is for identifying damage such as scratches or defects in the coating liquid layer S after drying, and is not used for timing adjustment of coating liquid supply / stop.

  The control device 102 is configured as a computer having a ROM, a RAM, and the like in addition to a CPU that performs a logical operation, and drives and controls the entire coating apparatus 100. For example, the control device 102 drives and controls a motor associated with each roller included in the base material feed zone 200, the take-up storage zone 700, and the like to transport the base material K at a constant speed. Further, the control device 102 controls the heater 502 in the drying zone 500 to control the drying state of the formed coating liquid layer S, or the appearance of the coating liquid layer S based on the image captured by the appearance sensor 710. The quality determination and the marking by the marking device 720 on the coating liquid layer S with poor appearance are executed and controlled. In addition to such control commonly used for the coating apparatus 100, the control apparatus 102 calculates the coating length MD and coating width TD of the coating liquid layer S based on the sensor input from the second sensor 420 in the shape measurement zone 400. In addition to calculating and determining whether or not this is appropriate, adjusting the timing of starting and stopping the feeding of the coating liquid to the die head 310 based on sensor inputs from the first sensor 410 and the second sensor 420, and the basis weight sensor in the basis weight measurement zone 600 Based on the sensor input from 610, the coating liquid supply amount to the die head 310 is adjusted. Hereinafter, these timing adjustment and supply amount adjustment will be described. FIG. 4 is an explanatory diagram showing an outline of the control performed by the control device 102.

  As shown in the drawing, the control device 102 has already described the coating liquid layer S formed on the substrate K by the die head 310 in the coating zone 300 every time the coating liquid layer S is formed. Each time the first sensor 410, the second sensor 420, or the weight sensor 610 is reached and sensed by each sensor, the sensor input is accepted. Assuming that the illustrated sensor input locus P1 is the basis weight of the coating liquid layer S sensed by the basis weight sensor 610, the control device 102 inputs and detects the basis weight for each of the formed coating liquid layers S, and detects the detected amount. The determined basis weight (detected basis weight) is stored. This stored result is plotted in FIG. The control device 102 stores in advance a basis weight range Lmax allowed as a basis weight of the coating liquid layer S, a reference center value Lc thereof, and a feedback control feasibility determination range Hc for the basis weight. Then, the control device 102 monitors the transition of the sensing basis weight (detected basis weight) of the basis weight sensor 610, and starts counting when the detected basis weight deviates from the feasibility determination range Hc.

  After that, the control device 102 monitors the transition of the detected basis weight, and if the execution possibility determination range Hc deviates continuously m times (for example, 3 to 5 times) (counting result = m), feedback control of the basis weight is performed. As necessary, the parameter that defines the basis weight, that is, the coating liquid supply amount of the coating liquid pumping motor 324 described above is feedback-controlled so that the basis weight matches the reference center value Lc. The feedback correction amount Δh at the time of this feedback control may be the difference between the m-th detected basis weight where the detected basis weight continuously deviates from the execution feasibility determination range Hc and the reference center value Lc. It may be a difference between the m-th average detected basis weight that deviates continuously from the possibility determination range Hc and the reference center value Lc. In addition, the feedback correction amount Δh may be a specified value such as half of the feasibility determination range Hc or half of the basis weight range Lmax. By such feedback control, the coating liquid supply amount from the coating liquid pumping motor 324 is corrected, and the basis weight of the coating liquid layer S after execution of the feedback control matches the corrected coating liquid supply amount. In the case of FIG. 4 where the basis weight deviates from the upper limit side of the feasibility determination range Hc, the basis weight of the coating liquid layer S after execution of the feedback control is reduced by a liquid amount that matches the feedback correction amount Δh. If the detected basis weight deviates from the basis weight range Lmax continuously at least twice, the coating liquid supply amount from the coating liquid pumping motor 324 may be feedback-corrected as described above.

