JP4742659B2 - Coating method and coating apparatus - Google Patents
Coating method and coating apparatus Download PDFInfo
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- JP4742659B2 JP4742659B2 JP2005122160A JP2005122160A JP4742659B2 JP 4742659 B2 JP4742659 B2 JP 4742659B2 JP 2005122160 A JP2005122160 A JP 2005122160A JP 2005122160 A JP2005122160 A JP 2005122160A JP 4742659 B2 JP4742659 B2 JP 4742659B2
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Description
本発明は、塗工方法および塗工装置に関するものであり、特に写真感光乳化剤、磁性材料液、反射防止性能等の機能を発現する光学薄膜用の塗工液などを、プラスチックフィルムや紙、金属箔等の可撓性支持体（以下、ウェブと称する）に塗工して、高機能を発現するシート状のものを製造するための塗工方法および塗工装置に関する。 TECHNICAL FIELD The present invention relates to a coating method and a coating apparatus, in particular, a photographic photosensitive emulsifier, a magnetic material solution, a coating solution for an optical thin film that exhibits functions such as antireflection performance, and the like. The present invention relates to a coating method and a coating apparatus for producing a sheet-like material which is coated on a flexible support (hereinafter referred to as a web) such as a foil and exhibits high functions.
高機能を発現するシート状のものを製造するプロセスとして蒸着などのドライプロセスと塗工などのウェットプロセスの二つに分けられる。そのウェットプロセスにおいて近年ダイヘッドを用いたいわゆる「前計量タイプ」の塗工方式の利用が進んでいる。そのダイヘッドを用いる塗工方式の中でエクストルージョン方式においては、走行するウェブに直接ダイヘッドを押し付けて塗工する方法と、バックアップロールに巻きつけて搬送されるウェブにダイヘッドの先端を近接させて塗工する方法がある。後者の方式の場合はビードを確実に形成させるためにビード部を減圧せねばならず、例えば特許文献１のように減圧チャンバーを設置することは広く知られている。
またその減圧チャンバーも、特に１ｍを超えるような製品幅の場合はチャンバー内の風の流れによって予期せぬ故障を誘発することもあり、例えば特許文献２の中に例示されているように仕切り板のような物をチャンバー内に設けてチャンバー内の気流の乱れを回避しようと言う試みは以前より検討されている。
There are two types of processes for producing sheet-like products that exhibit high functionality: dry processes such as vapor deposition and wet processes such as coating. In recent years, the so-called “pre-weighing type” coating method using a die head has been used in the wet process. Among the coating methods using the die head, in the extrusion method, the die head is directly pressed onto the traveling web and the coating is performed, and the tip of the die head is brought close to the web that is wound around the backup roll and conveyed. There is a way to work. In the case of the latter method, the bead portion must be depressurized in order to reliably form a bead. For example, it is widely known to install a depressurization chamber as in
In addition, the decompression chamber, especially in the case of a product width exceeding 1 m, may induce an unexpected failure due to the flow of wind in the chamber. For example, as shown in
特許文献は以下の通りである。
しかしながら、製造塗工中は減圧にするために減圧チャンバーに設けられる廃液口の先端はバルブを設置して流路を閉じたり、流路の先端を液封状態にするなり何らかの閉じられた状態になるために、閉じられた後に垂れ流すなどの行為によってダイヘッドから吐出された塗工液はチャンバー内に溜められ続ける。常時ということではないのであるが、長時間製造を続けているとチャンバー内に無視できない量の廃液が溜まることになる。 However, during production coating, the tip of the waste liquid port provided in the decompression chamber to reduce the pressure is installed with a valve to close the flow path, or the flow path tip is liquid-sealed, or it is in a closed state. Therefore, the coating liquid discharged from the die head by an action such as dripping after being closed continues to be stored in the chamber. Although this is not always the case, if production is continued for a long time, a non-negligible amount of waste liquid will accumulate in the chamber.
通常の減圧チャンバーでは溜まることを防ぐために廃液口は大きく取られることが普通である。最初は廃液が仕切り板のダイヘッド側の区画に溜まるのであるが、廃液口が大きく取られているがゆえにある程度溜まると仕切り板のを挟んで反対側の区画（以後反ダイヘッド側の区画と称す）にも廃液が流れ始めることになる。 In order to prevent accumulation in a normal decompression chamber, a large waste liquid port is usually taken. Initially, the waste liquid collects in the partition on the die head side of the partition plate. However, if the waste liquid port is collected to a certain extent, the partition on the opposite side across the partition plate (hereinafter referred to as the partition on the anti-die head side) The waste liquid will begin to flow.
