JP4106384B2 - Manufacturing method of wire bar for precision coating, wire bar for precision coating, and wire bar coating device for precision coating using the same - Google Patents

Description

  The present invention relates to a manufacturing method of a precision coating wire bar for precisely coating a coating liquid on a continuously running support, a precision coating wire bar, and a precision coating wire bar coating apparatus using the same.

  One device for applying a coating solution to a continuously running support is a rod coater, and one type of the rod coater is a wire bar coating device. This wire bar coating device rotates a wire bar formed by closely winding a thin wire on the surface of a round rod-like rod, and uses the capillary phenomenon of a fine groove formed between the wires to apply the coating liquid to the surface of the wire bar. And the applied liquid is transferred and applied to a support such as a continuously running film.

  This wire bar coating apparatus requires almost no fine adjustment, and since the coating thickness can be easily changed by changing the wire diameter, it is widely used in the coating field. In particular, this wire bar coating apparatus is often used for coating with a coating thickness of about 5 μm or more as a wet coating thickness, and the coating solution is mainly of a relatively good leveling property. I did not.

  On the other hand, it is generally known that the coating by the wire bar produces a tatami-shaped unevenness in the coating film. This is because the wire of the wire bar is spirally wound tightly around the surface of the polished rod. It is thought that there are minute gaps and climbing, and there are subtle variations that are not actually tightly wound.

  On the other hand, in recent years, for example, in the field of production of optical functional films, there has been an increasing demand for coating an ultrathin film with a wet film thickness of 5 μm or less. However, as described above, it has been extremely difficult to satisfy the above requirements by applying a wire bar due to slight variations between the wires caused by winding, or due to fine flaws in the wires themselves.

In view of the above circumstances, in Patent Document 1, the surface of the rod having a diameter in the range of 2 to 20 mm and having a roundness of 5 μm or less is mirror finished, and the diameter is in the range of 20 to 400 μm on this surface. There has been proposed a coating wire bar formed by closely winding a wire having a roundness of 2 μm or less in a spiral manner.

  By the way, “mirror finish” described in Patent Document 1 is generally “polishing so that the surface of a workpiece is reflected to a certain level or more by polishing or buffing” in this technical field. It does not matter how much the surface roughness of the workpiece is, and there is no specific provision that it should be reflected to some extent, and it is extremely sensory. Has been. Therefore, depending on what is used as the rod, that is, depending on the material of the rod used, the surface roughness is completely different, and the surface roughness varies even though it is a mirror surface.

A typical example of such mirror finish is a cylinder inner surface of a hydraulic or pneumatic device and a piston rod sliding on the inner surface. Certainly, these surfaces shine like a mirror on the surface and seem to be beautifully finished, but it has been confirmed that the surface roughness is about 1.5 to 3 s. However, it is considered that such a numerical range can sufficiently achieve the target in the hydraulic or pneumatic equipment that guarantees confidentiality between the surfaces.
JP 2005-021749 A

  However, if this is the case where a wire bar is manufactured by winding an extra fine wire, for example, a wire having a diameter of 100 μm or less, around the rod surface, a desired high-precision wire bar can be manufactured in such a numerical range of the micron order. There wasn't. In other words, in the wire bar manufactured by simply mirror-finishing the surface of the rod described in Patent Document 1 and winding the wire in close contact with the surface, a thin layer coating, especially a wet film thickness of 5 μm or less is required. It was impossible to apply a thin layer with high accuracy.

  In Patent Document 1, it is proposed that the mirror finish is performed by burnishing with a burnishing amount in the range of 5 to 50 μm, more preferably in the range of 15 to 40 μm. Further, this burnishing process is in the range of elastic deformation, and since it is determined that the plastic deformation causes an adverse effect due to the plastic deformation, it is determined that the range is the elastic deformation limit. However, considering the fact that in the range of elastic deformation, in general, considerable restoration occurs after processing, the above proposal has been questioned. Further, a centerless material with a relatively good finish with a surface roughness of about 4 to 5.5 s is generally used for the rod, but the accuracy of this rod also usually varies in the range of 0 to 20 μm in outer diameter, In centerless polishing, there is a variation in the roundness of a triangular onigiri shape of about 8 to 10 μm, which is a feature of the centerless polishing, so a slight difference of about 1 to 2 μm in the burnishing process is a precision thin layer that affects the quality of the coating film. It was considered an important problem for application.