  The coating liquid layer S formed by receiving the feedback control and correcting the coating liquid supply amount is located at the position where the die head 310 and the coating guide roller 302 are disposed, and whether or not the feedback control can be executed is determined. The coating liquid layer S that has become an opportunity to be determined is at the sensing position of the basis weight sensor 610. Therefore, the formed coating liquid layer S already exists between the two coating liquid layers S, and feedback control is not involved for these coating liquid layers S. For this reason, the above-mentioned number of times m that determines whether or not feedback control can be performed is determined based on the coating liquid layer S in the process of being transported between the position where the die head 310 and the coating guide roller 302 are disposed and the sensing position of the basis weight sensor 610. It may be determined according to the number. For example, the number m may be half the number of coating liquid layers S in the process of transporting to the basis weight sensor 610, or may be about 1/3 to 1/5 (natural number). Alternatively, the number m may be set based on the transition state of the detected basis weight monitored by the control device 102. For example, in the transition status of the detected basis weight after the above-described counting is started, in FIG. 4, the difference between the upper limit of the basis weight range Lmax and the upper limit of the feasibility determination range Hc is half based on the increase status. The number of times of arrival may be predicted, and the number of times of prediction may be set as the above number m.

  On the other hand, as shown in the sensor input locus P2 indicated by a dotted line in the figure, when the detected basis weight once deviating from the execution feasibility determination range Hc falls within the execution feasibility determination range Hc, the control device 102 executes the feedback control described above. Without monitoring, the transition of the detected basis weight is continuously monitored. When the detected basis weight again deviates from the execution feasibility determination range Hc, counting is started. In the situation such as the sensor input locus P2, the count up to that point is reset.

  For the coating length MD and coating width TD of the coating liquid layer S, the control device 102 observes the transition of the detected coating length and the detected coating width as shown in FIG. Then, the control device 102 starts the spray start timing and the stop timing of the coating liquid in response to m consecutive deviations from the execution feasibility determination range Hc for the coating length MD and the coating width TD (see FIG. 3). Alternatively, the distance Dd (see FIG. 2) of the die head 310 is adjusted. Specifically, the control device 102 performs feedback control of the drive timing of the electromagnetic actuator 328 that defines the above timing and the drive control of the drive motor 334 that defines the distance Dd. Since the first sensor 410 and the second sensor 420 for sensing the coating length MD and the coating width TD are immediately downstream of the positions where the die head 310 and the coating guide roller 302 are disposed, It is not necessary to consider the number of coating liquid layers S in the conveyance process, and the number of coating liquids MD or the coating width TD is assumed to be a number of times that may deviate from the execution determination range Hc. It may be the same as the specified number of times or the number of times of the basis weight.

  FIG. 5 is a flowchart showing the contents of the coating control process performed by the control device 102. As illustrated, the control device 102 inputs detection values from each of the first sensor 410, the second sensor 420, and the basis weight sensor 610 (step S100). Next, the control device 102 stores the input sensor detection value and observes the transition of the detection weight, the detection coating length MD, and the detection coating width TD for each detection value (step S110). In step S110, as described with reference to FIG. 4, the control device 102 compares the detected values of the detected basis weight, the detected coating length MD, and the detected coating width TD with the respective execution feasibility determination ranges Hc. From the comparison result, the control device 102 determines whether or not there is a deviation from the execution possibility determination range Hc, counts the number of times when a continuous deviation occurs, and within the range from outside the execution determination range Hc. Reset the count when convergence to.

  Next, the control device 102 determines whether the detected value of the detected weight per unit area, the detected coating length MD, or the detected coating width TD has deviated continuously from the execution feasibility determination range Hc by the number of times m. It is determined whether or not (step S120). Here, if it is determined that none of the detection values has caused the continuous deviation of the number m, this routine is once ended. On the other hand, if it is determined in step S120 that any one of the detected values has caused the continuous deviation of the number m, the control device 102 determines whether the detected value that has caused the continuous deviation of the number m is the detected basis weight. It is determined whether or not (step S130). The situation that has proceeded to step S130 includes the first situation in which all of the detected basis weight, the detected coating length MD, and the detected coating width TD have caused continuous deviation of the number m, and the detected coating amount in addition to the detected basis weight. The second situation in which either one of the length MD and the detection coating width TD has caused the continuous deviation of the number m, and the detection coating length MD and / or the detection coating width TD other than the detection weight are the number m. And a third situation in which a continuous departure has occurred. Therefore, in step S130, an affirmative determination is made for the first situation and the second situation in which the detected basis weight has caused the continuous deviation of the number m, and the third situation in which the detected basis weight has not caused the continuous deviation of the number m. Is negatively determined.