通常の減圧チャンバーは減圧にするための吸引口が反ダイヘッド側の区画の壁面に単数または複数箇所設置されている。そのために廃液がそちらの区画に流れ込むとそのまま直接吸引口からも廃液が引かれることになり、チャンバー内でその吸引気流により液が跳ね搬送中のウェブを汚したり、吸引口の中に液が流入すると流れ込んだ液により吸引ムラが引き起こされ、大きな減圧度変動につながることから段状の塗工ムラなど様々な面状故障を引き起こす。 In a normal decompression chamber, one or a plurality of suction ports for decompressing are provided on the wall surface of the partition on the side opposite to the die head. For this reason, when the waste liquid flows into that section, the waste liquid is drawn directly from the suction port, and the liquid splashes in the chamber due to the suction air current, and the web being conveyed is contaminated, or the liquid flows into the suction port. Then, the flowed liquid causes suction unevenness, which leads to large fluctuations in the degree of reduced pressure, causing various surface failures such as stepwise coating unevenness.
本願発明は問題を解決するために以下のような手段をとることが有効である。 In order to solve the problem, the present invention is effective to take the following measures.
すなわち、請求項１にかかる発明は、バックアップロールにダイヘッド先端の平坦部を近接させて塗工する塗工方法において、減圧チャンバーの内側にチャンバーの深さの１／５以上１未満の高さである仕切り板を設け、前記仕切り板により区切られたチャンバー全体の底面積の１／２より大きく３／４以下である底面積のダイヘッド側の区画内に廃液を受けるとともに、排出し、かつ、仕切り板により区切られたダイヘッド側と反対側の区画では廃液を排出しないことを特徴とする塗工方法を提供するものである。
That is, the invention according to
請求項２にかかる発明は、請求項１における塗工方法において、塗工中の減圧度が大気圧に対して３００Ｐａ以上であることを特徴とする塗工方法を提供するものである。
The invention according to
請求項３にかかる発明は、バックアップロールとダイヘッド先端の平坦部が近接している塗工装置において、減圧チャンバーの内側にチャンバーの深さの１／５以上１未満の高さである仕切り板を設け、前記仕切り板により区切られたチャンバー全体の底面積の１／２より大きく３／４以下である廃液が落下する位置の底面積のダイヘッド側の区画内に廃液を排出する手段を設けるとともに、ダイヘッド側の反対側の区画に吸気手段を設け廃液を排出する手段を設けないことを特徴とする塗工装置を提供するものである。 According to a third aspect of the present invention, in the coating apparatus in which the backup roll and the flat portion at the tip of the die head are close to each other, a partition plate having a height not less than 1/5 and less than 1 of the depth of the chamber is provided inside the vacuum chamber. Providing a means for discharging the waste liquid into a section on the die head side of the bottom area of the position where the waste liquid that is larger than 1/2 of the entire bottom area of the chamber divided by the partition plate and is 3/4 or less falls; there is provided a coating apparatus characterized that it will not provide a means for discharging the set only waste the inlet means to the partition opposite the die head side.
以上の方法を用いることにより、請求項１や３においては、チャンバー内の気流の乱れを抑制するための仕切り板の効果を生かしながら、廃液の逆流による長時間塗工のネックを同時に改善できる。また、区画の大きさが、ダイヘッド側の区画は廃液が溜まっていくことになるためにチャンバー全体の底面積の１／２以下の大きさだと簡単に水位が上がって故障の要因となる。しかしあまり反ダイヘッド側の区画が１／４未満だと狭いと仕切り板と吸引口の距離が近くなりすぎるために減圧チャンバー内の気流の乱れを生じせしむる。そこでダイヘッド側の区画の大きさとして底面積がチャンバー全体の底面積の１／２より大きく３／４以下であると効果を生ずる。
By using the above method, in
さらに区画を区切る仕切り板だが、上記と同様に廃液が溜まっていくことを考えると１／５未満では効果が薄く、高くした方が良いが、あまり高くし１以上だと仕切り板の最上部がバックアップロールに巻きつけて搬送されるウェブと距離が近すぎるため減圧チャンバー内の気流の乱れを生じせしむるので１／５以上１未満で効果を生ずる。 Although it is a partition plate that divides the compartment, considering that waste liquid accumulates in the same way as above, the effect is less if it is less than 1/5, and it is better to make it higher, but if it is too high and 1 or more, the top of the partition plate is Since the distance between the web wound around the backup roll and the web conveyed is too close, the turbulence of the air flow in the decompression chamber is caused, so that the effect is produced at 1/5 or more and less than 1.