By the way, after making a shaft with a length of 500 mm from 10 centerless standard materials, burnishing, and winding a wire with a diameter of 35 μm, I made a wire bar.
In the case of a good wire bar, a very beautiful rainbow pattern similar to when the CD surface is reflected on the wire-wound surface can be produced, but in the half of the manufactured wire bars, a fairly beautiful rainbow pattern was seen, whereas the remaining In half, the rainbow pattern was quite disturbing. It is unclear whether this will affect the performance of the wire bar, but it was thought that it was not sufficient in the case of extra fine wires.

  Conventionally, the wire bar is usually manufactured by winding a wire around a rod by a craftsman's manual work, but recently, the amount of feed is changed depending on the wire diameter in the case where the skill of the craftsman is mechanized or more advanced. However, for the reasons described above, there are few wire bars for precisely obtaining ultra-thin coating films. In the field, the appearance of wire bars for precision coating has been strongly desired.

  The present invention has been made in view of the above circumstances, and the object of the present invention is to produce an ultra-thin coating film having a wet film thickness of 5 μm or less on a continuously running support without causing streaks or unevenness. An object of the present invention is to provide a method for producing a wire bar for precision coating that can be applied uniformly and with high precision, a wire bar for precision coating, and a wire bar coating device for precision coating using the same.

The above object of the present invention is to provide a precision coating wire bar for precisely applying a coating solution to a continuously running support, using a centerless polished elongated rod, fixing both ends of the rod and fixing the rod. And rotating the grinding wheel to the bending direction of the rod and moving it in the longitudinal direction while pressing the grinding wheel on the outer periphery of the rotating rod with a constant pressure, and grinding and removing the protrusions on the outer periphery of the rod, Finishing the surface roughness of the rod to 0.5 s or less, washing the finished surface of the rod to remove the oil film, and winding the wire tightly with a wire interval of 1.5 μm or less to produce a wire bar, Further, after grinding the surface of the wire bar with a fine grinding wheel, the surface of the wire bar is ground with a soft grinding stone or a film-like grinding stone using a soft support. It is achieved by providing a method of manufacturing a wire bar for precision coating, characterized in that.

  The above object of the present invention is achieved by providing a precision coating wire bar manufactured by the above manufacturing method.

  Still further, the object of the present invention is to provide a precision coating wire bar coating apparatus characterized in that a coating liquid is applied to a traveling body using the precision coating wire bar manufactured by the above manufacturing method. Is achieved.

According to the inventor's research, the following technical matters have been investigated. That is, first, as described above, the wire bar application uses the capillary phenomenon between the wires, so if the distance between adjacent wires is truly constant, even if there is a gap of about 2 to 3 μm, it is precise. Application is theoretically possible. However, since the wire is wound spirally, if there is a gap of this degree, a thrust load is applied to the wire while applying the coating liquid, and this gap may become uneven later. is there. Therefore, in order for the wire spacing to be constant at all times, the wire needs to be wound on the rod with a spacing of 0, which requires that the rod surface be completely flat. However, such a rod is ideal only, and it is impossible to realize this realistically. In other words, in order to increase the surface roughness of the rod surface, the target is achieved by using a fine grindstone and grinding slowly over time, but cylindrical grinding is generally used for grinding this rod. A grinding wheel core and a workpiece core are fixed, and both are rotated and gradually ground . In this process, a rod such as a rod having a diameter of about 6 to 10 mm and a length of about 1000 mm is a grinding wheel. This is because bending occurs due to the load from the surface, and uniform grinding cannot be performed. Therefore, it is common to grind with a steady rest. However, this steady rest is made of metal to increase accuracy, so metal powder may get in the contact area and damage it. It may end up. Therefore, if the steady rest is moved in order to grind this part again, the rod surface may be damaged due to changing the steady rest position even if fine grinding is performed. The meaning will be lost.

  In addition, as described above, the wire bar is formed by closely winding a wire around the surface of the rod, and therefore the accuracy of the wire itself to be used is important in addition to the surface roughness of the rod surface. Therefore, as a result of studying the accuracy of the wire itself to be used, the present inventor has found that the wire surface is not subject to fine scratches during wire manufacture, particularly during drawing and drawing with a die. It has been found that an oil film of oils necessary for drawing and stretching is formed, and if this oil film has a problem of 1.5 μm, it becomes a factor that affects accuracy.