  If the control device 102 makes an affirmative determination in step S130, the coating liquid supply amount of the coating liquid pumping motor 324 that defines the basis weight of the coating liquid layer S is set to a feedback correction amount Δh as shown in FIG. Is used for feedback control (step S140). Specifically, the number of revolutions of the coating liquid pressure feed motor 324 is controlled to increase or decrease according to the feedback correction amount Δh for the basis weight. As a result, the amount of the coating liquid sprayed onto the substrate K from the die head 310 is increased or decreased using the feedback correction amount Δh related to the basis weight. Thereafter, the control device 102 resets the number m of the detected basis weight (step S150), and ends this routine. As described above, the affirmative determination in step S130 causes a continuous deviation of the number m of times for at least one of the detected coating length MD and the detected coating width TD in addition to the detected basis weight (first). Situation, second situation), detection coating length MD and detection coating width TD are not subjected to feedback control. In other words, if the detected basis weight, at least one of the detected coating length MD and the detected coating width TD are simultaneously deviating m times, feedback control on the basis weight is prioritized. In this case, since the count is not reset for the detected coating length MD and the detected coating width TD, the number m of deviations is counted up from the current value in this routine after the next time.

  On the other hand, if a negative determination is made in step S130, the control device 102 has detected which of the detected coating length MD and the detected coating width TD other than the detected basis weight has caused a continuous deviation of the number m. Determine. In the present embodiment, following the negative determination in step S130, it is determined whether the detected coating length MD has caused a continuous deviation of the number m (step S160). Here, if an affirmative determination is made, the spray start timing and stop timing of the coating liquid that defines the coating length MD of the coating liquid layer S, that is, the drive timing of the electromagnetic actuator 328 of the coating liquid delivery valve 325 are shown in FIG. As shown, feedback control is performed using the feedback correction amount Δh (step S170). Thereby, the spraying start timing and the stop timing of the coating liquid from the die head 310 to the base material K are corrected by using the feedback correction amount Δh related to the coating length MD. Thereafter, the control device 102 resets the number m of times for the detected coating length MD (step S180), and ends this routine.

  If the control device 102 makes a negative determination in step S160, the distance Dd (see FIG. 2) of the die head 310 that defines the coating width TD of the coating liquid layer S is used as the feedback correction amount Δh as shown in FIG. Feedback control (step S190). Thereby, the distance Dd of the die head 310 is corrected by using the feedback correction amount Δh with respect to the coating width TD, and this correction is performed by correcting the drive amount of the drive motor 334 in the die head position adjustment mechanism 330. Thereafter, the control device 102 resets the number m of times for the detected coating width TD (step S200), and ends this routine.

