JP3924685B2 - Method and apparatus for forming a film on a substrate of a plate-shaped recording medium - Google Patents

Description

  The present invention relates to a method and apparatus for forming a film on a substrate of a plate-shaped recording medium such as a CD (compact disc), a DVD (digital versatile disc), or a Blu-ray disc.

  Conventionally, in a plate-like recording medium such as a CD, DVD, and Blu-ray disc, various layers such as a recording layer, an adhesive layer, and a cover layer (transparent) are formed on a resin substrate such as polycarbonate. The recording layer is formed of an organic dye film. The cover layer is formed of a transparent ultraviolet curable resin or thermosetting resin film. Also for the adhesive layer, a transparent resin adhesive is used and applied to a predetermined range.

These various layers rotate the substrate at a high speed (3000 to 10000 rpm), supply a liquid for forming a film near the center of rotation of the substrate, and spread the film forming liquid by centrifugal force to form a substrate. A method is employed in which a liquid film (meaning a liquid film) having a predetermined thickness is formed thereon, and then the liquid film is cured by irradiation with ultraviolet rays or heating. Such a method is called a spin coating method, and an apparatus called a spin coater is used (for example, see Patent Document 1).

JP-A-9-161328, paragraph (0022-0024, 0029, FIG. 1)

  The above-described spin coating method using a spin coater has not only the problem that the equipment is complicated and large, but it is difficult to control the film thickness to be formed on the substrate. As described above, in order to spread the film-forming liquid toward the outer periphery of the substrate by centrifugal force, the tendency of the film thickness to increase toward the outer periphery of the substrate is unavoidable, and the demand for strict film thickness accuracy is met. It was extremely difficult.

  Since the film-forming liquid is spread by rotating the substrate at a high speed, the liquid flows not only to the outer peripheral edge of the substrate but also to the outer peripheral end surface, and is further shaken off from the substrate. For this reason. After the formation of the liquid film, it is necessary to remove the liquid film on the outer peripheral edge and the outer peripheral end surface of the substrate by cleaning. And since the liquid shaken off from the substrate is sucked by the blower and discharged to the outside of the equipment, the environment is polluted and the waste of the material (liquid composition for film formation) cannot be ignored. It was so great. In actual equipment, since 5 to 10 times the amount of liquid necessary for forming the liquid film is supplied and spread on the substrate, 80 to 90% of the liquid is wasted.

  The present invention has been made in view of such a situation, and can accurately form a film for forming various layers on the substrate of the plate-like recording plate, and further, waste of materials and contamination of the environment can be prevented. It is an object to provide a novel method and apparatus which is not present.

The present invention is basically based on supplying a liquid for film formation onto a substrate by an ink jet printer. That is, the invention of claim 1 is a method for forming various films for a recording layer, an adhesive layer, a cover layer, etc. on a substrate of a plate-shaped recording medium.
The outer surface of the substrate, along the edge of the film forming region, by using an inkjet printer by applying the ultraviolet-curable liquid for film forming, a liquid dammed formed by curing a coated the liquid,
Next, while applying vibration to the substrate, an ultraviolet curable liquid for film formation is applied to the film formation region surrounded by the liquid stop weir using an inkjet printer, and smoothed by vibration to have a predetermined film thickness. Forming a liquid film,
Further, formed by curing the liquid film smoothed is applied to the film forming region, a recording layer, an adhesive layer, a film on a substrate of the plate-like recording medium, characterized in that the film forming the cover layer or the like It is a method to do.
Further, the liquid film formed in the film forming region can be stored in a vacuum atmosphere to remove bubbles in the liquid film and then cured.
Furthermore, by repeating the process from the formation of the liquid stop weir to the curing of the liquid film a plurality of times,
A film can also be formed on the substrate of the plate-shaped recording medium.

