KR102471993B1 - Film coating method - Google Patents

Abstract

In the film coating method according to embodiments of the present invention, the lead film and the base film connected by the joint are supplied through a roller. The coating gap of the slot die from the surface of the lead film or base film is placed higher than the height of the step by the joint. A coating layer is formed by continuously coating the composition from the lead film to the base film through a slot die.

Description

Film coating method {FILM COATING METHOD}

The present invention relates to a film coating method. More specifically, it relates to a film coating method using a roll method.

For example, in an image display device such as a liquid crystal display (LCD) device or an organic light emitting display (OLED) device, various functional members such as a touch sensor and a polarizing film may be inserted. .

As the image display device becomes thinner, the functional member is also manufactured in a thinner film type. For example, functional layers such as an adhesive layer and a protective layer may be formed on a base film through a roll-to-roll film coating process.

In order to improve process yield, it is necessary to continuously perform a coating process by connecting a plurality of the base films to each other. Accordingly, a joint portion for connecting the base films may be formed, and in this case, a step difference (a difference in height) may be generated by the joint portion.

A loss area in which the coating process is stopped may be generated due to the step difference, and thus process cost and efficiency may be reduced, and it may be difficult to implement a continuous coating process.

For example, Korean Patent Registration No. 10-1803468 discloses a roll-lamination device for pressure-sensitive adhesive coating. However, it is not aware of the interruption of the coating process due to the above-described film level difference.

Korean Patent Registration No. 10-1803468

One object of the present invention is to provide a film coating method with improved reliability and efficiency.

One object of the present invention is to provide an optical film manufacturing apparatus having improved reliability and efficiency.

1. Feeding the base film connected to the lead film by a joint through a roller; arranging a coating gap of the slot die from the surface of the lead film or the base film to be higher than a step height caused by the joint; and forming a coating layer by continuously coating a composition from the lead film to the base film through the slot die.

2. The method of 1 above, wherein the lead film includes a first lead film connected to the base film at the front end of the coating progress direction and a second lead film connected to the base film at the distal end of the coating progress direction. .

3. The method of 2 above, wherein the joint comprises a first joint connecting the first lead film and the base film of the front end portion, and a third joint connecting the second lead film and the base film of the distal portion. , film coating method.

4. In the above 1, the step of forming the coating layer,

continuously coating the composition over the first lead film, the first joint, and the base film of the front end; and continuously coating the composition over the base film of the end portion, the third joint portion, and the second lead film.

5. The film coating method according to 1 above, wherein a plurality of the base films are connected and provided through the second joint.

6. The film coating method according to 5 above, wherein the forming of the coating layer comprises continuously coating the composition over the base films and the second joint.

7. The film coating method according to 1 above, comprising exposing the coating layer to light using a filter that blocks light having a wavelength of 300 nm or less.

8. The film coating method according to 1 above, further comprising preventing the base film from being separated by using a blocking roller spaced apart at a predetermined height in a vertical direction from the base film or the coating layer.

9. Forming a coating layer on the base film; and exposing the coating layer to light using a filter that blocks light having a wavelength of 300 nm or less.

10. The film coating method according to 9 above, wherein the coating layer includes a liquid crystal composition.

11. A feeding roller feeding the film; a conveying roller positioned on a lower surface of the film and moving the film; and a blocking roller disposed vertically and spaced apart from an upper surface of the film at a predetermined height.

12. The optical film manufacturing apparatus according to 11 above, wherein the surface of the blocking roller includes nylon or stainless steel.

13. The optical film manufacturing apparatus according to 11 above, further comprising a motor for rotating the blocking roller.

14. The optical film manufacturing apparatus according to 11 above, wherein the blocking roller faces the transfer roller in a direction perpendicular to the upper surface of the film.

15. In the above 11, the conveying roller support coupled to the conveying roller; a blocking roller support coupled to the blocking roller; and a coupling portion connecting the transfer roller support portion and the blocking roller support portion.