  As described above, in the coating apparatus 100 of the present embodiment, the formation state of the coating liquid layer S that has been formed on the base material K is detected with respect to the basis weight, the coating length MD, and the detected coating width TD. (Step S110 / FIG. 4). If the detected fabric weight, the detected coating length MD, or the detected coating width TD deviates from the execution feasibility determination range Hc, the die head 310 is set so that the detected fabric weight falls within the execution feasibility determination range Hc. Feedback control (step S140) for correcting increase / decrease of the coating liquid supply amount to the head, and intermittent supply liquid supply start to the die head 310 so that the detected coating length MD falls within the execution feasibility determination range Hc. Feedback control for correcting the length of the stop (step S170) and feedback control for correcting the distance Dd between the die head 310 and the substrate K so that the detected coating width TD falls within the execution feasibility determination range Hc (step S170). S190). Therefore, through the above feedback control, the coating liquid layer S formed on the substrate K can be matched with the coating liquid layer shape within the allowable range, and at this time, it is not necessary to stop the equipment. As a result, according to the coating apparatus 100 of the present embodiment, the formation state of the coating liquid layer S can be standardized while maintaining productivity. Further, since the productivity does not decrease, according to the coating apparatus 100 of the present embodiment, it is possible to reduce the cost and improve the quality of a product in which the coating liquid layer S is intermittently formed on the substrate K. . For example, if the substrate K is an electrolyte membrane film formed using a fluorine-based resin having proton conductivity, and the coating liquid is a catalyst ink in which catalyst-carrying carbon particles and ionomer are dispersed, a membrane electrode A joined body can be manufactured, and cost reduction and quality improvement of the membrane electrode assembly can be achieved.

  In the coating apparatus 100 according to the present embodiment, if the detected basis weight, at least one of the detected coating length MD and the detected coating width TD are simultaneously deviating m times, the detected basis weight is determined to be feasible. The feedback control (step S140) of the coating liquid supply amount that falls within the range Hc is executed with priority. Therefore, according to the coating apparatus 100 of the present embodiment, the thickness and weight of the coating liquid layer S, which is important from the viewpoint of improving the product quality and defined by the basis weight, are preferentially stabilized and uniformized. Can be achieved preferentially through preferential stabilization. Then, after the basis weight is stabilized, the detection coating length MD and the detection coating width TD can also be stabilized.

  In the coating apparatus 100 of the present embodiment, feedback control for increasing / decreasing the coating liquid supply amount (step S140) and feedback control for correcting the start / stop timing of intermittent coating liquid supply to the die head 310 (long and short) Each feedback control of step S170) and feedback control for correcting the distance Dd between the die head 310 and the substrate K (step S190) is performed by detecting the detected basis weight, the detected coating length MD, or the detected coating width TD. The process is executed when the deviation from the execution possibility determination range Hc is continuously deviated m times. Therefore, according to the coating apparatus 100 of the present embodiment, the basis weight of the coating liquid layer S, the coating length MD, and the coating width TD can be stabilized without inadvertently increasing the execution frequency of the feedback control. Can be achieved. And since the said frequency | count m used as the execution opportunity of feedback control was each determined with the fabric weight of coating liquid layer S, coating length MD, and coating width TD, rapid stabilization can be achieved.

  The present invention is not limited to the above-described embodiment, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features of the embodiments corresponding to the technical features in each embodiment described in the summary section of the invention are intended to solve part or all of the above-described problems, or part of the above-described effects. Or, in order to achieve the whole, it is possible to replace or combine as appropriate. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

  In the above embodiment, the base material K is a single body, but a base material with a peelable back film attached to the back surface may be used. Such a back film can be formed of a polyester film such as PET (polyethylene terephthalate) or PEN (polyethylene naphthalate), or a polymer film such as polystyrene.

  In the above embodiment, the basis weight sensor 610 has an X-ray transmission type sensor structure. However, a sensor structure including a pulse transmitter and a receiver or a reflection type sensor structure may be used.

DESCRIPTION OF SYMBOLS 100 ... Coating apparatus 102 ... Control apparatus 200 ... Base material delivery zone 201 ... Base material supply roller 202-204 ... Upstream side guide roller 205 ... Tension roller 206-207 ... Downstream side guide roller 300 ... Coating zone 301 ... Upstream guidance Roller 302 ... Coating guide roller 310 ... Die head 312 ... Coating hole 320 ... Coating liquid pressure feeding mechanism 321 ... Coating liquid tank 322 ... Agitating motor 324 ... Coating liquid pressure feeding motor 325 ... Coating liquid delivery valve 326 ... Die supply Path 327 ... Return flow path 328 ... Electromagnetic actuator 330 ... Die head position adjustment mechanism 332 ... Die head drive table 334 ... Drive motor 400 ... Shape measurement zone 410 ... First sensor 420 ... Second sensor 430 ... Drying delivery guide roller 500 ... Drying zone 502 ... He 600 ... Weight per unit area measurement zone 601 ... Upstream roller 602 ... Downstream roller 610 ... Weight sensor 700 ... Winding accommodation zone 701 ... Substrate recovery roller 702-706 ... Upstream guide roller 707 ... Tension roller 710 ... Appearance sensor 720 ... Marking equipment K ... Base material S ... Coating liquid layer Lmax ... Weight per unit area Δh ... Feedback correction amount P1 ... Sensor input locus P2 ... Sensor input locus MD ... Coating length (detection coating length)
TD ... coating width (detection coating width)
Lc: Reference center value Hc: Executability determination range Dd: Separation Sr: Spray form

