JP7019049B2 - Laminate manufacturing method and manufacturing equipment - Google Patents

Description

The present disclosure relates to a method for manufacturing a laminate and a manufacturing apparatus.

A method of forming a target coating layer on a substrate by a continuous process of a roll-to-roll method to produce a laminated body is known.

As an example of a method for producing a laminate, Japanese Patent Application Laid-Open No. 2014-188450 describes that a coating liquid containing a resin material and a solvent is applied to one surface of a long film conveyed in the longitudinal direction. Two or more cover members are provided to cover the thickness portions of the coating film and the film at both ends in the width direction after the coating film is formed and at least until the drying apparatus is filled with the solvent volatilized from the coating film. In the coating film control device, two or more cover members are connected in the film transport direction, and one or more perforated cover members having holes and one or more non-perforated cover members having no holes are provided. A laminated film using a coating film control device, which is provided with a cover member, has an exhaust means for exhausting a solvent volatilized from the coating film to the outside through a hole of the perforated cover member, and can rearrange the installation location of the cover member. The manufacturing method is disclosed.

Further, Japanese Patent Application Laid-Open No. 2011-36803 uses a manufacturing process having a base material supply step, a coating step, a drying step, and a winding step, and a polymer is placed on a film base material having at least one inorganic barrier layer. In the method for producing a barrier film for producing a barrier film having at least one polymer layer by applying a layer-forming coating liquid, at least the coating step is a coating chamber in a reduced pressure environment of -0.1 kPa to -1.0 kPa. Using a coating machine having a decompression chamber on the upstream side, the decompression degree of the decompression chamber is from -0.2 kPa to -3.0 kPa, and the relationship between the decompression degree of the decompression chamber and the coating chamber is the decompression of the decompression chamber. Degree> Disclosed is a method for producing a barrier film in which the decompression degree of the coating chamber and the decompression degree difference between the decompression chamber and the coating chamber are 0.1 kPa to 2 kPa.

By a continuous process using the roll-to-roll method, the base material to be continuously transported is wrapped around a backup roll, and a coating liquid containing an organic solvent is applied on the wound base material using a die coater to obtain the target coating layer. A method of forming and producing a laminate is known.
In such a method for producing a laminate, the coating film immediately after coating having the lowest solid content concentration is usually dried gently in order to be less susceptible to disturbance (that is, the thickening rate of the coating film is increased). The rise is gradual).
However, even if the coating film immediately after application is gently dried, it is insufficient to suppress the occurrence of wind unevenness.
Here, the "wind unevenness" is a pattern such as a streak or a spot formed on the surface of the coating layer in a direction substantially parallel to the transport direction of the base material. In the case of a streak-like pattern, for example, the maximum width is 1 mm to 20 mm and the length is 30 cm or more, and in the case of a speckled pattern, for example, the maximum diameter is 1 mm to 10 mm. Have.

Therefore, an object to be solved by one embodiment of the present invention is to provide a method for manufacturing a laminated body and a manufacturing apparatus capable of forming a coating layer in which the occurrence of wind unevenness is suppressed on a base material. ..

Specific means for solving the problem include the following aspects.

<1> A step a of winding a continuously transported base material on a backup roll, applying a coating liquid containing an organic solvent to the base material on the backup roll, and forming a coating film.
Step b to reduce the organic solvent from the coating film on the backup roll by inhaling the gas on the coating film,
Have at least
When the atmospheric pressure on the substrate at the time of contact between the substrate and the coating liquid in step a is PA and the atmospheric pressure on the substrate at the time of inhaling gas in step _{b is P B, PA and P B are as follows} . A method for producing a laminated body, which satisfies the conditions 1 and 2 of.
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa

<2> The method for producing a laminate according to <1>, wherein the wind speed of the gas on the coating film in step b is 1 m / s to 100 m / s.
<3> In <1> or <2>, the distance from the contact point between the base material and the coating liquid in step a to the point where the intake of gas on the coating film is started in step b is 100 mm or less. The method for manufacturing a laminate according to the description.
<4> The method for producing a laminate according to any one of <1> to <3>, wherein in step b, the gas on the coating film is sucked in until the solid content concentration of the coating film reaches 70% by mass. ..

<5> A backup roll around which a continuously transported base material is wound, and
A die coater that forms a coating film by applying a coating liquid containing an organic solvent on a base material wound on a backup roll.
A decompression chamber that is installed adjacent to the die coater and reduces the amount of organic solvent from the coating film on the backup roll by sucking in the gas on the coating film.
At least prepare
When the atmospheric pressure on the substrate at the time of contact between the substrate on the backup roll and the coating liquid applied by the die coater is PA, and the atmospheric pressure on the substrate at the time of _{inhaling gas in the decompression chamber is P B ,} P. _A laminated body manufacturing apparatus in which A and P _B satisfy the following conditions 1 and 2.
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa

<6> The apparatus for manufacturing a laminate according to <5>, wherein the wind speed of the gas on the coating film in the decompression chamber is 1 m / s to 100 m / s.
<7> The apparatus for producing a laminate according to <5> or <6>, further comprising a means for supplying gas to the decompression chamber.
<8> The distance from the contact point between the base material on the backup roll and the coating liquid applied by the die coater to the point where the inhalation of gas on the coating film is started in the decompression chamber is 100 mm or less. 5> The apparatus for manufacturing a laminated body according to any one of <7>.

<9> The apparatus for manufacturing a laminated body according to any one of <5> to <8>, wherein the distance between the tip surface of the side surface of the decompression chamber and the backup roll is 0.5 mm or less.
<10> The laminated body manufacturing apparatus according to <9>, wherein the distance between the front end surface of the decompression chamber and the backup roll is larger than the distance between the front end surface of the decompression chamber and the backup roll.
<11> The apparatus for manufacturing a laminated body according to any one of <5> to <10>, wherein the decompression chamber includes a main body portion and a side plate having an air supply slit and an exhaust slit.

<12> The apparatus for manufacturing a laminated body according to any one of <5> to <11>, wherein the surface temperature of the backup roll is 40 ° C. to 120 ° C.

According to one embodiment of the present invention, there is provided a method for manufacturing a laminated body and a manufacturing apparatus capable of forming a coating layer in which the occurrence of wind unevenness is suppressed on a base material.

It is a schematic side view which shows an example of the manufacturing apparatus of the laminated body which performs steps a and b in this disclosure. It is a schematic side view for demonstrating the structure of the decompression chamber of 1st Embodiment. It is a schematic side view for demonstrating the structure of the decompression chamber of the 2nd aspect.

Hereinafter, the method for producing the laminate of the present disclosure will be described in detail.
In the present disclosure, the term "process" is included in this term not only as an independent process but also as long as the intended purpose of the process is achieved even if it cannot be clearly distinguished from other processes.