16. The method of 15 above, coupled to the blocking roller, and inserted into the hole formed in the blocking roller support to be movable in the width direction of the film, further comprising a shaft connecting the blocking roller and the blocking roller support, Optical film manufacturing equipment.

17. The optical film manufacturing apparatus of 15 above, wherein the blocking roller support part includes a vertical long hole, and the coupling part is movably inserted into the vertical long hole to connect the blocking roller support part and the transfer roller support part.

18. The optical film manufacturing apparatus according to 17 above, wherein the height of the blocking roller is adjusted by movement of the coupling part in the vertical long hole.

19. The optical film manufacturing apparatus according to 11 above, further comprising a slot die for coating an optical layer on a surface of the film.

20. The optical film manufacturing apparatus according to 19 above, wherein the optical layer includes at least one selected from the group consisting of an adhesive layer, a protective film layer, a hard coating layer, and a liquid crystal layer.

According to embodiments of the present invention, a coating gap of a slot die may be increased than a step height of the joint portion by forming a joint portion connecting a plurality of base films with a thin tape. Therefore, it is possible to continuously perform the coating process on a plurality of base films without having to stop the coating process by the step difference.

In addition, in the coating process using the slot die, the coating process may be performed on the entire area of the base film starting from the lead film connected to the base film at the front end without loss of area. Thus, the cost effectiveness of the coating process can be improved.

An optical film manufacturing apparatus according to embodiments of the present invention may prevent curl from occurring on the film even if the film is deformed by heat by locating a blocking roller on the upper surface of the film to prevent curl of the film. can

1 and 2 are schematic diagrams for explaining a film coating method according to exemplary embodiments.
3 to 5 are schematic cross-sectional views for explaining a coating layer formed according to exemplary embodiments.
6 is a schematic diagram illustrating an exposure process of a coating layer formed according to exemplary embodiments.
7 is a schematic diagram illustrating a method for evaluating whether degradation occurs according to a wavelength of light exposed on a coating layer.
8 and 9 are photographs showing results obtained by evaluating a liquid crystal polarizing layer formed according to exemplary embodiments according to the method of FIG. 7 .
10 is a graph comparing optical performance of a liquid crystal polarizer formed using a filter and a liquid crystal polarizer formed without a filter according to exemplary embodiments.
11 and 12 are schematic cross-sectional and plan views for explaining a film coating method according to a comparative example, respectively.
13 is an image for explaining actual process execution in a film coating equipment of a comparative example.
14 and 15 are schematic diagrams illustrating an optical film manufacturing apparatus according to exemplary embodiments.
16 is an image showing the appearance of an optical film manufacturing apparatus according to an exemplary embodiment.
17 is a schematic diagram illustrating a method of adjusting a height between a film and a blocking roller according to exemplary embodiments.

According to embodiments of the present invention, a film coating method using a slot die for forming an adhesive layer, a protective film, etc. on base films connected by joints is provided.

Referring to the following drawings, the embodiment of the present invention will be described in more detail. However, the following drawings attached to this specification illustrate preferred embodiments of the present invention, and serve to further understand the technical idea of the present invention together with the contents of the above-described invention, so the present invention is described in such drawings should not be construed as limited to

1 and 2 are schematic diagrams for explaining a film coating method according to exemplary embodiments.

Referring to FIG. 1 , a coating process for forming a coating layer may be performed on the surface of the base film 100 through a slot die 180 while the base film 100 moves using a roller.

For example, the base film 100 may be supplied along a direction indicated by an arrow toward the slot die 180 while being wound around the supply roller 50 .

In one embodiment, a tensile force is applied to the base film 100 through the transfer roller 60, and the base film 100 may be moved from the supply roller 50.

The slot die 180 may be disposed between the supply roller 50 and the transfer roller 60 to perform the coating process. A liquid composition for forming a coating layer is stored inside the slot die 180, and the composition is sprayed toward the surface of the base film 100 through a discharge port of the slot die 180 to form the coating layer. For example, the coating process may proceed in a direction opposite to the direction in which the film travels as shown in FIG. 1 .

