KR20140118831A - Coating film controlling device and manufacturing method of laminated film using the same - Google Patents

Abstract

Provided are a coating film controlling device which obtains a film with a uniform thickness of a coating layer without wrinkles and a manufacturing method of laminated films. The coating film controlling device comprises two or more cover members which are connected to a returning direction of the film; at least one hole cover members with holes; one or more non-hole cover members without holes; and an exhaust equipment which exhausts a volatile solvent from the coating film outside via the holes of the hole cover members and has the characteristics of changing the installation position of the cover members.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a coating film control apparatus and a method of manufacturing a laminated film using the coating film control apparatus.

The present invention relates to a method for forming a coating film by coating a coating liquid containing at least a resin material and a solvent on one surface of a film continuous in the longitudinal direction to form a coating film, And a coating film control device for managing the amount and speed of the volatilizing solvent from immediately after application to a solvent volatilizing from the coating film, and a method for producing a laminated film using the same.

BACKGROUND ART Various displays such as a liquid crystal display and a plasma display have a laminated film on which a coat layer for imparting a specific function to a surface of a display is formed on one side of a film. As an apparatus for forming the coat layer on a film, a coating liquid containing a resin material and an organic solvent is applied to one surface of a long film which is conveyed in the longitudinal direction, and the coating liquid is dried and cured A laminated film production apparatus for forming a coat layer is known. The functions imparted to the film by the coat layer include, for example, a method in which a low refractive index layer is laminated on a high refractive index layer containing high refractive index fine particles and the surface reflected light reflected on the surface of the low refractive index layer, An antireflection function for reducing the reflected light by reversing the phase of the interface reflected light reflected at the interface of the refractive index layer to cancel out the reflected light; An anti-glare function that suppresses unnecessary light from being reflected from a light source (e.g., light or sunlight), or a damage prevention function that is obtained by laminating a coat layer having a hardness higher than that of a film on a film.

In the laminated film producing apparatus, a coating apparatus for coating a coating liquid on one side of a film is provided. As such a coating device, for example, a bar coating device such as Meyer bar, a gravure coating device, a die coating device or a screen printing device is used. The coating liquid immediately after being applied to the film by these coating apparatuses is liable to be boiled because the concentration of the organic solvent in the coating liquid is high. For this reason, when the coating liquid immediately after coating is dried by applying heat, so-called dolbid (bumping) may occur in the coating layer. When the dolbis occurs, there is a problem that the portion where the dolbis is formed in the coat layer is whitened.

In order to suppress this dolby, there is a laminated film production apparatus in which a preliminary drying apparatus for performing a predetermined treatment on a film formed on one side of a coated film is provided. As this preliminary drying apparatus, a drying zone in which dry air flowing from one side to the other side in the film width direction is generated is provided immediately after the application position where the film is applied to the film, There has been proposed a preliminary drying apparatus that performs preliminary drying in which the solvent concentration is lowered to some extent (see, for example, Patent Document 1). Since the preliminary drying apparatus described in Patent Document 1 is a large-scale apparatus, it is not usually carried out after the installation site is once determined. Then, after the installation location is determined, optimum manufacturing conditions of the preliminary drying apparatus are determined. The same procedure is applied to other preliminary drying apparatuses.

[Patent Document 1] Japanese Patent No. 4147370 Specification

However, in the preliminary drying apparatus described in Patent Document 1, once the installation location is determined, the manufacturing conditions are determined on the assumption that the installation location is determined.

Further, in the coating liquid applied to the film, leveling occurs in which the coating liquid tends to have a uniform thickness in the film width direction and the conveying direction with the lapse of time. In the preliminary drying apparatus described in Patent Document 1, since a drying zone for generating dry air flowing in the width direction of the film is provided immediately after the application position where the film is applied to the film, the composition of the coating material and the type of the solvent Therefore, there is a case where the coating film is waved due to the influence of the drying wind. If pre-drying is performed to lower the concentration of the organic solvent contained in the coating film in the state where the coating film is waved, the viscosity of the coating film becomes high in a state where the thickness of the coating film is uneven, making it difficult to level. For this reason, in the preliminary drying apparatus disclosed in Patent Document 1, leveling is not sufficiently performed, and there is a possibility that the thickness of the coating film becomes uneven. In addition, the coating film may cause hardening shrinkage when cured. This curing shrinkage is larger in the thick part of the coating film than in the thinner part. Therefore, if the coating film having a non-uniform thickness is cured, wrinkles may be formed on the laminated film due to the partial difference in the amount of curing shrinkage.

SUMMARY OF THE INVENTION In view of the above circumstances, it is an object of the present invention to provide a coating film control apparatus and method for producing a laminated film, which can obtain a film having a coat layer without wrinkles by freely arranging constituent members of a coating film control apparatus, And to provide the above objects.

A coating film control apparatus of the present invention for solving the above object is a coating film control apparatus for coating a coating liquid containing a resin material and a solvent on one surface of a long film conveyed in the longitudinal direction, And at least two cover members covering the coating film and the thick portions at both ends in the width direction of the film until at least the solvent volatilizing from the coating film is filled in the drying apparatus,

The two or more cover members are connected in the transport direction of the film and include at least one hole cover member provided with a hole and at least one non-hole cover member provided with no hole,

And exhausting means for exhausting the solvent volatilizing from the coating film to the outside through the hole of the hole cover member,

And the position of the cover member can be changed.