In the present disclosure, the numerical range indicated by using "-" indicates a range including the numerical values before and after "-" as the minimum value and the maximum value, respectively.
In the numerical range described stepwise in the present disclosure, the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of the numerical range described in another stepwise description. Further, in the numerical range described in the present disclosure, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples.
When the reference numerals described in a plurality of drawings are the same, they refer to the same object. In addition, explanations may be omitted for overlapping configurations and reference numerals in the drawings.
In the present disclosure, a combination of two or more preferred embodiments is a more preferred embodiment.

As described above, the base material to be continuously transported is wound on a backup roll by a continuous process in a roll-to-roll method, and a coating liquid containing an organic solvent is applied on the wound base material using a die coater. A method of forming a coating layer to produce a laminated body is known.
In such a method for producing a laminate, the coating film immediately after coating, which has the lowest solid content concentration, is usually dried gently, but it is insufficient to suppress the occurrence of wind unevenness.
Therefore, when we investigated a technology to suppress the occurrence of wind unevenness, we made a clear distinction from the conventional method and by sucking air on the coating film to the coating film immediately after coating, which has the lowest solid content concentration. It was found that the occurrence of wind unevenness can be suppressed by removing the organic solvent and accelerating the drying (that is, thickening the coating film).

The method for producing the laminate of the present disclosure based on the above findings is as follows.
That is, in the method for manufacturing a laminate of the present disclosure, a step a of winding a continuously transported base material on a backup roll, applying a coating liquid containing an organic solvent to the base material on the backup roll, and forming a coating film. It has at least a step b of reducing the organic solvent from the coating film on the backup roll by sucking in the gas on the coating film, and the atmosphere on the substrate at the time of contact between the substrate and the coating liquid in the step a. When the pressure is PA and the atmospheric pressure on the substrate at the time of inhaling the gas in step _{b is P B, this is a method for producing a laminated body in which PA and P B satisfy the following} conditions 1 and 2.
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa

Condition 1 in the method for producing a laminated body of the present disclosure is that the atmospheric pressure P _B on the substrate at the time of inhaling the gas in step b is the basis at the time of contact between the substrate and the coating liquid in step a (that is, at the time of coating). It shows that the atmospheric pressure on the material is smaller than _PA .
Condition 2 indicates that the atmospheric pressure P _B on the substrate at the time of inhaling the gas in step b is atmospheric pressure −100 pa or less, and is in a depressurized state.
Here, "atmospheric pressure _PA on the base material" refers to the atmospheric pressure (that is, static pressure) at the time of contact between the base material and the coating liquid (for example, surrounded by the backup roll 110, the die coater 120, and the decompression chamber 130). Also, the pressure at point a in FIG. 1).
Further, the "atmospheric pressure on the base material P _B " is the atmospheric pressure at the upper part of the base material (1 mm to 10 mm above the base material, for example, 5 mm above) while the gas on the coating film is being sucked (that is,). (Static pressure) (for example, the pressure at point b in FIG. 1).
Further, the "atmospheric pressure" in the present disclosure means the atmospheric pressure in the indoor environment in which the manufacturing apparatus for manufacturing the laminated body of the present disclosure is placed.
The atmospheric pressure and the atmospheric pressures _PA and BP on the substrate are measured by a pressure gauge, specifically, for example, a general vacuum gauge type _A (manufactured by Toyo Keiki Kogyo).

By satisfying the above conditions 1 and 2, the organic solvent can be quickly removed from the coating film immediately after the coating film while the coating film is normally applied in the step a, and the coating film can be thickened.
As a result, in the method for producing a laminated body of the present disclosure, a coating layer in which the occurrence of wind unevenness is suppressed is formed on the base material.

The methods described in JP-A-2014-188450 and JP-A-2011-36803 do not describe the relationship of PA> _{P B in} the present disclosure.
Further, Japanese Patent Application Laid-Open No. 2014-188450 and Japanese Patent Application Laid-Open No. 2011-3683 do not describe the removal of the organic solvent by sucking the gas on the coating film from the coating film immediately after coating. Of course, the suppression of the occurrence of wind unevenness by this method has not been studied.

It is preferable that the method for producing the laminate of the present disclosure described above is carried out by the following apparatus for producing the laminate of the present disclosure.
That is, in the laminated body manufacturing apparatus of the present disclosure, a backup roll around which a continuously conveyed base material is wound and a coating liquid containing an organic solvent are applied onto the base material wound on the backup roll to form a coating film. It is provided with at least a die coater for forming a die coater and a decompression chamber which is installed adjacent to the die coater and reduces organic solvent from the coating film on the backup roll by sucking gas on the coating film.
When the atmospheric pressure on the substrate at the time of contact between the substrate on the backup roll and the coating liquid applied by the die coater is PA, and the atmospheric pressure on the substrate at the time of _{inhaling gas in the decompression chamber is P B ,} P. _A laminated body manufacturing apparatus in which A and P _B satisfy the following conditions 1 and 2.
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa
The laminated body manufacturing apparatus of the present disclosure is provided with a decompression chamber, and by using this decompression chamber, the above conditions 1 and 2 can be satisfied.

Hereinafter, the manufacturing method and the manufacturing apparatus of the laminated body of the present disclosure will be described in detail with reference to the drawings.

[Step a]
In step a, the base material that is continuously conveyed is wrapped around a backup roll, and a coating liquid containing an organic solvent is applied to the base material on the backup roll to form a coating film.
An example of step a will be described with reference to FIGS. 1 and 2.
Here, FIG. 1 is a schematic side view showing an example of a laminated body manufacturing apparatus for performing steps a and b.

In step a, a coating liquid 150 containing an organic solvent is applied to the base material 140 wound on the backup roll 110 using a die coater 120 to form a coating film 152 on the base material 140.
Here, the atmospheric pressure PA on the substrate in the step a is preferably in the range of atmospheric pressure ₋₁₀₀ Pa to atmospheric pressure, and more preferably atmospheric pressure.
When the atmospheric pressure _PA on the substrate is in the above range, good coatability can be obtained, and it becomes easy to form a coating film having high film thickness uniformity.

Hereinafter, the backup roll, the die coater, the base material, and the coating liquid used in the step a will be described.

(Backup role)
The backup roll 110 is rotatably configured and is a member capable of winding a base material and continuously transporting the backup roll 110, and is rotationally driven at the same speed as the transport speed of the base material 140.
As the backup roll 110, a known one can be used without particular limitation.
As the backup roll 110, for example, one having a hard chrome-plated surface can be preferably used.
The thickness of the plating is preferably 40 μm to 60 μm from the viewpoint of ensuring conductivity and strength.
Further, the surface roughness of the backup roll is preferably 0.1 μm or less in terms of the surface roughness Ra from the viewpoint of reducing the variation in the frictional force between the base material 140 and the backup roll 110.