For example, the base film 100 may serve as a base layer for forming an optical film such as a sensor film such as a touch sensor, a polarizing plate, or a retardation film. For example, the base film 100 may include cyclic olefin polymer (COP), polyethylene terephthalate (PET), polyacrylate (PAR), polyetherimide (PEI), polyethylene naphthalate (PEN), polyphenylene sulfide ( PPS), polyallylate, polyimide (PI), cellulose acetate propionate (CAP), polyethersulfone (PES), cellulose triacetate (TAC), polycarbonate (PC), cyclic olefin copolymer ( COC), polymethyl methacrylate (PMMA), and the like.

The composition discharged from the slot die 180 is, for example, an adhesive composition such as pressure sensitive adhesive (PSA) or optically clearance adhesive (OCA), or a resin for forming a protective film. It may include a composition, a hard coat composition, a liquid crystal composition for forming a liquid crystal retardation or a liquid crystal optical layer, and the like.

According to example embodiments, in order to implement a continuous film coating process, the coating process may be performed by connecting the plurality of base films 100 through the joint 130 .

Referring to FIG. 2 , a first lead film 110 is a first joint at the front end of one of the plurality of base films 100 (eg, the first base film in which the coating process starts). It can be connected via unit 132 . The first lead film 110 may be included as a dummy film inserted by applying an initial tensile force for movement of the base film 100 and considering a process tolerance.

For example, the first lead film 110 is a film that is cut and discarded after completion of the coating process, and a relatively inexpensive film such as PET may be used.

As will be described later, the joint portion 130 including the first joint portion 132 may be formed using a thin tape to form a thin thickness in consideration of the coating gap of the slot die 180 .

A step is created between the surface of the base film 100 (or the top surface of the first lead film 110) and the top surface of the first joint 132 by the first joint 132, and accordingly, the height of the step ( H2) can be caused.

According to example embodiments, the slot die 180 may be disposed to have a coating gap H1 greater than the step height H1. The coating gap H1 may be a vertical height between the upper surface of the base film 100 or the first lead film 110 and the discharge port (eg, slot die lip) of the slot die 180 .

According to example embodiments, the coating of the composition through the slot die 180 may start from the first lead film 110 and proceed to the base film 100 along the coating direction indicated by an arrow in FIG. 2 . . For example, the coating may start from the midpoint of the upper surface of the lead film 110 and continuously proceed toward the base film 100 .

As described above, since the coating gap 180 of the slot die 180 is larger than the step height H2 by the first joint 132, continuous coating without interruption of coating due to the step of the joint 132 this can proceed.

For example, the step height H2 may be about 5 to 40 μm, and the height of the coating gap H1 may be about 50 to 150 μm in consideration of composition spraying efficiency.

3 to 5 are schematic cross-sectional views for explaining a coating layer formed according to exemplary embodiments.

Referring to FIG. 3 , as described with reference to FIGS. 1 and 2 , coating of the composition is initiated from the first lead film 110 through the slot die 180 to form the first joint 132 and the base film 100 ) can be continuously coated over.

Accordingly, for example, the coating layer 140 continuously extending from the middle point of the first lead film 110 to the base film 100 beyond the first joint 132 may be formed.

Referring to FIG. 4 , a plurality of base films 100 may be connected through the second joint 134 and supplied through the above-described roller. As described above, since the coating gap H1 of the slot coating die 180 can be maintained higher than the height of the step by the second joint 134, the coating is continuously performed without stopping the coating by the second joint 134. An extended coating layer 140 may be formed.

In one embodiment, the coating process may be stopped for attachment of the base films 100 through the second joint 134 . Even in this case, since the coating gap H1 is maintained higher than the step height, the start position of the subsequent coating process can be freely adjusted. Accordingly, the size of a loss region (eg, a region where the coating layer 140 is not formed on the surface of the base film 100) due to the interruption of the coating process can be significantly reduced.

Referring to FIG. 5 , the base film 100 disposed at the distal end in the coating direction may be connected to the second lead film 115 through the third joint 136 .