  Based on such knowledge, the present inventor has learned how to increase the surface roughness of the rod surface, and how to increase the accuracy of the wire tightly wound on the rod, thereby achieving high-precision precision coating. As a result of intensive research on whether to finally produce a wire bar for construction, etc., as described in the above claims, a method for producing a novel wire bar for precision coating, and a wire bar for precision coating, In addition, a wire bar coating apparatus for precision coating using the same has been devised.

According to the first aspect of the present invention, since extremely fine scratches on the surface of the wire are removed, even when an ultra-thin film having a wet film thickness of 5 μm or less is applied, defects such as streaks and unevenness are completely eliminated. A wire bar for precision coating that is not generated can be manufactured. Therefore, if the coating apparatus is configured using such a precision coating wire bar, the coating liquid can be applied to the ultra-thin layer with high precision on the continuously running support.

Hereinafter, the contents of the present invention will be described in detail based on examples. The present invention is not necessarily limited to the following examples, and it goes without saying that the configuration can be variously changed without departing from the scope of the claims.
(Example 1)
Using a specially developed rod grinding apparatus 10 as shown in FIG. 1, the center d polishing finish was fairly good with a diameter d of 6 to 12 mm, a length l of 1500 mm or more, and a surface roughness r of 4 to 5 s. A stainless steel rod 11 is used, and both ends of the rod 11 are securely fixed by the center pin 12. Then, the rod 11 is rotated with the rotation speed n set to a relatively low speed, and the outer periphery of the rotating rod 11 is cylindrical. While pressing the grinding wheel 13 comprising a constant pressure P of ² to 3 N / cm ² , the moving speed v is reduced and the rod 11 is moved in the length direction of the rod 11 so as to grind and remove the protrusion. The rod 11 was ground by a special precision grinding process in which the surface was precisely ground by letting it bend 11 (that is, following the deflection of the rod 11) . As a result, the roundness variation of the triangular rice ball shape of about 8 to 10 μm which the rod 11 having the centerless polishing finish as described above has not been corrected, but the roundness error of about 8 to 10 μm is not corrected. Since there was almost no effect on the coating, grinding was performed according to the outer periphery, and as a result, a very clean grinding with a surface roughness of about 0.8 to 1 s was achieved.
(Example 2)
Four rods 11 having a diameter d of 10 mm prepared in this way were prepared, and four types (sample No.) were prepared by closely winding a stainless steel wire 14 having a diameter d1 of 70 μm along each ground surface. (1) to (4) were fabricated, and this wire bar was incorporated into a coating apparatus, and an experiment was performed in which a coating liquid for LR (low reflection) was applied to a support having a width w of 1500 mm that traveled at a speed v of 25 m / min. I did it. Then, when the bar dirt generation position and the streak generation position in each sample were measured from the wire unwinding side (non-drive side), the results shown in Table 1 were obtained.

表１から、バー汚れの発生箇所はスジの発生箇所に較べかなり少なく、またバー汚れの発生場所が各試料とも単発的であるのに対し、スジの発生場所は単発的な部分とある幅をもって発生している部分があることが判明した。また、各試料はそれぞれロットが異なるにも拘わらず、バー汚れの発生場所及びスジの発生場所が各試料とも似通っているところがあることが判明した。

From Table 1, the location where the bar stain occurs is considerably smaller than the location where the stripe occurs, and the location where the bar stain occurs is single for each sample, whereas the location where the stripe occurs is a single portion and a certain width. It was found that there was a part that occurred. Further, it was found that although each sample had a different lot, there were places where the occurrence of bar dirt and the occurrence of streaks were similar to each sample.