The backup roll 110 is heated from the viewpoint of enhancing the drying promotion of the coating film and from the viewpoint of suppressing brushing of the coating film due to a decrease in the film surface temperature (that is, whitening of the coating film due to the occurrence of fine dew condensation). May be.
The surface temperature of the backup roll 110 may be determined according to the composition of the coating film, the curing performance of the coating film, the heat resistance of the base material 140, and the like, and is preferably 40 ° C to 120 ° C, preferably 40 ° C to 100 ° C. Is more preferable.

It is preferable that the backup roll 110 detects the surface temperature and the surface temperature of the backup roll 110 is maintained by the temperature control means based on the temperature.
The temperature control means of the backup roll 110 includes a heating means and a cooling means. As the heating means, induction heating, water heating, oil heating and the like are used, and as the cooling means, cooling with cooling water is used.

The diameter of the backup roll 110 is 100 mm from the viewpoint of easy wrapping of the base material 140, easy application by the die coater 120, securing of the installation position of the decompression chamber 130, and manufacturing cost of the backup roll 110. It is preferably ~ 1000 mm, more preferably 100 mm to 800 mm, still more preferably 200 mm to 700 mm.

The transport speed of the base material 140 on the backup roll 110 is preferably 10 m / min to 100 m / min from the viewpoint of ensuring productivity and coatability.

The lap angle of the base material 140 with respect to the backup roll 110 is preferably 60 ° or more, more preferably 90 ° or more, from the viewpoint of stabilizing the transport of the base material 140 at the time of coating and suppressing the occurrence of uneven thickness of the coating film. .. Further, the upper limit of the lap angle may be less than 360 °, and can be set to, for example, 180 °.
The lap angle is an angle including a transport direction of the base material 140 when the base material 140 comes into contact with the backup roll 110 and a transport direction of the base material 140 when the base material 140 is separated from the backup roll 110. To say.

(Daicoater)
The die coater 120 refers to a coating device that applies a coating liquid 150 onto a base material 140 via a manifold 124 formed in the die block main body 122 and a slit 126 communicating with the manifold 124.
The die coater 120 is arranged so that the tip thereof and the discharge port face each other with respect to the surface of the backup roll 110.

The die coater 120 has a die block main body 122 composed of one block or a plurality of blocks, and the die block main body 122 forms a manifold 124 and a slit 126.
The manifold 124 is a space extending along the width direction of the die coater 120, and the coating liquid 150 supplied to the die coater 120 is expanded in the coating width direction (that is, the width direction of the die coater 120) to temporarily spread the coating liquid 150. It is stored.
The slit 126 is a space that communicates with the manifold 124 and extends from the manifold 124 toward the tip of the die coater 120 along the width direction of the die coater 120. The slit 126 is opened to the outside at the tip of the die coater 120 and serves as a discharge port for discharging the coating liquid 150.

Here, the distance between the tip of the die coater 120 and the backup roll 110 (that is, the distance D1 shown in FIG. 2) is determined according to the thickness of the base material, the viscosity of the coating liquid, the film thickness of the coating film to be formed, and the like. However, for example, it is set in the range of 0.05 mm to 0.50 mm.
The distance D1 refers to the shortest distance between the tip of the die coater 120 and the backup roll 110.
The distance D1 can be measured with a taper gauge.

(Base material)
The base material 140 is not particularly limited as long as it is a long base material that can be continuously conveyed, and may be appropriately determined according to the use of the laminated body.
Considering the ease of winding around the backup roll, a polymer film is preferably used as the base material 140.
Specific examples of the base material 140 include various polymer films described later.

(Coating liquid)
The coating liquid 150 is a coating liquid containing an organic solvent, and can be used without limitation as long as it can form a target coating layer.
For example, the coating liquid 150 may be a curable coating liquid containing a polymerizable or crosslinkable compound, or may be a non-curable coating liquid.
In the method and apparatus for manufacturing the laminated body of the present disclosure, it is possible to form a coating layer in which the occurrence of wind unevenness is suppressed. Therefore, as the coating liquid 150, for example, a coating liquid for forming a hard coat layer, a liquid crystal layer, a refractive index adjusting layer, etc. in an optical film, which is a thin layer of 5 μm or less, can be applied.

The content of the organic solvent in the coating liquid is not particularly limited, but is preferably 20% by mass or more, preferably 30% by mass, based on the total mass of the coating liquid, from the viewpoint of easily forming a coating film in which the occurrence of wind unevenness is suppressed. % Or more is more preferable, 40% by mass or more is further preferable, and 50% by mass or more is particularly preferable. The upper limit of the content of the organic solvent in the coating liquid may be determined according to the type of the coating liquid capable of forming the target coating layer, and may be less than 100% by mass, more than 80% by mass. preferable.

Here, as an example of the coating liquid, a coating liquid for forming a hard coat layer (hereinafter, also referred to as a coating liquid for forming a hard coat layer) will be described, but the present disclosure is not limited to this aspect.
The hard coat layer is preferably formed by a cross-linking reaction or a polymerization reaction of an ionizing radiation curable compound. That is, it is preferable that the coating liquid for forming the hard coat layer contains, for example, a polymerizable compound such as a monomer or an oligomer, a polymerization initiator, and a solvent.
As the polymerizable compound, a compound exhibiting polymerizability with active energy rays such as light, electron beam, and radiation is preferable, and among them, a compound exhibiting photopolymerizability is preferable.
Examples of the compound exhibiting photopolymerizability include compounds having an unsaturated double bond such as a (meth) acryloyl group, a vinyl group, a styryl group, and an allyl group, and among them, a compound having a (meth) acryloyl group is preferable.

-Compounds with unsaturated double bonds-
Examples of the compound having an unsaturated double bond include a monomer, an oligomer, a polymer and the like, and among them, a polyfunctional monomer having two or more (preferably three or more) unsaturated double bonds is preferable.

Examples of the polyfunctional monomer having two or more unsaturated double bonds include (meth) acrylic acid diesters of alkylene glycol, (meth) acrylic acid diesters of polyoxyalkylene glycol, and (meth) acrylic acid diesters of polyhydric alcohol. Examples include (meth) acrylic acid diesters of ethylene oxide or propylene oxide adducts, epoxy (meth) acrylates, urethane (meth) acrylates, polyester (meth) acrylates, etc., among which polyhydric alcohols (Meta) acrylic acid diesters are preferable.

Specific examples of the polyfunctional monomer having two or more unsaturated double bonds include 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, and neopentyl glycol. Di (meth) acrylate, ethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, pentaerythritol tetra (meth) acrylate, pentaerythritol tri (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethylene oxide (EO) Modified trimethylolpropane tri (meth) acrylate, propylene oxide (PO) modified trimethylolpropane tri (meth) acrylate, EO modified trimethylolpropane tri (meth) acrylate, trimethylolethanetri (meth) acrylate, trimethylolpropane Tetra (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, pentaerythritol hexa (meth) acrylate, polyurethane polyacrylate, polyester polyacrylate, caprolactone Examples thereof include denatured tris (acetyloxyethyl) isocyanurate.