According to example embodiments, the coating process through the slot die 180 may be performed to the upper surface of the second lead film 115 over the base film 100 and the third joint 136 at the distal end. .

Accordingly, the coating layer 140 may be formed using substantially the entire area of the surface of the base film 100 at the distal end.

1 to 5 show a single-sided coating process of forming a coating layer on one surface of the base film 100 for convenience of description, but the above-described double-sided coating process in which the coating layer is applied to the upper and lower surfaces of the base film 100 A film coating method according to examples may be applied.

6 is a schematic diagram illustrating an exposure process of the coating layer 140 formed according to an exemplary embodiment.

In some embodiments, the film coating process may further include a process of exposing the coating layer 140 to light using a filter 300 that blocks light having a wavelength of 300 nm or less.

For example, a liquid crystal optical layer may be formed by curing the coating layer 140 through the exposure process. For example, the liquid crystal optical layer may be a liquid crystal polarizing layer.

As shown in FIG. 6 , the filter 300 is installed between the light source 400 and the coating layer 140 to block light having a wavelength of 300 nm or less among light emitted from the light source 400 .

Accordingly, it is possible to prevent high-energy light from reaching the coating layer 140, thereby preventing deterioration in optical performance of the liquid crystal optical layer formed by curing the coating layer 140.

For example, when the liquid crystal optical layer is formed by the exposure process, the light source 400 may be a high-pressure mercury lamp or a Xenon lamp.

For example, when the liquid crystal optical layer is formed by the exposure process, the base film 100 on which the coating layer 140 is formed may be a transparent base film having a transmittance of 80% or more for a wavelength of 380 nm to 780 nm.

For example, the transparent base film may be a cellulose ester such as triacetyl cellulose, diacetyl cellulose, or cellulose acetate propionate, but is not limited thereto.

For example, when a liquid crystal optical layer is formed by the exposure process, the coating layer 140 may include a liquid crystal composition.

The liquid crystal composition may include, for example, a polymerizable liquid crystal compound, a dichroic dye, a photopolymerization initiator, and a solvent.

The polymerizable liquid crystal compound refers to a compound that has a liquid crystal phase by including a mesogen capable of expressing liquid crystal and a terminal group capable of polymerization. For example, the polymerizable liquid crystal compound may form a polarizing layer by being polymerized into a body that maintains a liquid crystal phase aligned in a certain direction.

The polymerizable liquid crystal compound may be, for example, a polymerizable liquid crystal compound exhibiting a smectic phase. The smectic phase includes a smectic A phase, a smectic B phase, a smectic D phase, a smectic E phase, a smectic F phase, a smectic G phase, a smectic H phase, a smectic I phase, a smectic J phase, or a smectic phase. It may be a methic K phase.

The polymerizable liquid crystal compound may be used without limitation as long as it is a compound including a mesogen capable of expressing liquid crystal and a terminal group capable of polymerization, and the polymerizable liquid crystal compound may be a mixture of two or more polymerizable liquid crystal compounds. may be

The dichroic dye has polarization characteristics, and refers to a dye having a property in which absorbance in the direction of the major axis of the molecule is different from absorbance in the direction of the minor axis of the molecule.

For example, any known dichroic dye having a maximum absorption wavelength at 300 to 700 nm may be used without limitation.

The photopolymerization initiator is a compound that initiates a polymerization reaction of a polymerizable liquid crystal compound, and refers to a compound that generates active radicals or acids by light.

For example, the photopolymerization initiator may be an acetophenone-based compound, a benzoin-based compound, a benzophenone-based compound, a triazine-based compound, an anthraquinone-based compound, a thioxanthone-based compound, or an anthracene-based compound.

The solvent is for dissolving each component of the above-described liquid crystal composition, and any solvent that is inert to the polymerization reaction of the polymerizable liquid crystal compound may be used without limitation.

For example, the solvent may be an alcohol-based solvent, an ester-based solvent, a ketone-based solvent, an aliphatic hydrocarbon-based solvent, an aromatic hydrocarbon-based solvent, a nitrile-based solvent, an ether-based solvent, or a chlorine-containing solvent.

