JP5162504B2 - バー塗布装置、及びバー塗布方法 - Google Patents
バー塗布装置、及びバー塗布方法 Download PDFInfo
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Description
関係、バーホールド角等を規定することで、バー振動による段状塗布ムラや、バーとバー
支持部材との間に発生する泡による塗布スジ故障を防止することが提案されている(特許
文献2)。
Rbとし、バー支持部材のバー受け部断面の円弧の曲率半径をRhとしたときに、Rb/
Rhが0.9〜1.0の範囲とし、バー支持部材のバーホールド角を90°以上180°
以下にするバー塗布方法が提案されている(特許文献3)。
せん断力を付与して低粘度化する方法(特許文献4)、ロッドコーターにおいて、ロッド
のワイヤー間の溝に引っかかる異物や凝集物を除去するための異物除去ブラシ等をロッド
バーホルダに設ける方法(特許文献5)等が提案されている。また、支持体上に塗布膜を
形成した後、掻き取りローラにより余剰液を掻き取り必要膜厚を得る塗布方法において、
掻き取りローラ表面の乾きに起因する塗布故障を抑制するために、掻き取りローラ表面に
塗布液又は溶剤を供給する方法が提案されている(特許文献6)。
(2) ΔP1=12ηqL/δu3
(3) ΔP2=(6ηU/a)×(1/(h0−aXb)−1/h0)
(4) q=Q/(60×ρ×W)
(但し、η:塗布液粘度[Pa・s]、q:排液路を流れる塗布液の単位幅流量[m2/s]、Q:塗布液の供給量[kg/min]、ρ:塗布液密度[kg/m3]、L:排液路長さ[m]、U:ウエブ速度[m/s]、a:堰の先端面の傾き(=tanθ)、h0:堰の先端面の開始点とウエブとのクリアランス[m]、Xb:ビード長さ[m]、H:排液路から先端面の開始点までの堰高さ[m]、W:排液路の幅[m]、δu:排液路のクリアランス[m]、g:重力加速度[m/s2])
液溜部を構成する堰と、排液路とを備えたバー塗布装置において、上記(1)〜(4)式を満たすように塗布液の供給量を制御することにより、過剰供給された塗布液は堰をオーバーフローせずに、排液路から排出される。これにより動的接触線が乱れるのを防止することができる。また、堰の先端面とウエブとの間に確実に塗布液のビードを形成することができる。
(2) ΔP1=12ηqL/δu3
(3) ΔP2=(6ηU/a)×(1/(h0−aXb)−1/h0)
(4) q=Q/(60×ρ×W)
(但し、η:塗布液粘度[Pa・s]、q:排液路を流れる塗布液の単位幅流量[m2/s]、Q:塗布液の供給量[kg/min]、ρ:塗布液密度[kg/m3]、L:排液路長さ[m]、U:ウエブ速度[m/s]、a:堰の先端面の傾き(=tanθ)、h0:堰の先端面の開始点とウエブとのクリアランス[m]、Xb:ビード長さ[m]、H:排液路から先端面の開始点までの堰高さ[m]、W:排液路の幅[m]、δu:排液路のクリアランス[m]、g:重力加速度[m/s2])
本発明のバー塗布方法は、前記発明において、前記排液路のクリアランスが0.1×10−3〜10×10−3[m]の範囲であることが好ましい。
(1)液溜り内の塗布液が堰の先端面の開始点の高さまで持ち上がり、ウエブ間で挟まれること、(2)液溜り内の塗布液が堰の先端面の終了点よりオーバーフローしない(溢れない)ことが、必要となる。
さらに(a)は以下式のように変形することができる。
ここで(P2−P1)は、排液路の入口側の圧力P1と先端面の開始点の圧力P2との差であり、液溜り堰の先端面と排液路での塗布液の持つポテンシャル[Pa]を意味する。従って、塗布液密度ρ[kg/m3]、排液路から先端面の開始点までの堰高さH[m]、重力加速度g[m/s2]とすると、以下の式で表すことができる。
ここで、P1は排液路入口部にて塗布液の持つ圧力であり、P0は大気圧であるから、(P1−P0)は塗布液が排液路を通過する際に受ける圧力損失[Pa]を表している。ΔP1(=P1−P0)は、塗布液粘度η[Pa・s]、単位幅流量q[m2/s]、排液路長さL[m]、排液路のクリアランスδu[m]から、平行平板間に挟まれる流体の受ける圧力損失を求める式を用いて以下のように求められる。
塗布液の供給量をQ[kg/min]、密度ρ[kg/m3]とすると、一秒間に幅W[m]の排液路を流れる塗布液の単位幅流量q[m2/s]は、次式となる。
したがって、堰の先端面とウエブに挟まれる塗布液の受ける圧力損失△Pは次式となる。
一方で、堰先端面においてウエブと堰先端面の間に満たされている塗布液が受ける圧力損失を堰先端面とウエブに挟まれる塗布液の受ける圧力の直接計算により求めることができる。
この堰先端面においてウエブと堰先端面の間に満たされている塗布液内ではウエブに同伴される流速分布と塗布液内部の液圧により押し出そうとする流速分布があり、ウエブ速度U[m/s]とすると、単位幅流量は次式で示される。