The compound having an unsaturated double bond can be used alone or in combination of two or more.
The content of the compound having an unsaturated double bond in the coating liquid for forming a hard coat layer is the total solid content in the coating liquid for forming a hard coat layer from the viewpoint of imparting a sufficient polymerization rate and imparting hardness and the like. On the other hand, 40% by mass to 98% by mass is preferable, and 60% by mass to 95% by mass is more preferable.

-Initiator-
The coating liquid for forming a hard coat layer preferably contains a polymerization initiator.
The polymerization initiator is preferably a photopolymerization initiator, for example, acetophenones, benzoins, benzophenones, phosphinoxides, ketals, anthraquinones, thioxanthones, azo compounds, peroxides, 2,3-dialkyl. Examples thereof include dione compounds, disulfide compounds, fluoroamine compounds, aromatic sulfoniums, lofin dimers, onium salts, borate salts, active esters, active halogens, inorganic complexes and coumarins.
Specific examples, preferred embodiments, commercial products, etc. of the photopolymerization initiator are described in paragraphs [0133] to [0151] of JP-A-2009-0986658, and may be preferably used in the present disclosure as well. can.
In addition, as a polymerization initiator, "Latest UV Curing Technology" {Technical Information Association, Inc.} (1991), p. 159 and "Ultraviolet Curing System" by Kiyomi Kato (Published by General Technology Center in 1989), p. Various examples are also described in 65 to 148, and these can also be used.

The polymerization initiator may be used alone or in combination of two or more.
The content of the polymerization initiator in the composition for the hard coat layer is set to a sufficiently small amount so as to polymerize the polymerizable compound contained in the composition for the hard coat layer and not to increase the starting points too much. From the viewpoint of the above, 0.5% by mass to 8% by mass is preferable, and 1% by mass to 5% by mass is more preferable with respect to the total solid content in the composition for the hard coat layer.

-Organic solvent-
The coating liquid for forming a hard coat layer may contain various organic solvents as a solvent.
As the organic solvent, an ether solvent, a ketone solvent, an aliphatic hydrocarbon solvent, an aromatic hydrocarbon solvent and the like can be used.
Specifically, for example, dibutyl ether, dimethoxyethane, diethoxy ethane, propylene oxide, 1,4-dioxane, 1,3-dioxolane, 1,3,5-trioxane, tetrahydrofuran, anisole, phenetol, and methyl ethyl ketone (also known as MEK). , Diethyl ketone, dipropyl ketone, diisobutyl ketone, cyclopentanone, cyclohexanone (also called anon), methylcyclohexanone, methylisobutylketone, 2-octanone, 2-pentanone, 2-hexanone, ethylene glycol ethyl ether, ethylene glycol Examples thereof include isopropyl ether, ethylene glycol butyl ether, propylene glycol methyl ether, ethyl carbitol, butyl carbitol, hexane, heptane, octane, cyclohexane, methylcyclohexane, ethylcyclohexane, benzene, toluene and xylene.

Further, the organic solvent preferably contains, for example, a hydrophilic solvent other than the above. As the hydrophilic solvent, an alcohol solvent, a carbonate solvent, or an ester solvent may be used.
Specifically, for example, methanol, ethanol, isopropanol, n-butyl alcohol, cyclohexyl alcohol, 2-ethyl-1-hexanol, 2-methyl-1hexanol, 2-methoxyethanol, 2-propoxyethanol, 2-butoxyethanol. , Diacetone alcohol, dimethyl carbonate, diethyl carbonate, diisopropyl carbonate, methyl ethyl carbonate, methyl n-propyl carbonate, ethyl forylate, propyl formic acid, pentyl notate, methyl acetate, ethyl acetate, propyl acetate, methyl propionate, propionic acid Ethyl, ethyl 2-ethoxypropionate, methyl acetoacetate, ethyl acetoacetate, methyl 2-methoxyacetate, methyl 2-ethoxyacetate, ethyl 2-ethoxyacetate, acetone, 1,2-diacetoxyacetone, acetylacetone, ethylene glycol mono Examples thereof include butyl acetate, propylene glycol monomethyl ether acetate, and diethylene glycol acetate.

As the organic solvent, one type alone or two or more types can be used in combination.
The solvent in the coating liquid for forming the hard coat layer is preferably used so that the solid content of the coating liquid for forming the hard coat layer is in the range of 20% by mass to 80% by mass. That is, the content of the solvent in the coating liquid for forming the hard coat layer is preferably 20% by mass to 80% by mass, more preferably 25% by mass to 70% by mass, based on the total mass of the coating liquid for forming the hard coat layer. , 30% by mass to 60% by mass is more preferable.

-Surfactant-
The coating liquid for forming a hard coat layer may contain a surfactant.
The surfactant is not particularly limited, but a fluorine-based surfactant or a silicone-based surfactant is preferable. Further, the surfactant is preferably a high molecular weight compound rather than a low molecular weight compound.

As the surfactant, one type alone or two or more types can be used in combination.
The content of the surfactant is preferably 0.01% by mass to 0.5% by mass, preferably 0.01% by mass to 0.3% by mass, based on the total solid content of the coating liquid for forming the hard coat layer. Is more preferable.

-Other ingredients-
The coating liquid for forming a hard coat layer may contain other components such as inorganic particles, resin particles, a monomer for adjusting the refractive index, and a conductive compound.

The coating liquid for forming a hard coat layer is not limited to the above composition, and for example, the coating liquid described in Japanese Patent No. 5933353, Japanese Patent No. 5331919, etc. may be applied.

[Step b]
In step b, the organic solvent is reduced from the coating film on the backup roll by inhaling the gas on the coating film.
An example of step b will be described with reference to FIGS. 1 to 3.

In step b, the gas on the coating film 152 is sucked into the coating film 152 on the backup roll 110 by using the pressure reducing chamber 130. The gas on the coating film 152 is sucked by the decompression chamber 130, so that the organic solvent in the coating film is reduced.
Here, the atmospheric pressure P _B on the substrate in the step b is smaller than the atmospheric pressure _PA on the substrate as shown in condition 1, and is atmospheric pressure −100 Pa or less as shown in condition 2.
By satisfying these conditions, a coating film in which the occurrence of wind unevenness is suppressed is formed, and as a result, a coating layer in which the occurrence of wind unevenness is suppressed is formed.

As the atmospheric pressure P _B on the substrate in the step b, the degree of decompression is preferably high, preferably atmospheric pressure −1000 Pa or less, and more preferably atmospheric pressure −10000 Pa or less, from the viewpoint of making it less susceptible to disturbance.
The lower limit of the atmospheric pressure P _B on the base material may be determined from the device limit of the decompression chamber 130, suppression of floating of the base material 140 from the backup roll 110, etc., and is set to, for example, atmospheric pressure -50000 Pa. be able to.

Hereinafter, the decompression chamber used in step b will be described.