When the coating layer 140 includes the liquid crystal composition described above, a liquid crystal polarizing layer may be formed through the exposure process.

In addition, in the exposure process, the coating layer 140 is cured using the filter 300 that blocks light having a wavelength of 300 nm or less, thereby forming a liquid crystal polarizing layer that is prevented from being deteriorated by high energy light.

7 is a schematic diagram illustrating a method for evaluating whether degradation occurs according to a wavelength of light exposed on a coating layer. 8 and 9 are photographs showing results obtained by evaluating a liquid crystal polarizing layer formed according to exemplary embodiments according to the method of FIG. 7 .

Referring to FIG. 7 , the coating layer 140 may be formed on the base film 100 according to the above-described coating method. The light emitted from the light source 400 may be dispersed by the dispersion grating 500 and irradiated onto the coating layer 140 . A wavelength range of light irradiated onto the coating layer 140 may be about 220 nm to about 520 nm.

FIG. 8 is a photograph showing whether the coating layer 140 including Magenta (D128) as a dichroic dye is degraded according to the wavelength according to the evaluation method of FIG. 7 . Referring to the portion indicated by the circle, when the coating layer 140 is cured by light having a wavelength of 300 nm or less, the formed liquid crystal polarizing layer may be deteriorated.

FIG. 9 is a photograph showing whether or not degradation occurs according to the wavelength of the coating layer 140 including Orange (OK287) as a dichroic dye according to the evaluation method of FIG. 7 . Referring to the portion indicated by the circle, when the coating layer 140 is cured by light having a wavelength of 300 nm or less, the formed liquid crystal polarizing layer may be deteriorated.

10 is a graph comparing transmittances (Py, Ty) of a liquid crystal polarizer formed using the filter and a liquid crystal polarizer formed without using the filter according to exemplary embodiments.

Referring to FIG. 10 , a liquid crystal polarizer formed using the filter (indicated by a square shape) may have higher transmittance than a liquid crystal polarizer formed without using a filter (indicated by a diamond shape).

According to exemplary embodiments, vertical deviation of the base film may be prevented by using a blocking roller arranged to be spaced apart from the base film or the coating layer in a vertical direction at a predetermined height.

Accordingly, the blocking roller may prevent the film from being deformed by heat and separating the film from the transfer line in the vertical direction. In addition, by preventing the vertical direction deviation of the film, it is possible to prevent curl (Curl) from being formed on the film.

In addition, since the blocking roller does not directly contact the upper surface of the film, it is possible to effectively prevent horizontal direction deviation (eg, meandering) due to the pressure by the roller not being equally transmitted to the upper surface of the film.

For example, the height H of which the top surface of the film is separated from the blocking roller is not particularly limited, and may be adjusted according to the type of the film and the degree of curl. For example, the height may be 0.1 cm to 2 cm, but is not limited thereto.

11 and 12 are schematic cross-sectional and plan views for explaining a film coating method according to a comparative example, respectively. Similar reference numerals are used for components corresponding to those described with reference to FIGS. 1 to 5 .

Referring to FIG. 11 , the first lead film 210 and the base film 200 are connected through the first joint 232, and the coating gap H3 of the slot die 280 is the first joint 232 ) may be disposed lower than the step height (H4) by.

In the case of Comparative Example, since the coating process is stopped by the step height H4, the coating process starts from the middle region of the base film 200.

Referring to FIG. 12 , a second joint 234 connecting the base films is formed, and a third joint 236 connecting the base film 200 and the second lead film 215 at the end portion is formed. can

In the case of the comparative example, whenever the slot die 280 approaches the joint portions 232, 234, and 236, the coating process is stopped by the step height H4, so that the formation of the coating layer 240 is stopped. , L2, L3) occur (for example, loss occurs in the gap area reaching / advancing section) In addition, whenever the coating process is stopped, the flow rate stabilization time of the composition stored in the slot die 280 is required, so , the widths of the loss regions L1, L2, and L3 may be further increased.