請求項２においては、塗工中の減圧度が大気圧に対して３００Ｐａ未満では区画の面積の関係上特に困難であったので、この場合に特段の効果が得られる。
In
まずは廃液の逆流を防ぐために廃液を排出する手段が設けられており、例えば廃液口などの手段で設けられている。廃液口は本来廃液が溜まることを前提としている減圧チャンバー内のダイヘッド側の区画にのみ設けることとし、仕切り板を挟んだ反対側の区画には一切廃液口を設けない。そして廃液口は一つで十分であればそれでも十分な効果を上げうるが、従来の大きな廃液口が区画の片方のみに狭められることに対応するために、場合によっては複数の廃液口を当該区画に設けることもその効果を妨げるものではない。 First, a means for discharging the waste liquid is provided in order to prevent the backflow of the waste liquid. For example, a means such as a waste liquid port is provided. The waste liquid port is provided only in the section on the die head side in the decompression chamber that is supposed to accumulate the waste liquid, and no waste liquid port is provided in the opposite section across the partition plate. And if one waste liquid port is sufficient, it can still be effective, but in order to cope with the fact that the conventional large waste liquid port is narrowed to only one of the compartments, in some cases, a plurality of waste liquid ports may be attached to the compartment. It does not interfere with its effect.
廃液口の位置は減圧チャンバーの側面でも底面でも効果に変化はない。廃液口の大きさはなるべく大きい方がチャンバー内の廃液の溜まりを防ぐことができるので有効だが、大きすぎるとチャンバー内の気流の流れが乱れるために大きくても一箇所につき１５００ｍｍ2から１００００ｍｍ2程度の断面積であることが望ましい。その形状は円や楕円、四角形など問わない。 There is no change in the effect of the position of the waste liquid port on the side surface or the bottom surface of the vacuum chamber. It is effective that the size of the waste liquid port is as large as possible because it can prevent the accumulation of waste liquid in the chamber. However, if it is too large, the flow of air in the chamber will be disturbed, so even if it is large, about 1500 mm 2 to 10000 mm 2 It is desirable that the cross-sectional area be The shape may be a circle, an ellipse, or a rectangle.
また区画の大きさだが、ダイヘッド側の区画は廃液が溜まっていくことになるためにある程度の大きさがないと簡単に水位が上がって故障の要因となる。しかしあまり反ダイヘ
ッド側の区画が狭いと仕切り板と吸引口の距離が近くなりすぎるために減圧チャンバー内の気流の乱れを生じせしむる。そこで望ましいダイヘッド側の区画の大きさとして底面積で考えるとチャンバー全体の底面積の１／２より大きく３／４未満であることがわかった。
Also, the size of the compartment, but the waste on the die head side accumulates, so if there is no certain size, the water level will rise easily and cause a failure. However, if the section on the side opposite to the die head is too narrow, the distance between the partition plate and the suction port becomes too close, and the air flow in the decompression chamber is disturbed. Therefore, it was found that when considering the size of the partition on the die head side in terms of the bottom area, it is larger than 1/2 of the bottom area of the entire chamber and less than 3/4.
更に区画を区切る仕切り板だが、上記と同様に廃液が溜まっていくことを考えるとなるべく高くした方が良いが、あまり高くすると仕切り板の最上部がバックアップロールに巻きつけて搬送されるウェブと距離が近すぎるため減圧チャンバー内の気流の乱れを生じせしむる。そこで望ましい仕切り板の高さはチャンバーの深さの１／５以上１未満である。またそのときのチャンバーの深さとしては５０ｍｍ以上３００ｍｍ以下が望ましい。ここで言うチャンバーの深さと言うのは吸引口のある反ダイヘッド側の区画における、吸引口を持つ壁面の高さを指す。例えば本発明の実施形態の一例として示した図１におけるｈ１が深さになり、ｈ２／ｈ１の値が１／５以上１未満が望ましいということになる。 It is a partition plate that divides the compartment, but it is better to make it as high as possible considering that waste liquid accumulates as in the above, but if it is too high, the top of the partition plate is wound around the backup roll and the distance to the web being conveyed Is too close to the air flow in the decompression chamber. Therefore, a desirable partition plate height is 1/5 or more and less than 1 of the depth of the chamber. Further, the depth of the chamber at that time is preferably 50 mm or more and 300 mm or less. The chamber depth here refers to the height of the wall surface having the suction port in the section on the side opposite to the die head where the suction port is located. For example, h1 in FIG. 1 shown as an example of the embodiment of the present invention is the depth, and the value of h2 / h1 is preferably 1/5 or more and less than 1.