Therefore, further, the situation of the winding portion at the above-described bar dirt occurrence place and streak occurrence place, that is, the radius of the wire 14 wound around the outer periphery of the rod 11 as shown in the partial enlarged sectional view in FIG. When the direction height h and the distance between the center lines in the cross section of the adjacent wire 14 , that is, the wire pitch p, are measured with a surface roughness meter and enlarged 200 times, FIG. The results shown in Fig. 1 were obtained. Here, FIG. 2A shows a portion where no failure has occurred in the wire 14 wound around the rod 11, that is, a portion where the wire pitch p is accurate, and FIG. FIG. 2 (C) shows a portion where a streak is generated with a certain width, and FIG. 2 (D) shows a portion where bar stain is generated only once. In these drawings, a circle indicates a defective portion. In FIG. 2B, it was found that the wire pitch p is shifted by 5 μm or more at the circled portion.
Further, in FIG. 2 (C), both the tip height and the wire pitch p are shifted, and in FIG. 2 (D), there is a portion where only one height h protrudes at a flaw portion called dirt. It was.

Further, as described above, paying attention to the fact that there are similarities in the occurrence of streaks in each sample, when the wire 14 is unwound from the corresponding sample (wire bar), the streak having a certain width is observed. It was found that the coating solution soaked into the portion of the rod 11 and the portion from the unwinding side of the wire 14 to a similar streak occurrence site, so that the coating solution soaked into the rod 11 and the rod 11 was dirty. Furthermore, when the dirty part was investigated, it turned out that the part with a strong stain | pollution | contamination is a streak. Further pursuing, especially in this portion, the wire pitch p is disturbed (therefore, it is necessary to increase the surface roughness), and when the wire 14 is wound, the similar streaks described above are used. It has been found that chatter vibration of the drive motor that is brake-controlled near the place of occurrence is resonated and transmitted greatly, which causes the winding part to vibrate (thus, it is necessary to suppress chatter vibration of this drive motor). .
(Example 3)
Using the above knowledge and using three sample rods 11 with a surface roughness of 0.8 s or less, the wire 14 is closely wound spirally by a machine that takes measures against chatter vibration of the brake control motor, and the three types ( Sample No. 5-7) wire bars were prepared. Thereafter, as described above, this wire bar was incorporated into a coating apparatus, and a coating experiment was conducted. The occurrence of bar dirt and streaks was evaluated, and the results shown in Table 2 were obtained.

表２に示すように、スジの発生は殆どなくなり、僅かにバー汚れを残すのみとなった。
このバー汚れの発生状況を示したのが図３である。図３に示されるように、この実験によれば、ワイヤピッチｐの乱れが殆どなく完全に近い状態であつたが、バー汚れと称する僅かなキズの発生が２箇所に見られた。そこで、この発生箇所のワイヤ１４を巻きほぐして見たところ、大きさはかなり小さくなってはいるが前記同様の汚れが見られた。この汚れの発生原因につき究明したところ、この汚れは制御モータからの振動を受けて発生していること（よってこの制御モータの振動を抑える必要があること）が判明した。また、僅かなキズの発生箇所、具体的にはスジが出ている所及び何となくスジっぽい所について精査してみたところ、ワイヤ間隔が２〜２．５μｍの範囲で発生していることが判明した。
（実施例４）
以上の知見を基に、モータ系の全てに防振処置を施し、かつロッド１１の面粗度を前述の特殊精密研削加工により０．５ｓ以下（好ましい範囲は０．５ｓ〜０．３ｓ）のレベルまで上げて仕上げ、この仕上げ面にワイヤ１４を１．５μｍ以下のワイヤ間隔をもって螺旋状に密着巻回してワイヤバーを製作した。なお、前述したように、使用するワイヤ１４には油膜が形成されていることに着目し、このワイヤ１４を巻回する前によく洗浄し、油膜を取り除いたものを使用した。このようにして試作したワイヤバーを塗布装置に組込み、前記同様の実験及び評価を行なったところ、バー汚れ、スジ、傷は皆無となり、どの点を取っても図４に示すような結果が得られた。