As shown in FIG. 12 , a first loss region L1 is generated in the base film 200 at the front end contacting the first joint 232, and the second loss region L1 is formed across both sides of the second joint 234. A loss region L2 region may occur. In addition, a third loss region L3 may occur in the base film 200 at an end portion contacting the third joint 236 .

13 is an image for explaining actual process execution in a film coating equipment of a comparative example. Referring to FIG. 13 , the loss area described with reference to FIGS. 11 and 12 may appear as indicated by an arrow.

However, according to the exemplary embodiments described above, the coating gap of the slot die 180 may be disposed higher than the step height by forming the joint 130 with a thin film tape. Accordingly, since the coating process may be continuously performed from the first lead film 110 to the second lead film 115, the loss area in the comparative example may be substantially removed or significantly reduced.

Therefore, it is possible to increase the usable area of the base film 100 and significantly improve process continuity and efficiency.

14 and 15 are schematic diagrams illustrating an optical film manufacturing apparatus according to exemplary embodiments. 16 is an image showing a state of an optical film manufacturing apparatus according to an exemplary embodiment.

An optical film manufacturing apparatus according to exemplary embodiments of the present invention includes a supply roller 50 for supplying a film 10 and a transfer roller 60 located on a lower surface of the film 10 and moving the film 10 And it may include a blocking roller 70 disposed spaced apart from the upper surface of the film 10 at a predetermined height in a vertical direction.

Accordingly, the apparatus for manufacturing the optical film can prevent the film 10 from being separated in the vertical direction even if the film 10 is deformed by the process of drying the film 10 at a high temperature. It is possible to effectively prevent curls from being formed.

In addition, since the blocking roller 70 is spaced apart from the film 10, the upper surface of the film 10 and the blocking roller 70 may not directly contact each other, unlike conventional pinch rolls. Accordingly, since pressure is not applied evenly on the film 10 , meandering in which the film 10 is separated in the horizontal direction can be effectively prevented.

The surface of the blocking roller 70 according to example embodiments may include nylon or stainless-steel.

For example, the nylon may be MC nylon, nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12 or nylon 46.

For example, the stainless-steel may be austenitic (SUS 304), ferritic (SUS 430), martensitic (SUS410), biphasic (SUS329) or precipitation hardening (SUS630).

Accordingly, durability and chemical resistance of the blocking roller 70 may be excellent, foreign matter may be prevented from being generated on the film 10, and thus optical film manufacturing efficiency and reliability may be further improved.

In example embodiments, the optical film manufacturing apparatus may further include a motor unit rotating the blocking roller 70 .

The motor unit may, for example, rotate the blocking roller 70 in a direction opposite to that of the conveying roller 60 . Accordingly, deviation of the film 10 in the vertical direction can be more effectively prevented, thereby more effectively preventing curl from occurring on the film 10 deformed by heat.

As shown in FIGS. 14 and 15 , the blocking roller 70 according to exemplary embodiments may face the conveying roller 60 in a direction perpendicular to the upper surface of the film 10 .

Accordingly, it is possible to effectively prevent curl from occurring on the film 10 by preventing the film 10 from being separated in the vertical direction while the transfer roller 60 transfers the film 10. have.

As shown in FIG. 15 , an optical film manufacturing apparatus according to exemplary embodiments includes a conveying roller support 84 coupled with a conveying roller 60, a blocking roller support 82 coupled with a blocking roller 70, and A coupling part 86 connecting the transfer roller support 84 and the blocking roller support 82 may be further included.

As shown in FIG. 15 , the optical film manufacturing apparatus according to example embodiments may further include a shaft 80 connecting the blocking roller 70 and the blocking roller support 82 to each other.

In some embodiments, as shown in FIG. 15 , the shaft 80 may be inserted into the blocking roller 70 to couple the shaft 80 and the blocking roller 70 . For example, the blocking roller 70 may be fixed to the shaft 80 by additionally coupling a bolt 85 to the end of the shaft 80 . For example, the shaft 80 to which the blocking roller 70 is coupled may be inserted into a shaft coupling hole of the blocking roller support 82 to connect the blocking roller 70 and the blocking roller support 82 .