Claims (7)

A coating apparatus that intermittently forms a spray mark sprayed with a coating liquid on a substrate as a coating liquid layer,
A die head that sprays the coating liquid against the substrate;
A first control for adjusting, as a first control amount, a coating liquid supply amount when the intermittent supply of the coating liquid to the die head is performed; and start and stop of the intermittent coating liquid supply. Relative to the die head, the second control that adjusts the timing as the second control amount and the third control that adjusts the distance between the die head and the substrate as the third control amount are used together. A coating control unit that intermittently forms the coating liquid layer on the base material,
A formation state detection unit for detecting the formation state of the coating liquid layer already formed on the substrate;
The coating control unit
For the formed coating liquid layer, at least one of the first to third control amounts is set so that the coating liquid layer shape state detected by the forming state detection unit matches the allowable coating liquid layer shape. Coating device with feedback control. The formation state detection unit detects the basis weight of the formed coating liquid layer as the coating liquid layer shape state,
2. The feedback control of the first control amount according to claim 1, wherein the coating control unit feedback-controls the first control amount in accordance with a basis weight difference between the detected basis weight and an allowable basis weight in the coating liquid layer shape in the allowable range. The coating apparatus as described. The formation state detection unit detects, as the coating liquid layer shape state, the coating length along the relative driving direction of the base material with respect to the die head for the formed coating liquid layer,
The coating control unit feedback-controls the second control amount in accordance with a layer length difference between the detected coating length and an allowable coating length in the allowable coating liquid layer shape. The coating apparatus according to claim 1. The formation state detection unit detects, as the coating liquid layer shape state, a coating width that intersects a relative driving direction of the base material with respect to the die head for the formed coating liquid layer,
The coating control unit feedback-controls the third control amount in accordance with a layer width difference between the detected coating liquid width and an allowable coating liquid width in the allowable coating liquid layer shape. The coating apparatus according to claim 1.   The said coating control part performs the feedback control according to the said fabric weight difference degree preferentially, when the feedback control according to the said fabric weight difference degree is needed simultaneously with another feedback. Item 5. A coating apparatus according to any one of Items 4 to 4.   When the coating control unit performs feedback control of the first to third control amounts, any one of the detected items of the basis weight, the coating length, and the coating liquid width corresponds. 5. The feedback control corresponding to the deviated detection item is performed when the allowable weight per unit area, the allowable coating length, or the allowable coating liquid width deviates continuously over a plurality of times. The coating apparatus in any one of. It is a coating method for intermittently forming a spray mark sprayed with a coating liquid on a substrate as a coating liquid layer,
A first control for adjusting a coating liquid supply amount as a first control amount when intermittently supplying the coating liquid to a die head that sprays the coating liquid facing the substrate; Second control for adjusting the timing of intermittent application liquid supply start and stop as the second control amount, and third control for adjusting the distance between the die head and the substrate as the third control amount And a coating process for intermittently forming the coating liquid layer on the substrate that is driven relative to the die head, and
Performing a detection step of detecting the formation status of the coating liquid layer already formed on the substrate;
In the coating process,
Feedback control is performed on at least one of the first to third control amounts so that the coating liquid layer shape detected in the detection step matches the allowable coating liquid layer shape with respect to the formed coating liquid layer. The coating method.

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