According to a fourth aspect of the present invention, there is provided an apparatus for forming various films for a recording layer, an adhesive layer, a cover layer, etc. on a substrate of a plate-shaped recording medium.
A plurality of trays supporting the substrate are provided so as to be movable along the transfer line, and at appropriate positions on the transfer line,
An ink jet printer for applying an ultraviolet curable liquid for film formation along the edge of the film forming region of the substrate, and a liquid stop weir forming station comprising means for curing the applied film forming liquid;
A liquid film forming station comprising: means for applying vibration to the tray; and an ink jet printer for applying an ultraviolet curable liquid for film formation to a film forming region surrounded by the liquid stop weir;
An apparatus for forming a film on a substrate of a plate-shaped recording medium, wherein a curing station provided with means for curing a liquid film formed at the liquid film forming station is provided side by side.
In the case of this apparatus, a deaeration station provided with means for removing bubbles in the liquid film formed at the liquid film forming station may be installed between the liquid film forming station and the curing station.

FIG. 1 schematically shows a process in which the liquid applied on the substrate according to the present invention forms a film. In the figure, 10 is a substrate of a plate-shaped recording medium, 11 is a dot of ultraviolet curable liquid ejected from an ink jet printer, and 12 is a liquid film smoothed by vibration. (Note that the dots 11 and the liquid film 12 are not drawn in a relative size with respect to the substrate 10) The ultraviolet curable liquid for forming the film is an inkjet printer as shown in (a). Since the dot 11 is applied to the film forming region S on the substrate 10, the film forming region S can be accurately controlled by the movement control of the ink jet printer, and the liquid can be applied to a necessary region.

When the ultraviolet curable liquid is applied to the substrate 10 by using an ink jet printer, the substrate 10 is vibrated as indicated by an arrow V. Therefore, the dots 11 also vibrate together with the substrate 10 and merge with adjacent dots 11. To do. By combining a large number of dots 11, the top of the dots 11 is smoothed, and a liquid film 12 having a predetermined thickness t can be formed on the substrate 10 as shown in FIG.

  In this way, a film constituting a recording layer, an adhesive layer, a cover layer, or the like can be formed on the substrate 10 by curing the liquid film 12 smoothed by vibration by irradiation with ultraviolet rays or infrared rays. . The liquid ejected by the ink jet printer is appropriately selected according to the type of the target film. When forming the recording layer, it is an organic dye liquid, when forming the adhesive layer, it is a transparent adhesive liquid, and when forming the cover layer, it is a transparent resin liquid.

The height h of the dot 11 and the area s of the skirt vary depending on the viscosity of the liquid to be ejected and the amount of the liquid to be ejected. Therefore, the amount of the ultraviolet curable liquid ejected by the ink jet printer and the density of the dots 11 are changed depending on the type and thickness of the target film. In some cases, the thickness t is less than the thickness required for the target film. In such a case, the process of forming a smoothed liquid film and curing can be repeated a plurality of times to obtain the required thickness.

Prior to the formation of the liquid film, when the liquid stop weir is formed along the edge of the film formation region, it can be schematically represented as shown in FIG. As shown in FIGS. 4A and 4B, first, an ultraviolet curable liquid or a thermosetting liquid for film formation is ejected from the ink jet printer along the edge of the film formation region S of the substrate 10 to form the substrate. The liquid stop weir 13 can be formed at the edge of the film forming region S by applying the material on the surface 10 and curing it by irradiating ultraviolet rays or infrared rays.

  After the liquid stop weir 13 is formed, it is the same as described above, and the film forming liquid is ejected from the ink jet printer into the film forming region S surrounded by the liquid stop weir 13 as shown in FIG. Then, the liquid film 12 whose surface is smoothed is formed in the film forming region S by applying the dot 11 in the form of the dot 11 on the substrate 10 and vibrating the substrate 10 as indicated by the arrow V. When the liquid stop weir 13 is formed first, it is possible to limit the application area of the liquid for film formation so as not to protrude from the film formation area S, which is effective in managing the film formation area.