For example, by adjusting the overall length of the shaft 80, the position where the blocking roller 70 is disposed in the width direction of the film 10 can be properly adjusted.

For example, the shaft 80 may be installed to be movable in the width direction of the film 10 by being inserted into the shaft coupling hole of the blocking roller support 82 .

Accordingly, by moving the shaft 80 in the width direction of the film 10, it is possible to adjust the position where the blocking roller 70 is disposed in the width direction of the film 10. Therefore, irrespective of the type and width of the film 10, the optical film manufacturing apparatus can effectively prevent curl from occurring.

For example, the height H between the film 10 and the blocking roller 70 can be adjusted by adjusting the positional relationship between the blocking roller support 82, the transfer roller support 84, and the coupling portion 86. have.

17 is a schematic diagram illustrating a method of adjusting a height between a film and a blocking roller according to exemplary embodiments.

As shown in FIG. 17 , the blocking roller support 82 according to exemplary embodiments may include a vertical long hole 88 formed long in a direction parallel to the height H direction. In addition, the coupling part 86 may be movably inserted into the vertical long hole 88 to connect the blocking roller support 82 and the transfer roller support 84.

Referring to FIG. 17 , the coupling part 86 may be moved in the height direction H in the vertical long hole 88 . Accordingly, the height H between the film 10 and the blocking roller 70 may be adjusted.

For example, when the coupling part 86 moves to the lower part of the vertical long hole 88, the length in the height direction formed by the blocking roller support part 82 and the transfer roller support part 84 increases, and the film 10 and the height H between the blocking roller 70 may be increased.

For example, when the coupling part 86 moves to the upper end of the vertical long hole 88, the length in the height direction formed by the blocking roller support part 82 and the transfer roller support part 84 is reduced, so that the film 10 and The height H between the blocking rollers 70 may be reduced.

The optical film manufacturing apparatus according to example embodiments may separate the blocking roller 70 from the blocking roller support 82 .

For example, as shown in FIG. 15, by separating the shaft 80 coupled to the shaft coupling hole of the blocking roller support 82 from the blocking roller support 82, the blocking roller 70 is moved to the blocking roller support ( 82) can be separated. For example, the blocking roller 70 may be separated from the shaft 80 to separate the blocking roller 70 from the blocking roller support 82 .

For example, when the blocking roller 70 is fixed to the shaft 80 by the bolt 85, after removing the bolt 85 from the shaft 80, the blocking roller 70 is separated from the shaft 80. By doing so, the blocking roller 70 can be separated from the blocking roller support 82 . For example, the separated blocking roller 70 may be combined with the blocking roller support 82 again.

For example, after being removed from one position of the optical film manufacturing apparatus, the blocking roller 70 may be disposed again at another position capable of effectively preventing the occurrence of curls. Accordingly, it is possible to more effectively prevent curl from occurring on the film 10 .

As described above, the apparatus for manufacturing an optical film according to exemplary embodiments includes the blocking roller 70 spaced apart from the upper surface of the film 10 by a predetermined height, and the film 10 is displaced in the horizontal direction and the vertical direction. can be effectively prevented.

In the Comparative Example, the conventional optical film manufacturing apparatus includes a pinch roller for fixing the upper and lower surfaces of the film together, so that the film may be prevented from moving in the vertical direction. However, when the pressure applied on the film 10 is not constant, the pinch roller of the comparative example may be displaced in the horizontal direction, and thus the film 10 may meander.

Referring to FIG. 14 , according to example embodiments, the optical film manufacturing apparatus may further include a slot die 180 coating an optical layer on a surface of the film 10 .

For example, as described above, the slot die 180 includes the coating layer forming composition therein, and the coating gap H1 of the slot coating die 180 is maintained higher than the height of the step by the joint, so that the coating is stopped. A continuously extending coating layer may be formed.

For example, the optical layer is not particularly limited, and may include at least one selected from the group consisting of an adhesive layer, a protective film layer, a hard coating layer, and a liquid crystal layer.