(Decompression chamber)
As shown in FIG. 1, the decompression chamber 130 is arranged adjacent to the die coater 120 on the downstream side in the transport direction of the base material.
By arranging the decompression chamber 130 and the die coater 120 apart from each other, the atmospheric pressure PA on the substrate can be adjusted to the above _- mentioned preferable range.
For example, as shown in FIG. 2, the separation distance D2 between the die coater 120 and the decompression chamber 130A can be set in the range of 1 mm to 5 mm.
The distance D2 refers to the shortest distance between the side surface of the die coater 120 and the side surface of the decompression chamber 130A.

By adjusting the separation distance D2, the contact point between the base material and the coating liquid in step a (that is, the contact point between the base material on the backup roll and the coating liquid coated by the die coater) is on the coating film in step b. The distance to the point where the gas intake is started (that is, the point where the gas intake on the coating film is started in the decompression chamber) can be changed.
Here, the contact point between the base material and the coating liquid in step a is the point c on the base material 140 in FIG. 1, and the point at which the inhalation of the gas on the coating film in step b is started is in FIG. A point d on the base material 140 at the shortest distance from the upstream end of the base material in the decompression chamber 130 in the transport direction.
The distance between the point c and the point d is preferably 50 mm or less, more preferably 30 mm or less.
The lower limit of the distance between the point c and the point d is considered to be about 1 mm due to the design of the device.

Further, the range in which the gas on the coating film is taken in by the decompression chamber 130 is not particularly limited, and may be performed until the base material 140 is separated from the backup roll 110, and the size of the decompression chamber 130 is acceptable. Further, as long as the transport and stabilization of the base material 140 can be achieved, the base material 140 may be continued until after the base material 140 is separated from the backup roll 110.
That is, the gas intake in the step b is performed on the coating film on the backup roll, but may be continuously performed on the coating film on the substrate away from the backup roll.
However, from the viewpoint of increasing the size of the decompression chamber 130, the point d in FIG. 1 (the point at which the intake of gas on the coating film is started in the decompression chamber) to the point e in FIG. 1 (the coating film in the decompression chamber). It is preferable that the distance is in the range of 100 mm to 500 mm (more preferably 100 mm to 200 mm) by the point at which the intake of the above gas ends).
Here, the point e is a point on the base material at the shortest distance from the downstream end portion of the base material of the decompression chamber 130 in the transport direction.
In order to make the distance between the point d and the point e within the above range, the length of the base material 140 of the decompression chamber 130 in the transport direction may be adjusted. That is, the length of the base material 140 of the decompression chamber 130 in the transport direction may be 100 mm to 500 mm.

Further, the range in which the gas on the coating film is sucked by the decompression chamber 130 is until the solid content concentration of the coating film reaches 60% by mass (preferably 70% by mass) from the viewpoint of easily suppressing the occurrence of wind unevenness. It is preferable to do so.
That is, in step b, it is preferable to inhale the gas on the coating film until the solid content concentration of the coating film reaches 60% by mass (preferably 70% by mass).
Therefore, for example, at the above point e, the length of the base material 140 of the pressure reducing chamber 130 in the transport direction should be set so that the solid content concentration of the coating film is 60% by mass (preferably 70% by mass) or more. Just do it. Specifically, the relationship between the intake time of the gas on the coating film by the decompression chamber 130 and the change in the solid content concentration of the coating film is obtained in advance, and the solid content concentration of the coating film is 60% by mass (preferably). , 70% by mass), the length of the base material 140 of the decompression chamber 130 in the transport direction may be set so that the point e comes after the position.

Here, the solid content concentration of the coating film can be measured by, for example, an optical interferometry film thickness meter. Specifically, the solid content concentration of the coating film is measured by using, for example, an infrared spectroscopic interferometry film thickness meter SI-T80 manufactured by KEYENCE CORPORATION, and the optical thickness of the film from the time of application to the formation of a dry film. It can be done online by measuring.
Specifically, first, the optical thickness of the film from the time of application to the time when it becomes a dry film is measured. Next, the thickness of the dried film (that is, the dry film) is measured with a contact thickness gauge. The thickness of the dry film measured by the contact thickness meter is divided by the optical thickness to correct it. Based on the corrected value, the thickness of the wet film (coating film) is calculated from the optical thickness. Then, the amount of solvent is obtained from the thickness of the wet film (coating film) at the measurement point. Then, the solvent mass is obtained from the obtained solvent amount, and the value of the solid content concentration at the measurement point is obtained.

The decompression chamber 130 has a function of sucking gas on the coating film, and there is no limitation on the configuration as long as the atmospheric pressure P _B on the substrate can be set to atmospheric pressure −100 Pa or less.
In the present disclosure, the decompression chamber 130 will be described in more detail with reference to FIGS. 2 and 3, but is not limited to this configuration.
Here, FIG. 2 is a schematic side view for explaining the configuration of the decompression chamber of the first aspect, and FIG. 3 is a schematic side view for explaining the configuration of the decompression chamber of the second aspect.

The decompression chamber 130A of the first aspect shown in FIG. 2 is composed of a decompression chamber main body 131 and an exhaust port 132. The decompression chamber 130A (decompression chamber main body 131) has a substantially rectangular parallelepiped shape in which the surface facing the surface of the backup roll 110 is open in order to take in the gas on the coating film 152.
As shown in FIG. 2, the side surface of the decompression chamber main body 131 (that is, the surface parallel to the transport direction of the base material) has a tip surface 131A having an arc shape that matches the curvature of the backup roll 110 when viewed from the side. Have.
Here, the arc shape does not have to be strictly a partial shape of the circumference, and may be a shape similar to the partial shape of the circumference.

The distance D3 between the arcuate tip surface (an example of the tip surface of the side surface of the decompression chamber) 131A and the backup roll 110 is 0.5 mm or less from the viewpoint of setting the atmospheric pressure P _B on the substrate to atmospheric pressure -100 Pa or less. In order to make the atmospheric pressure P _B on the substrate smaller, the distance D3 is preferably made smaller, and 0.4 mm or less is more preferable.
Further, from the viewpoint of suppressing contact with the base material 140, contact with the coating film 152, and the like, the lower limit of the distance D3 is preferably 0.1 mm.
Here, the distance D3 refers to the shortest distance between the arcuate tip surface 131A and the backup roll 110.
The distance between the arcuate tip surface 131A and the backup roll 110 can be measured by the same method as the distance D1.