  After the liquid film 12 is formed, the liquid film is cured to form films constituting various layers such as a recording layer, an adhesive layer, and a cover layer on the substrate 10.

As described above, according to the present invention, an ultraviolet curable liquid for forming a film is ejected by an ink jet printer and applied onto a substrate to form a liquid stop weir along the edge of the film forming region. Apply UV curable liquid in the form of dots from the inkjet printer in the enclosed film formation area , smooth it by vibration to form a liquid film, remove bubbles if necessary, and cure the liquid film By doing so, the liquid for film formation can be restricted so as not to protrude from the film formation area, so that the area for forming the film can be arbitrarily and accurately, and the liquid is not applied to unnecessary portions. It can be no need for cleaning, Ru management effective der film formation region. Further, the thickness of the film can be made accurate and uniform over the entire surface of the substrate. In addition to contributing to simplification of equipment, waste of materials and environmental pollution can be eliminated.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  FIG. 3 shows a configuration of an implementation apparatus in which the tray 20 that supports the substrate 10 is moved along a linear conveyance line L by a linear conveyor (not shown). In the transfer line L, a substrate supply station 30, a liquid film forming station 40, a deaeration station 50, a curing station 60, and a substrate discharge station 70 are provided at equal intervals. The tray 20 is configured to sequentially move toward the substrate discharge station 70 while stopping at each station.

  Outside the substrate supply station 30 and the substrate discharge station 70, a transfer device provided with substrate handling means such as a vacuum chuck is installed. The substrate supply station 30 is configured to sequentially supply the substrates 10 one by one to the tray 20 by the transfer device, and the substrate discharge station 70 is configured to sequentially discharge the substrates 10 from the tray 20 by the transfer device.

In the liquid film forming station 40, a plurality of inkjet printers 41 (shown in the case of seven) and the ultrasonic vibrator 42 shown in FIG. While applying vibration to the substrate 10, it is possible to apply an ultraviolet curable liquid for film formation. The plurality of inkjet printers 41 can reciprocate in the direction of arrow 43 in FIG. 3, and the printer head 44 of each inkjet printer 41 has an arrow 45 (see FIG. 4) orthogonal to the arrow 43. The top surface of the substrate 10 supported by the tray 20 can be covered with the printer head 44 of at least one ink jet printer 41.

The PC board 46 that controls the operation of each ink jet printer 41 is connected to a control device 47 that is a personal computer that comprehensively manages the application of the liquid for film formation. Further, each printer head 44, the ultraviolet curable liquid for film formation (e.g., viscosity 20mpa.s liquid) is connected to a liquid tank 48 that stores the said liquid is excessive or insufficient for the film forming Without being supplied to the printer head 44.

  The ultrasonic transducer 42 is installed so that it can be coupled and detached from the tray 20 moving to the liquid film forming station 40. When the tray 20 stops at the station, the ultrasonic vibrator 42 is coupled to the tray 20, and when the tray 20 starts to move along the transport line L, the ultrasonic vibrator 42 is detached from the tray 20, The movement of 20 is not hindered.

  Next, as shown in FIG. 5, the deaeration station 50 has a dome-shaped vacuum chamber 51 installed at the top of the tray 20. The vacuum chamber 51 is connected to a vacuum source 52 such as an exhaust pump so that the internal air can be exhausted. The vacuum chamber 51 can be moved up and down with respect to the tray 20 as indicated by an arrow 53. When the vacuum chamber 51 is lowered, the lower opening edge 54 is in contact with the upper surface of the tray 20, and when it is raised, the opening edge 54 is moved to the tray 20. The movement of the tray 20 is prevented from being hindered away from the 20.