The apparatus for manufacturing an optical film according to exemplary embodiments of the present disclosure may include a blocking roller 70 to prevent curl or meander that may occur during transport of a film. In addition, the slot die 180 may be further included to form a continuously extending coating layer without stopping the coating.

10: film 50: supply roller
60: conveying roller 70: blocking roller
80: shaft 82: blocking roller branch
84: conveying roller support part 86: coupling part
88: vertical long hole 100, 200: base film
110, 210: first lead film 115, 215: second lead film
130: joint 132: 232: first joint
134: 234: second joint 136, 236: third joint
180, 280: slot die 140, 240: coating layer
300: filter 400: light source
500: distributed grating L1, L2, L3: loss area
H: height L: horizontal distance

Claims (20)

supplying a base film connected to a lead film and a joint through a roller;
arranging a coating gap of the slot die from the surface of the lead film or the base film to be higher than a step height caused by the joint;
forming a coating layer by continuously coating a composition from the lead film to the base film through the slot die; and
and preventing the base film from escaping by using the base film or the coating layer and a blocking roller spaced apart at a predetermined height in a vertical direction from the roller.
The film coating method according to claim 1, wherein the lead film includes a first lead film connected to a base film at a front end of the coating progress direction and a second lead film connected to a base film at a distal end of the coating progress direction.
The film of claim 2 , wherein the joint portion comprises a first joint portion connecting the first lead film and the base film of the front end portion, and a third joint portion connecting the second lead film and the base film of the distal portion portion. coating method.
The method according to claim 3, wherein the forming of the coating layer,
continuously coating the composition over the first lead film, the first joint, and the base film of the front end; and
and continuously coating the composition over the base film of the end portion, the third joint portion, and the second lead film.
The film coating method according to claim 1, wherein a plurality of the base films are connected and provided through a second joint.
The film coating method of claim 5, wherein the forming of the coating layer comprises continuously coating the composition over the base films and the second joint.
The film coating method according to claim 1, comprising exposing the coating layer to light using a filter that blocks light having a wavelength of 300 nm or less.
delete delete The method according to claim 7, wherein the coating layer comprises a liquid crystal composition, the film coating method.
a supply roller for supplying the film;
a conveying roller positioned on a lower surface of the film and moving the film; and
And a blocking roller spaced apart from the upper surface of the film and the supply roller in a vertical direction at a predetermined height to prevent separation of the film, the optical film manufacturing apparatus.
12. The optical film manufacturing apparatus according to claim 11, wherein the surface of the blocking roller includes nylon or stainless-steel.
The method according to claim 11, Further comprising a motor for rotating the blocking roller, the optical film manufacturing apparatus.
12 . The optical film manufacturing apparatus according to claim 11 , wherein the blocking roller faces the conveying roller in a direction perpendicular to the upper surface of the film.
The method of claim 11,
a conveying roller support coupled to the conveying roller;
a blocking roller support coupled to the blocking roller; and
Further comprising a coupling portion connecting the transfer roller support portion and the blocking roller support portion, the optical film manufacturing apparatus.
The optical film of claim 15 , further comprising a shaft coupled to the blocking roller and inserted into a hole formed in the blocking roller support to be movable in a width direction of the film to connect the blocking roller and the blocking roller support. manufacturing device.
The method according to claim 15, wherein the blocking roller support comprises a vertical long hole,
The optical film manufacturing apparatus of claim 1 , wherein the coupling portion is movably inserted into the vertical long hole and connects the blocking roller support portion and the transfer roller support portion.
18. The optical film manufacturing apparatus according to claim 17, wherein a height of the blocking roller is adjusted by movement of the engaging portion in the vertical long hole.
The method according to claim 11, Further comprising a slot die for coating the optical layer on the surface of the film, the optical film manufacturing apparatus.
The apparatus according to claim 19 , wherein the optical layer includes at least one selected from the group consisting of an adhesive layer, a protective film layer, a hard coating layer, and a liquid crystal layer.

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