As shown in Table 2, the generation of streaks was almost eliminated, and only a slight bar stain was left.
FIG. 3 shows the occurrence of this bar stain. As shown in FIG. 3, according to this experiment, the wire pitch p was hardly disturbed and was almost completely, but slight scratches called bar dirt were observed in two places. Then, when the wire 14 at this occurrence point was unwound and viewed, the same stain was seen although the size was considerably small. As a result of investigating the cause of the contamination, it has been found that the contamination is generated by the vibration from the control motor (therefore, it is necessary to suppress the vibration of the control motor). Also, after examining the occurrence of slight flaws, specifically streaks and some streaks, it was found that the wire spacing was in the range of 2 to 2.5 μm. did.
Example 4
Based on the above knowledge, all of the motor system is subjected to vibration isolation, and the surface roughness of the rod 11 is 0.5 s or less (preferable range is 0.5 s to 0.3 s) by the above-described special precision grinding. The wire bar was manufactured by closely winding the wire 14 in a spiral manner with a wire interval of 1.5 μm or less on the finished surface. Note that as described above, an oil film was formed on the wire 14 to be used, and the wire 14 was washed well before being wound and the oil film was removed. When the prototyped wire bar was incorporated into the coating apparatus and subjected to the same experiment and evaluation as described above, there was no bar dirt, streaks, or scratches, and the results shown in FIG. 4 were obtained at any point. It was.

According to this experiment, the wire pitch p and the wire height h are not disturbed at all over the entire length of the rod 11, and precise coating of the coated wire bar without defects such as streaks and unevenness is performed. did it. Nevertheless, in this experiment, two extremely fine scratches that did not affect the quality were found.
(Example 5)
Therefore, this fine scratch was polished with a soft fine grindstone, or a paper grindstone called a polishing tape (film-shaped grindstone using a soft support), and as a result of conducting the same experiment as described above using this wire bar, There were no surface failures. In addition to the fact that the wire 14 is thoroughly washed in advance and is wound around the rod 11 after removing the oil film, in addition to being able to make a highly accurate wire bar as described above, the oil film is eluted and the solvent It was confirmed that the problem of entering into the coating liquid of the type and having an adverse effect was solved.

  In addition, it is preferable that the diameter d of the rod 11 to be used is 40 mm or less and about 2 mm, and the diameter d1 of the wire 14 is 150 μm or less and about 15 μm. When such a material is used, a more accurate wire bar can be manufactured. Has also been confirmed by the inventors' experiments. This is because a rod with a diameter d exceeding 40 mm has no meaning as a wire bar, and if a wire with a diameter d1 larger than 150 μm is used, the coating film becomes thick and does not require such a high winding accuracy. is there.

  As described above, according to the method for manufacturing a wire bar according to the present invention, an ultra-high precision wire bar can be manufactured. Since the manufactured wire bar is compatible, it is applied to a conventional wire bar coating apparatus. In addition, according to the applied wire bar coating apparatus, it is possible to apply an ultra-thin and highly accurate coating film to a continuously running support that cannot be obtained by a conventional wire bar coating apparatus.

It is explanatory drawing which shows the grinding method of a rod. The situation when a wire is wound around a rod in the improvement stage is shown in a graph. (A) is a portion where a wire is wound around a rod with an accurate wire pitch, and (B) is a single line of streaks. (C) shows a portion where a streak is generated with a certain width, and (D) shows a portion where bar dirt is generated only once. It is the figure which showed the condition when winding a wire around the rod which added the improvement like FIG. It is the figure which showed the winding condition of the rod and wire which finally improved, like FIG. It is a partial expanded sectional view for demonstrating the precision of the wire wound by the rod.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Rod grinding device 11 Rod 12 Center pin 13 Grinding wheel 14 Wire h Wire radial direction height p Wire pitch r Surface roughness

Claims (3)

In a precision coating wire bar manufacturing method for precisely applying a coating solution to a continuously running support, a centerless polished elongated rod is used, both ends of the rod are fixed, the rod is rotated, and the rod is rotated. While pressing the grinding wheel on the outer periphery of the rod with a constant pressure, the grinding wheel is moved in the longitudinal direction by allowing the rod to bend, thereby removing the protrusions on the outer periphery of the rod, and the surface roughness of the rod is reduced. After finishing to 0.5 s or less, the wire after cleaning the finished surface of the rod and removing the oil film is closely wound spirally with a wire interval of 1.5 μm or less to produce a wire bar, and the surface of the wire bar is finely divided. after grinding by the grinding wheel, fine, characterized in that the film-shaped grinding wheel with support of soft grinding or soft formed by grinding the surface of the wire bar Method of manufacturing a wire bar coating. A wire bar for precision coating manufactured by the manufacturing method according to claim 1. A wire bar coating apparatus for precision coating, wherein the coating liquid is applied to a continuously running support using the wire bar for precision coating according to claim 2.

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