As shown in FIG. 6, the curing station 60 is provided with an ultraviolet lamp 61 and a reflecting mirror 62 having a concave surface. The ultraviolet rays 63 emitted from the ultraviolet lamp 61 can be applied to the substrate 10 supported on the tray 20. This apparatus, which irradiates ultraviolet rays 63, sprays ultraviolet curable liquid onto the substrate 10 through the ink jet printer 41, and cures it to form a film with a predetermined thickness in a predetermined region. Can be formed. As a technique for forming a liquid film with an ultraviolet curable liquid on the substrate 10 via the inkjet printer 41, for example, a known technique disclosed in Japanese Patent Application Laid-Open No. 11-259913 can be used.

Next, the operation of the apparatus will be described. When the substrate 10 is conveyed to the liquid film forming station 40, the ink jet printer 41 and the ultrasonic vibrator 42 operate, and as described in FIG. A film forming liquid is applied to the film forming region in the form of dots 11, and the dots 11 are smoothed by vibration to form a liquid film 12 having a predetermined thickness.

Substrate 10 liquid film 12 is formed on the film formation region is then conveyed to a degassing station 50. Here, the vacuum chamber 51 is lowered and the substrate 10 is held in a vacuum atmosphere. When the substrate 10 is held in a vacuum atmosphere, the bubbles mixed in the liquid film 12 move to the vacuum atmosphere side, so that the bubbles are removed from the liquid film 12.

  The substrate 10 on which the liquid film 12 from which bubbles have been removed in this way is formed is then transported to the curing station 60. Here, the ultraviolet lamp 61 is turned on and the liquid film 12 is irradiated with the ultraviolet ray 63. The liquid film 12 made of an ultraviolet curable liquid is cured by being irradiated with the ultraviolet light 63 and fixed on the substrate 10 to form films constituting various layers such as a recording layer, a cover layer, and an adhesive layer.

FIG. 7 shows a region of the film formed on the substrate 10. (A) of FIG. 7 represents the region of the film 14 constituting the recording layer, represents a (b) the area of the membrane 15 constituting the cover layer and the adhesive layer. In the case of the film 14 of (a), there is a region where the film 14 is not formed in the central portion 10 a and the outer peripheral edge portion 10 b of the substrate 10. In the case of (b), there is a region where the film 15 is not formed on the outer peripheral edge portion 10 b of the substrate 10. The application of the ultraviolet curable liquid for film formation to the formation region of the film 14 in (a) and the formation region of the film 15 in (b) is accurately performed by the control device 47 to which the PC board 46 of each inkjet printer 41 is connected. Can be controlled. And since the film forming liquid is not applied to the region of the substrate 10 where the film of the central portion 10a and the outer peripheral edge portion 10b is not formed, it is possible to prevent unnecessary portions from being cleaned as in the conventional case.

  If the required film thickness cannot be ensured by a single pass from the liquid film forming station 40 to the curing station 62, the substrate 10 collected at the substrate discharge station 70 is supplied again to the substrate supply station 30 and the same. This film forming operation can be repeated to obtain the required film thickness. In addition, a plurality of sets of the liquid film forming station 40, the deaeration station 50, and the curing station 60 are installed between the substrate supply station 30 and the substrate discharge station 70 so that a plurality of film forming operations are automatically performed. It can also be. Depending on the type of film forming liquid applied via the ink jet printer 41, the thickness of the film, etc., bubbles may not be mixed into the liquid film 12. Therefore, in such a case, the deaeration station 50 can be prevented from operating, or the apparatus can be configured without the deaeration station 50.

Further, the liquid to be applied is not limited to the ultraviolet curable liquid. It is also possible to use a thermosetting liquid. When a thermosetting liquid is used, the ultraviolet lamp 61 constituting the curing station 60 is replaced with an infrared lamp ( see, for example, JP-A-11-259913) .

  Furthermore, the linear conveyance line L by a linear conveyor can also be made into the cyclic | annular conveyance line (refer FIG. 8) by a rotary table.

FIG. 8 shows a configuration of the present invention as an apparatus according to another embodiment. 3 is a device that can form the liquid stop weir 13 described in FIG. 2.