The decompression chamber main body 131 is connected to a blower (not shown) via an exhaust port 132. By operating the blower, gas is taken in from the exhaust port 132, and the inside of the decompression chamber 130A (decompression chamber main body 131) is depressurized more than the atmospheric pressure.
Then, by adjusting the degree of decompression inside the decompression chamber 130A (decompression chamber main body 131), the atmospheric pressure P _B on the substrate at the time of inhaling gas in the decompression chamber 130A is set to atmospheric pressure −100 Pa or less.
Here, on the outer periphery of the surface of the decompression chamber main body 131 facing the surface of the backup roll 110 (in addition to the arcuate tip surface 131A, the front end surface on the back surface of the decompression chamber and the front end surface on the front surface of the decompression chamber), the decompression chamber 130A A mechanism for controlling the inflow and outflow of gas to the gas may be provided. Specifically, for example, a mechanism for adjusting the pressure loss by providing a gap such as a labyrinth can be mentioned. The labyrinth may be in multiple stages, and the size of the gap may be changed for each stage.
By providing the gas inflow suppression mechanism, it becomes easy to increase the degree of decompression inside the decompression chamber 130A (decompression chamber main body 131).

The decompression chamber 130B of the second aspect shown in FIG. 3 is composed of a decompression chamber main body 133, two side plates 136, a back plate 137, and a front plate 138.
The decompression chamber main body 133 has an air supply slit 134 which is a means for supplying gas to the decompression chamber 130B, and an exhaust slit 135 which is a means for exhausting gas from the decompression chamber 130B.

The decompression chamber 130B has a space surrounded by a decompression chamber main body 133, two side plates 136, a back plate 137, and a front plate 138, and gas is supplied from the air supply slit 134 of the decompression chamber main body 133. Moreover, by exhausting the gas from the exhaust slit 135, convection of the gas is generated in the space.
The wind speed of the gas on the coating film in the decompression chamber 130B is preferably in the range of 0.5 m / s to 100 m / s, and is in the range of 1 m / s to 100 m / s due to the addition of the above gas convection. 10 m / s to 100 m / s is a more preferable range.
The wind speed of the gas on the coating film is the wind speed 1 mm above the surface of the coating film with an omnidirectional anemometer, specifically, for example, Anemomaster (Anemomaster anemometer MODEL-611 series, KANOMAX). It is a measured value.

Further, by adjusting the balance between the amount of gas supplied from the air supply slit 134 of the decompression chamber main body 133 and the amount of gas discharged from the exhaust slit 135, the space of the decompression chamber 130B is depressurized more than the atmospheric pressure. Can be done.
Then, by adjusting the degree of decompression in the space of the decompression chamber 130B, the atmospheric pressure PB on the substrate at the time of inhaling the gas in the decompression chamber _130B is set to atmospheric pressure −100 Pa or less.
The air supply slit 134 and the exhaust slit 135 each have a gap of, for example, 0.1 mm to 5 mm, and gas is supplied and exhausted through the gap.

The side plate 136 is a plate-shaped member contact-arranged on the side surface of the decompression chamber main body 133 (that is, a surface parallel to the transport direction of the base material).
As shown in FIG. 3, the side plate 136 has a tip surface (an example of the tip surface of the side surface of the decompression chamber) 136A having an arc shape that matches the curvature of the backup roll 110 when viewed from the side.
The distance D3 between the arcuate tip surface 136A and the backup roll 110 is the same as the distance D3 between the arcuate tip surface 136A and the backup roll 110 in the decompression chamber 130A, and the preferred embodiment and measurement method are also the same.

The back plate 137 is a plate-shaped member contacted and arranged on the back surface of the decompression chamber main body 133 (that is, a surface perpendicular to the transport direction of the base material and a surface on the downstream side in the transport direction of the base material).
Further, the front plate 138 is a plate-shaped member contact-arranged on the front surface of the decompression chamber main body 133 (that is, a surface perpendicular to the transport direction of the base material and an upstream side in the transport direction of the base material).
The back plate 137 and the front plate 138 have a front end surface 137A and a front end surface 138A facing the surface of the backup roll, respectively.

The distance D4 between the tip surface of the back plate 137 (an example of the tip surface of the back surface of the decompression chamber) 137A and the backup roll 110 is 0.5 mm from the viewpoint that the atmospheric pressure P _B on the substrate is atmospheric pressure -100 Pa or less. It is preferably as follows, and in order to make the atmospheric pressure P _B on the substrate smaller, it is preferable to reduce the distance D4, and more preferably 0.4 mm or less.
Further, from the viewpoint of suppressing contact with the base material 140, contact with the coating film 152, and the like, the lower limit of the distance D4 is preferably 0.1 mm.
Here, the distance D4 refers to the shortest distance between the tip surface 137A of the back plate 137 and the backup roll 110.
The distance between the tip surface 137A of the back plate 137 and the backup roll 110 can be measured by the same method as the distance D1.

The distance D5 between the tip surface of the front plate 138 (an example of the front tip surface of the decompression chamber) 138A and the backup roll 110 is 0.5 mm from the viewpoint that the atmospheric pressure P _B on the substrate is atmospheric pressure -100 Pa or less. It is preferably as follows, and in order to make the atmospheric pressure P _B on the substrate smaller, it is preferable to reduce the distance D5, and more preferably 0.4 mm or less.
Further, from the viewpoint of suppressing contact with the base material 140, contact with the coating film 152, and the like, the lower limit of the distance D5 is preferably 0.1 mm.
Here, the distance D5 refers to the shortest distance between the tip surface 138A of the front plate 138 and the backup roll 110.
The distance between the tip surface 138A of the front plate 138 and the backup roll 110 can be measured by the same method as the distance D1.

Further, it is preferable that the distance D5 is larger than the distance D3 between the arc-shaped tip surface 136A and the backup roll 110 described above, from the viewpoint of reducing the disturbance of the coating film due to the dynamic pressure of the wind at the inlet of the decompression chamber.

Here, the same gas inflow suppression mechanism as described in the first aspect may be provided on the outer periphery of the surfaces of the two side plates 136, the back plate 137, and the front plate 138 facing the surface of the backup roll 110. good.
By providing the gas inflow suppression mechanism, it becomes easy to increase the degree of decompression inside the decompression chamber 130B.

Step b is performed using the decompression chamber as described above, and as a result, a coating film in which the occurrence of wind unevenness is suppressed is formed.

In the method for producing a laminate of the present disclosure, in addition to the above-mentioned steps a and b, a drying step of drying the thickened coating film in step b and irradiation of the coating film after the drying step with active energy rays. It may have a curing step of curing the coating film.

[Drying process]
In the drying step, the solvent is reduced from the coating film formed in the layer coating step.
The drying means used in the drying step is not particularly limited, and examples thereof include a method using an oven, a warm air blower, an infrared (IR) heater, and the like.
In the drying by a warm air blower, the warm air may be blown from the surface opposite to the coating film forming surface of the base material, or a diffusion plate may be installed so that the coating film does not flow with the warm air.
The drying conditions may be determined according to the type of the formed coating film, the coating amount, the transport speed, and the like, and are preferably carried out in the range of, for example, 30 ° C. to 140 ° C. for 10 seconds to 10 minutes.