以上のような発明の効果が顕著に現れるのは減圧度の大きい場合であり、具体的には３００Ｐａ以上の場合に特に有効である。 The effect of the invention as described above appears remarkably when the degree of decompression is large, and specifically, it is particularly effective when the pressure is 300 Pa or more.
幅６５０ｍｍのポリエチレンテレフタレート基材を使用し、幅６４０ｍｍのエクストルージョン型のダイヘッドを用いてメチルエチルケトン（ＭＥＫ）と酢酸メチルを希釈溶剤とする５０ｗｔ％のアクリル系のＵＶ硬化樹脂塗工液を湿潤膜厚１０μｍとなるように５０ｍ／ｍｉｎの速度で塗工した。塗工液の粘度は５ｍＰａｓで表面張力が２５ｍＮ／ｍである。それぞれの条件で１時間連続塗工を行って故障が起きるかどうかを目視で確認した。評価は問題が発生しない場合は○×にて記した。問題がある場合は×とし、何回かに一回の割合で起こるような故障の場合は「ほぼ○」と記した。使用したバックアップロールの径は２００ｍｍで減圧チャンバーの深さは１２０ｍｍとし、奥行きは１５０ｍｍとし、減圧度は大気圧に対して５００Ｐａに設定した。表１にその結果を示す。 Using a polyethylene terephthalate substrate with a width of 650 mm, using an extrusion-type die head with a width of 640 mm, wet film thickness of 50 wt% acrylic UV curable resin coating solution with methyl ethyl ketone (MEK) and methyl acetate as diluent solvents Coating was performed at a speed of 50 m / min so as to be 10 μm. The viscosity of the coating solution is 5 mPas and the surface tension is 25 mN / m. It was visually confirmed whether or not a failure occurred after continuous coating for 1 hour under each condition. The evaluation was marked with XX when no problem occurred. When there was a problem, it was marked as “X”, and in the case of a failure that occurred once every few times, “almost ○” was marked. The diameter of the used backup roll was 200 mm, the depth of the decompression chamber was 120 mm, the depth was 150 mm, and the degree of decompression was set to 500 Pa with respect to atmospheric pressure. Table 1 shows the results.
以上の結果より廃液口をダイヘッド側の区画のみに限定することが良好な結果が得られ、更にそのときのダイヘッド側の区画は減圧チャンバーの底面積の１／２より大きく３／４以下が良好で、仕切り板の高さは減圧チャンバーの深さの１／５以上１未満が良好であることがわかった。 From the above results, it is possible to obtain a good result that the waste liquid port is limited only to the section on the die head side, and the section on the die head side at that time is more than 1/2 of the bottom area of the decompression chamber and not more than 3/4. Thus, it was found that the height of the partition plate was good at 1/5 or more and less than 1 of the depth of the decompression chamber.
本発明は、塗工方法に関するものであり、特に写真感光乳化剤、磁性材料液、反射防止性能等の機能を発現する光学薄膜用の塗工液などを、プラスチックフィルムや紙、金属箔等の可撓性支持体（以下、ウェブと称する）に塗工して、高機能を発現するシート状のものを製造する場合に有効である。 The present invention relates to a coating method, in particular, a photographic photosensitive emulsifier, a magnetic material solution, a coating solution for an optical thin film that exhibits functions such as antireflection performance, and the like, such as a plastic film, paper, and metal foil. It is effective in the case of manufacturing a sheet-like material that expresses a high function by coating on a flexible support (hereinafter referred to as a web).
１ ダイヘッド
２ バックアップロール
３ 減圧チャンバー
４ ダイヘッド側の区画
５ ダイヘッド側と反対側の区画
1
Claims (3)
In the coating apparatus in which the flat portion at the tip of the backup roll and the die head is close to each other, a partition plate having a height of 1/5 or more and less than 1 of the depth of the chamber is provided inside the vacuum chamber, and is partitioned by the partition plate. In addition, a means for discharging the waste liquid is provided in the section on the die head side of the bottom area where the waste liquid that is larger than ½ of the bottom area of the entire chamber and 3/4 or less falls, and the section on the opposite side of the die head side is provided. coating apparatus characterized that it will not provide a means for discharging the set only waste the inlet means.
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| JP2004050007A (en) * | 2002-07-18 | 2004-02-19 | Konica Minolta Holdings Inc | Coating method |
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| JPH057816A (en) * | 1991-06-28 | 1993-01-19 | Konica Corp | Web coating device |
| JPH057820A (en) * | 1991-07-08 | 1993-01-19 | Konica Corp | Web coating device |
| JP4877567B2 (en) * | 2001-08-22 | 2012-02-15 | 大日本印刷株式会社 | Coating equipment |
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