  In the apparatus, the tray 20 can be moved along an annular conveyance line M by a rotary table (not shown). A substrate supply station 30 is provided for the annular transfer line M, and a liquid stop weir forming station 80, a deaeration station 50, and a curing station 60 are arranged at regular intervals in the clockwise direction from the substrate supply station 30. A substrate discharge station 70 is sequentially provided.

  As shown in FIG. 9, the liquid stop weir forming station 80 is provided with a drive shaft 82 that rotates the tray 20 as indicated by an arrow 81 so that the drive shaft 82 can be coupled to and detached from the tray 20. Further, two inkjet printers 83 and two ultraviolet spot lamps 84 are provided on the upper side of the tray 20.

  Each inkjet printer 83 and ultraviolet spot lamp 84 can be set in the direction of arrow 86 (FIG. 8) by the control device 85. Further, the printer head 87 of each ink jet printer 83 reciprocates in the direction of an arrow 88 (FIG. 9) orthogonal to the arrow 86.

  The liquid film forming station 40, the deaeration station 50, and the curing station 60 are configured in the same manner as the apparatus described with reference to FIG.

In the case of this apparatus, the substrate 10 supplied to the tray 20 of the substrate supply station 30 is first transported to the liquid stop weir forming station 80. When the substrate 10 is transported to the liquid stop weir forming station 80, the drive shaft 82 is coupled to the tray 20 and rotates the tray 20 and the substrate 10. In this state, the two inkjet printers 83 and the ultraviolet spot lamps 84 that have been set are operated, and the film forming liquid is sprayed and applied toward the substrate 10 and irradiated from the ultraviolet spot lamps 84. The ultraviolet light hits the applied liquid as an ultraviolet spot 89 (see FIG. 8), and is cured. As a result, as described with reference to FIG. 2, the annular liquid stop weirs 13 are double formed in the radial direction along the edge of the film forming region of the substrate 10.

  In this way, the substrate 10 on which the liquid stop weir 13 is formed along the edge of the film forming region is subsequently transferred to the liquid film forming station 40, the deaeration station 50, and the curing station 60 in sequence. In each station, as in the case of the apparatus described with reference to FIG. 3, the film forming liquid is applied in the form of dots 11 to the area (film forming area) surrounded by the liquid stop weir 13 and smoothed by vibration. After being done, the bubbles are removed and cured.

  In the case of the apparatus of FIG. 8 as well, the required film thickness may not be obtained by one pass from the liquid stop weir forming station 80 to the curing station 60. In such a case, the tray 20 circulates the annular conveyance line M a plurality of times so that it passes through the liquid stop weir forming station 80 to the curing station 60 a plurality of times, or the annular conveyance line having an increased diameter. A plurality of sets from the liquid stop weir forming station 80 to the curing station 60 can be installed in M so that the required film pressure can be obtained.

  Further, in the liquid stop weir forming station 80, the film forming liquid is applied to the entire area of the film forming area S as shown in FIG. It is also possible to cure the edges by irradiation of the ultraviolet spot 89 sequentially. In this case, since the liquid film 12 is also formed in the film formation region S, when the predetermined film thickness is obtained, the liquid film 12 is cured by the curing station 60, and a necessary film can be obtained.

  Finally, in the liquid film forming station 40, the ultrasonic vibrator 42 installed to vibrate the substrate 10 can be replaced with other vibration means such as a vibration motor.