[Curing process]
In the curing step, the coating film after the drying step is irradiated with active energy rays to cure the coating film.
The means for irradiating the active energy rays used in the curing step is not particularly limited as long as it is a means for imparting energy capable of generating active species in the coating film to be irradiated.
Specific examples of the active energy ray include α-rays, γ-rays, X-rays, ultraviolet rays, infrared rays, visible rays, and electron beams. Of these, ultraviolet rays are preferably used as the active energy rays from the viewpoint of curing sensitivity and availability of equipment.

Examples of the light source of ultraviolet rays include tungsten lamps, halogen lamps, xenon lamps, xenon flash lamps, mercury lamps, mercury xenon lamps, carbon arc lamps and other lamps, and various lasers (eg, semiconductor lasers, helium neon lasers, argon ions). Examples include lasers, helium cadmium lasers, YAG (Yttrium Aluminum Garnet) lasers), light emitting diodes, cathode wire tubes, and the like.
The peak wavelength of ultraviolet rays emitted from the light source of ultraviolet rays is preferably 200 nm to 400 nm.
Further, as the amount of exposure energy of ultraviolet rays, for example, 100 mJ / cm ² to 500 mJ / cm ² is preferable.

From the above, it is possible to manufacture a laminated body in which a coating layer formed from a coating liquid is provided on a base material.

[Laminate]
The laminate obtained by the method for producing a laminate of the present disclosure has a base material and a target coating layer formed from a coating liquid.

(Base material)
The base material can be appropriately selected depending on the use of the laminate, and examples thereof include a polymer film.
For optical film applications, the light transmittance of the substrate is preferably 80% or more.
For optical film applications, when a polymer film is used as the substrate, it is preferable to use an optically isotropic polymer film.
Examples of the base material include a polyester-based base material (film or sheet such as polyethylene terephthalate and polyethylene naphthalate), a cellulose-based base material (film or sheet such as diacetyl cellulose and triacetyl cellulose (TAC)), and a polycarbonate-based base material. , Poly (meth) acrylic substrate (film or sheet such as polymethylmethacrylate), polystyrene-based substrate (film or sheet such as polystyrene, acrylonitrile-styrene copolymer), olefin-based substrate (polyethylene, polypropylene, cyclic or Polyethylene having a norbornene structure, film or sheet of ethylene-propylene copolymer, etc.), polyamide-based substrate (film or sheet of polyvinyl chloride, nylon, aromatic polyamide, etc.), polyimide-based substrate, polysulfone-based substrate, poly Ethersulfone-based base material, polyether ether ketone-based base material, polyphenylene sulfide-based base material, vinyl alcohol-based base material, polyvinylidene chloride-based base material, polyvinyl butyral-based base material, poly (meth) acrylate-based base material, polyoxy Examples thereof include a transparent base material such as a methylene-based base material and an epoxy resin-based base material, or a base material made of a blended polymer blended with the above polymer materials.

The base material may be one in which a layer is previously formed on the above-mentioned polymer film.
Examples of the layer formed in advance include an adhesive layer, a barrier layer against water, oxygen and the like, a refractive index adjusting layer and the like.

(Target coating layer)
The target coating layer formed from the coating liquid is not particularly limited, and examples thereof include a hard coat layer, a liquid crystal layer, and a refractive index adjusting layer for optical film applications.
The thickness of the layer formed from the coating liquid varies depending on the application, but by adopting the method for producing the laminate of the present disclosure, for example, it is in the range of 5 μm or less, more preferably 0.1 μm to 100 μm. can do.

(Other layers)
Further, another layer may be provided on the layer formed from the coating liquid, depending on the intended use.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the following Examples as long as the gist of the present invention is not exceeded.

(Preparation of base material)
As a base material, a long triacetyl cellulose (TAC) film (TD40UL, FUJIFILM Corporation, refractive index 1.48) having a thickness of 60 μm and a width of 1340 mm was prepared.

(Preparation of coating liquid 1 for forming a hard coat layer)
The mixture of each component described below is put into a mixing tank, stirred, and filtered through a polypropylene filter having a pore size of 0.4 μm to form a coating liquid for forming a hard coat layer (solid content content: 50% by mass, viscosity 2. 9 mPa · s) was prepared.

-Coating liquid for forming a hard coat layer 1-
-Polymerizable compound: Pentaerythritol tetraacrylate (NK ester, Shin Nakamura Chemical Industry Co., Ltd.): 48.4% by mass
-Photopolymerization initiator: Omnirad 184 (IGM Resins B.V.): 1.5% by mass
-Surfactant: Fluorosurfactant shown below: 0.1% by mass
-Organic solvent: Methyl ethyl ketone: 50% by mass

(Preparation of coating liquid 2 for forming a hard coat layer)
The mixture of each component described below is put into a mixing tank, stirred, and filtered through a polypropylene filter having a pore size of 0.4 μm to form a coating liquid for forming a hard coat layer (solid content content: 50% by mass, viscosity 3. 6 mPa · s) was prepared.

-Coating liquid for forming a hard coat layer 2-
-Polymerizable compound: Mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, Nippon Kayaku Co., Ltd.): 48.5% by mass
-Photopolymerization initiator: Omnirad 907 (IGM Resins B.V.): 1.5% by mass.
-Organic solvent: Methyl ethyl ketone: 35% by mass
-Organic solvent: Cyclohexanone: 15% by mass

(Examples 1 to 8 and Comparative Examples 1 and 2)
(Step a)
A coating liquid for forming a hard coat layer was applied onto the TAC film using a die coater.
Specifically, the base material was conveyed onto a backup roll having a surface temperature of 60 ° C. and an outer diameter of 300 mm, and a coating liquid for forming a hard coat layer was applied to the base material on the backup roll using a die coater. .. At this time, the lap angle of the base material was 150 °.
At this time, the atmospheric pressure _PA on the substrate was as shown in Table 1. Further, the distance D1 and the distance between the point c and the point d are also as shown in Table 1.
Further, in step a, the temperature at the time of discharging the coating liquid was 23 ° C., the coating width was 1300 mm, and the coating speed (that is, the transport speed of the base material) was 10 m / min.

(Step b)
Subsequently, the gas on the coating film was taken in by using the decompression chamber shown in FIG. 2 or FIG. The separation distance D2 between the die coater 120 and the decompression chamber 130A or the decompression chamber 130B was 20 mm.
Further, in Comparative Example 1, although the decompression chamber shown in FIG. 2 was provided, gas was not taken in from the exhaust port 132, and the inside of the decompression chamber 130A (decompression chamber main body 131) was not depressurized.
At this time, the atmospheric pressure P _B on the substrate was as shown in Table 1.
Further, the distance D3, the distance D4, the distance D5, the distance between the points d and the point e, the solid content concentration of the coating film at the point e, and the wind speed of the gas on the coating film were as shown in Table 1.