したがって、式(g)に式(h)を代入すると次式となる。
=6ηUΔx/y(x)2
堰先端面においてウエブと堰先端面の間に満たされている塗布液の圧力損失は上式の△xを水平方向に積分した形で、次式で示される圧力損失を受ける。
上式の両辺を微分すると以下の式となる。
(m) dx=(−1/a)*dy
なお、x=0のとき、y(x)=h0であり、x=Xbのとき、y(x)=−aXb+h0となるため、式(j)は式(n)のように置換積分され、計算することができる。
また、本発明において、(2)液溜り内の塗布液が堰の先端面の終了点よりオーバーフローしない(溢れない)ことが必要となる。式(f)で求めた△Pと式(n)で求めた△P2は等価である。式(n)ではXbの関数であり、Xbは堰先端面の開始点よりウエブと先端面の間で液が満たされる部分の水平距離(ビード長さ)となる。
最終的には、以下の式が導き出される。
但し、q=Q/(60×ρ×W)となる。
示す具体例により限定的に解釈されるべきものではない。
(2) ΔP1=12ηqL/δu3
(3) ΔP2=(6ηU/a)×(1/(h0−aXb)−1/h0)
(4) q=Q/(60×ρ×W)
Claims (8)
- 走行するウエブに塗布液を塗布するバーと、
前記バーの下側に設けられ、該バーを回転自在に支持する支持部材と、
前記バーに対して上流側に設けられた堰と、該堰は先端に先端面を備え、該先端面と前記ウエブとの間に塗布液のビードを形成し、
前記バー、前記支持部材、及び前記堰により構成された液溜部に塗布液を供給する供給路と、
前記液溜部に塗布液を供給するポンプと、
前記液溜部に過剰供給された塗布液を、排出する排液路を備え、
前記液溜部に供給される塗布液の供給量が、下記式(1)〜(4)を満たすように前記ポンプを制御する制御装置を備えたことを特徴とするバー塗布装置。
(1) 0≦ΔP1-ρgH≦ΔP2
(2) ΔP1=12ηqL/δu3
(3) ΔP2=(6ηU/a)×(1/(h0−aXb)−1/h0)
(4) q=Q/(60×ρ×W)
(但し、η:塗布液粘度[Pa・s]、q:排液路を流れる塗布液の単位幅流量[m2/s]、Q:塗布液の供給量[kg/min]、ρ:塗布液密度[kg/m3]、L:排液路長さ[m]、U:ウエブ速度[m/s]、a:堰の先端面の傾き(=tanθ)、h0:堰の先端面の開始点とウエブとのクリアランス[m]、Xb:ビード長さ[m]、H:排液路から先端面の開始点までの堰高さ[m]、W:排液路の幅[m]、δu:排液路のクリアランス[m]、g:重力加速度[m/s2]) - 前記排液路のクリアランスが0.1×10−3〜10×10−3[m]の範囲である請求項1記載のバー塗布装置。
- 前記堰の先端面の水平長さが1×10−3〜30×10−3[m]の範囲であり、前記堰の先端面の傾きが1/30〜5の範囲である請求項1又は2記載のバー塗布装置。
- 前記排液路から先端面の開始点までの前記堰の高さが5×10−3〜50×10−3[m]の範囲である請求項1〜3の何れか1記載のバー塗布装置。
- 走行するウエブに塗布液を塗布するバー塗布方法であって、
バーを回転することで、液溜部の塗布液を走行するウエブに塗布するステップと、
前記バーの上流側に設けられた堰の先端の先端面と前記ウエブとの間に塗布液のビードを形成するステップと、
前記液溜部に前記塗布液を供給し、過剰供給された前記塗布液を排液路から排出するステップと、を備え、
前記液溜部に供給される塗布液の供給量が、下記式(1)〜(4)を満たすことを特徴とするバー塗布方法。
(1) 0≦ΔP1-ρgH≦ΔP2
(2) ΔP1=12ηqL/δu3
(3) ΔP2=(6ηU/a)×(1/(h0−aXb)−1/h0)
(4) q=Q/(60×ρ×W)
(但し、η:塗布液粘度[Pa・s]、q:排液路を流れる塗布液の単位幅流量[m2/s]、Q:塗布液の供給量[kg/min]、ρ:塗布液密度[kg/m3]、L:排液路長さ[m]、U:ウエブ速度[m/s]、a:堰の先端面の傾き(=tanθ)、h0:堰の先端面の開始点とウエブとのクリアランス[m]、Xb:ビード長さ[m]、H:排液路から先端面の開始点までの堰高さ[m]、W:排液路の幅[m]、δu:排液路のクリアランス[m]、g:重力加速度[m/s2]) - 前記排液路のクリアランスが0.1×10−3〜10×10−3[m]の範囲である請求項5記載のバー塗布方法。
- 前記堰の先端面の水平長さが1×10−3〜30×10−3[m]の範囲であり、前記堰の先端面の傾きが1/30〜5の範囲である請求項5又は6記載のバー塗布方法。
- 前記排液路から先端面の開始点までの前記堰の高さが5×10−3〜50×10−3[m]の範囲である請求項5〜7の何れか1記載のバー塗布方法。
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