It is the model explaining the concept of one invention of this application, (a) is a figure of the state which apply | coated the liquid on the board | substrate in the shape of a dot, (b) is the state of smoothing a dot and forming the liquid film FIG. It is the model explaining the concept of another invention of this application, (a) is the top view which formed the liquid stop dam on a board | substrate, (b) is a front view similarly, (c) is a liquid dot to a film formation area. The figure of the state apply | coated in the form of (d) is a figure of the state which smoothed the dot and formed the liquid film. It is a block diagram of the apparatus which implemented invention of this application. It is a figure explaining the structure of the liquid film station of the apparatus of FIG. It is a figure explaining the structure of the deaeration station of the apparatus of FIG. It is a figure explaining the structure of the hardening station of the apparatus of FIG. It is a top view which showed the film | membrane formation area of the board | substrate, (a) is a figure of the film | membrane which comprises a recording layer, (b) is the figure of the film | membrane which comprises a cover layer and an adhesive layer. It is a block diagram of the other apparatus which implemented invention of this application. It is a figure explaining the structure of the liquid stop weir formation station of FIG. It is a figure explaining the case where a film | membrane is formed in the whole surface of a film | membrane formation area in the liquid stop dam formation station of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Substrate 10a Center part 10b Outer peripheral edge part 11 Dot 12 Liquid film 13 Liquid stop weir 14 Film 15 Film 20 Tray 30 Substrate supply station 40 Liquid film formation station 41 Inkjet printer 42 Ultrasonic vibrator 44 Printer head 46 PC board 47 Control device 48 Liquid tank 50 Deaeration station 51 Vacuum chamber 52 Vacuum source 54 Opening edge 60 Curing station 61 UV lamp 62 Reflector 63 UV 70 Substrate discharge station 80 Liquid stop weir forming station 82 Drive shaft 83 Inkjet printer 84 Ultraviolet spot lamp 85 Controller 87 Printer head 89 Ultraviolet spot S Film formation region V Vibration L Linear transport line M Annular transport line h Dot height s Dot hem area t Liquid film thickness

Claims (5)

In a method of forming various films for a recording layer, an adhesive layer, a cover layer, etc. on a substrate (10) of a plate-like recording medium,
The outer surface of the substrate (10), along the edge of the film forming region, using an inkjet printer (83) and applying a UV curable liquid for film forming, coating and said liquid is caused by the liquid dammed cure ( 13)
Next, while applying vibration to the substrate (10), an ultraviolet curable liquid for film formation is applied to the film formation region surrounded by the liquid stopping weir (13) using an ink jet printer (41), and vibration is applied. To form a liquid film (12) having a predetermined film thickness
Further, by curing the smoothed is applied to the film forming region liquid film (12), the recording layer, the adhesive layer, on a substrate of the plate-like recording medium, characterized in that the film forming the cover layer or the like A method of forming a film. The method of forming a film on a substrate of a plate-shaped recording medium according to claim 1 , wherein the liquid film (12) formed in the film forming region is accommodated in a vacuum atmosphere to remove bubbles in the liquid film. The method of forming a film on a substrate of a plate-shaped recording medium according to claim 1 or 2 , wherein the steps from the formation of the liquid stop weir (13) to the curing of the liquid film are repeated a plurality of times. In an apparatus for forming various films for a recording layer, an adhesive layer, a cover layer, etc. on a substrate (10) of a plate-like recording medium,
A plurality of trays (20) supporting the substrate (10) are provided so as to be movable along the transfer line, and at appropriate positions on the transfer line,
An inkjet printer (83) for applying an ultraviolet curable liquid for film formation along the edge of the film formation region of the substrate (10), and means (84) for curing the applied film formation liquid A liquid stop weir forming station (80),
A means (42) for applying vibration to the tray (20), and an ink jet printer (41) for applying an ultraviolet curable liquid for film formation to a film formation region surrounded by the liquid stop weir (13). A liquid film forming station (40) comprising:
A plate-like recording medium comprising a curing station (60) provided with means (61, 62) for curing the liquid film (12) formed at the liquid film forming station (40). An apparatus for forming a film on a substrate. Means (51, 52) for removing bubbles in the liquid film (12) formed at the liquid film forming station (40) is further provided between the liquid film forming station (40) and the curing station (60). The apparatus for forming a film on a substrate of a plate-like recording medium according to claim 4 , wherein a deaeration station (50) is installed.

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