(Drying process and curing process)
Subsequently, after the coating film was dried at 60 ° C. for 1 minute, the coating film was cured by irradiating it with ultraviolet rays at an exposure energy of 200 mJ / cm ² .
As a result, a hard coat layer having a thickness of 5 μm was formed.
The TAC film on which the hard coat layer was formed was wound into a roll.

As described above, the laminated body of each example was manufactured.
The physical characteristics (atmospheric pressure, distance, and wind speed) in the steps a and b are values measured by the above-mentioned method.

(Evaluation: Evaluation of wind unevenness)
The surface of the hard coat layer between 1 m and 10 m from the end (the end on the winding end side) of the laminate produced above was visually observed to evaluate wind unevenness.
The evaluation indexes are as follows.

-Evaluation index of wind unevenness-
1: No wind unevenness is seen.
2: One or two weak streaky wind unevenness was observed.
3: Strong streak-like wind unevenness was observed.
4: Wind unevenness in the form of streaks and spots was observed on the entire surface.

As shown in Table 1, it can be seen that, according to the manufacturing methods of Examples, a laminated body having a coating layer in which the occurrence of wind unevenness is suppressed can be obtained.
In particular, it can be seen that wind unevenness can be further suppressed by increasing the wind speed of the gas on the coating film by supplying and exhausting air as in the decompression chamber shown in FIG.

[Explanation of code]
110 Backup roll 120 Die coater 122 Die block body 124 Manifold 126 Slit 130, 130A, 130B Decompression chamber 131 Decompression chamber body 131A Arc-shaped tip surface 132 Exhaust port 133 Decompression chamber body 136 Side plate 136A Side plate tip surface 137 Back plate 138 Front plate 140 Substrate 150 Coating liquid 152 Coating a. Position to measure atmospheric pressure _PA on the substrate _b Position to measure atmospheric pressure PB on the substrate c Contact point between the substrate and coating liquid d Gas on the coating The point where the intake of gas starts e The point where the intake of gas on the coating film ends D1 The distance between the tip of the die coater and the backup roll D2 The distance between the die coater and the decompression chamber D3 The tip surface of the side surface of the decompression chamber and the backup roll Distance D4 Distance between the front end surface of the decompression chamber and the backup roll D5 Distance between the front end surface of the decompression chamber and the backup roll

The disclosure of Japanese application 2018-152978, filed August 15, 2018, is incorporated herein by reference in its entirety.
All documents, patent applications, and technical standards described herein are to the same extent as if the individual documents, patent applications, and technical standards were specifically and individually stated to be incorporated by reference. Incorporated by reference herein.

Claims (12)

A backup roll around which a continuously transported base material is wound, and
A die coater that forms a coating film by applying a coating liquid containing an organic solvent on a base material wound on a backup roll.
A decompression chamber that is installed adjacent to the die coater and reduces the amount of organic solvent from the coating film on the backup roll by sucking in the gas on the coating film.
At least prepare
Further having a means of supplying gas to the decompression chamber,
When the atmospheric pressure on the substrate at the time of contact between the substrate on the backup roll and the coating liquid applied by the die coater is PA, and the atmospheric pressure on the substrate at the time of _{inhaling gas in the decompression chamber is P B ,} P. _A laminated body manufacturing apparatus in which A and P _B satisfy the following conditions 1 and 2.
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa The apparatus for manufacturing a laminated body according to claim 1 , wherein the distance between the tip surface of the side surface of the decompression chamber and the backup roll is 0.5 mm or less. The laminated body manufacturing apparatus according to claim 2 , wherein the distance between the front end surface of the decompression chamber and the backup roll is larger than the distance between the front end surface of the decompression chamber and the backup roll. The laminated body manufacturing apparatus according to any one of claims 1 to 3 , wherein the decompression chamber includes a main body portion having an air supply slit and an exhaust slit, and a side plate. A backup roll around which a continuously transported base material is wound, and
A die coater that forms a coating film by applying a coating liquid containing an organic solvent on a base material wound on a backup roll.
A decompression chamber that is installed adjacent to the die coater and reduces the amount of organic solvent from the coating film on the backup roll by sucking in the gas on the coating film.
At least prepare
The distance between the tip surface of the side surface of the decompression chamber and the backup roll is 0.5 mm or less.
The distance between the front end surface of the decompression chamber and the backup roll is larger than the distance between the front end surface of the decompression chamber and the backup roll.
The atmospheric pressure on the substrate at the time of contact between the substrate on the backup roll and the coating liquid applied by the die coater is P. _A The atmospheric pressure on the substrate at the time of inhaling gas in the decompression chamber is P. _B If, P _A And P _B Is a laminated body manufacturing apparatus that satisfies the following conditions 1 and 2.
Condition 1: P _A > P _B
Condition 2: P _B ≤Atmospheric pressure-100Pa The laminated body manufacturing apparatus according to claim 5, wherein the decompression chamber includes a main body portion and a side plate having an air supply slit and an exhaust slit. A backup roll around which a continuously transported base material is wound, and
A die coater that forms a coating film by applying a coating liquid containing an organic solvent on a base material wound on a backup roll.
A decompression chamber that is installed adjacent to the die coater and reduces the amount of organic solvent from the coating film on the backup roll by sucking in the gas on the coating film.
At least prepare
The decompression chamber is configured to include a main body and side plates having an air supply slit and an exhaust slit.
The atmospheric pressure on the substrate at the time of contact between the substrate on the backup roll and the coating liquid applied by the die coater is P. _A The atmospheric pressure on the substrate at the time of inhaling gas in the decompression chamber is P. _B If, P _A And P _B Is a laminated body manufacturing apparatus that satisfies the following conditions 1 and 2.
Condition 1: P _A > P _B
Condition 2: P _B ≤Atmospheric pressure-100Pa The apparatus for manufacturing a laminated body according to claim 7, wherein the distance between the tip surface of the side surface of the decompression chamber and the backup roll is 0.5 mm or less. The apparatus for producing a laminate according to any one of claims 1 to 8, wherein the wind speed of the gas on the coating film in the decompression chamber is 1 m / s to 100 m / s. 2 . The apparatus for manufacturing a laminated body according to any one of claims 9 . The apparatus for manufacturing a laminated body according to any one of claims 1 to 10 , wherein the surface temperature of the backup roll is 40 ° C to 120 ° C. Step a of winding the continuously transported base material on a backup roll, applying a coating liquid containing an organic solvent to the base material on the backup roll, and forming a coating film.
Step b to reduce the organic solvent from the coating film on the backup roll by inhaling the gas on the coating film,
Have at least
When the atmospheric pressure on the substrate at the time of contact between the substrate and the coating liquid in step a is PA and the atmospheric pressure on the substrate at the time of inhaling gas in step _{b is P B, PA and P B are as follows} . Satisfy conditions 1 and 2 of
A method for manufacturing a laminated body , which is carried out by the laminated body manufacturing apparatus according to any one of claims 1 to 11 .
Condition 1: _PA > P _B
Condition 2: P _B ≤ atmospheric pressure-100 Pa

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