According to the film processing apparatus of the present invention, since the arrangement position of the cover member can be changed, the arrangement and the ratio of the hole cover member and the non-cover cover member can be appropriately adjusted, Can be obtained.

Further, the perforated cover member may be disposed closer to the drying apparatus, and the larger the total area of the hole may be.

In the coating film control apparatus of the present invention, the length of the hole cover member and the length of the non-covered cover member in the transport direction of the film may be substantially the same.

According to this aspect, it is not only easy to change the arrangement position of the cover member, but also makes it possible to easily manufacture the cover member and realize cost reduction.

In the coating film control apparatus of the present invention, the two or more cover members may be connected through a gap blocking member.

The clearance shielding member restricts the inflow of the gas outside the cover member into the cover member from the clearance between the cover members. Further, the clearance blocking member can be removed, and the two or more cover members after the arrangement position is changed without interfering with the change of the arrangement position of the cover member are connected again through the clearance blocking member.

In the coating film control apparatus of the present invention, the exhaust means may be provided with a rectifying member having a plurality of through holes penetrating in a direction intersecting with the one surface.

By providing the rectifying member, the gas between the film and the cover member can be sucked while suppressing the occurrence of turbulent flow, and the coating liquid is not waved, and the coating liquid applied on one side of the film is uniformly Coating can be controlled.

In addition, the exhaust means may suck the gas between the film and the cover member in a direction substantially perpendicular to one surface of the film.

Further, in the coating film control apparatus of the present invention, it is preferable that the rectifying member is a mesh.

By providing a net-like rectifying member, a high rectifying effect can be obtained with a simple structure.

A method for producing a laminated film of the present invention for solving the above object is a method for producing a laminated film comprising a coating step of applying a coating liquid containing a resin material and a solvent to one surface of a long film,

A natural drying step of passing the coating film control device according to any one of claims 1 to 5, wherein an amount and a speed of a solvent volatilized from the coating film are adjusted,

A main drying step of volatilizing the solvent contained in the coating film,

And a curing step of applying energy to the coating film and curing the coating film.

According to the method for producing a laminated film of the present invention, a film having a coat layer without wrinkles can be obtained.

According to the coating film control apparatus and the method for producing a laminated film of the present invention, a film having a coat layer without wrinkles can be obtained.

1 is a schematic view showing a laminated film production apparatus in which a coating control apparatus according to an embodiment of the present invention is disposed.
2 (a) is a sectional view taken along the line AA in Fig. 1, and Fig. 2 (b) is a sectional view taken along line BB in Fig.
3 is an exploded perspective view showing the exhaust means.
4 is a flowchart showing a laminated film production process by the laminated film production apparatus shown in Fig.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. A coating film control apparatus according to an embodiment of the present invention is a coating film control apparatus used in a laminated film production apparatus for laminating a coat layer on a resin film. Further, the coating film controlling apparatus of the present invention has a part of the function of preliminary drying described in Patent Document 1, but it is not important that the preliminary drying is performed, but the thickness of the coating film is made uniform.

In the following description, the coating liquid is referred to as a coating liquid before being applied to a film, and the coating liquid is referred to as a coating liquid after being applied.

1 is a schematic view showing a laminated film production apparatus in which a coating control apparatus according to an embodiment of the present invention is disposed.

The laminated film production apparatus 1 shown in Fig. 1 is a laminated film production apparatus in which a resin film F having a long length is conveyed at a substantially constant speed along the conveying path in the longitudinal direction of the resin film F, To form a laminated film. In the present embodiment, a film made of triacetyl cellulose having a film thickness of about 5 to 200 mu m is used as the resin film (F). Hereinafter, the upstream side of the conveying path is simply referred to as the upstream side, and the downstream side of the conveying path is simply referred to as the downstream side. In addition, a part of the resin film F having a long length may be simply referred to as a resin film (F).

The laminated film production apparatus 1 includes a delivery roll 2, a coating device 3, a coating film control device 4, a drying device 6, a light irradiation device 7, And a take-up roll (8). The resin film F having a long length is wound on the feed roll 2 provided at the upstream side end and is set in the laminated film production apparatus 1. [ On the other hand, the resin film F which has been conveyed to the downstream side end is wound up by the winding roll 8. In this laminated film production apparatus 1, the resin film F having a long length is transported at a substantially constant speed within a predetermined speed range. Thus, a laminated film can be produced at a substantially constant speed. In this embodiment, the transporting speed of the resin film (F) is set at 1 to 100 m / min. Depending on the composition (composition) of the coating liquid, the thickness of the coating film tends to become uneven as the transportation speed increases. The lower limit value of the conveying speed is preferably 30 m / min or more, more preferably 40 m / min or more, and particularly preferably 50 m / min or more from the viewpoint of cost reduction. The upper limit value of the conveying speed is not particularly limited.

The coating device 3 is composed of a gravure roll 31 for applying the coating liquid W to the resin film F, a liquid supply pan 32 containing a predetermined amount of the coating liquid W before coating, 33). ≪ / RTI > The coating liquid W applied to the resin film F by the coating device 3 is a liquid energy curable resin containing an organic solvent and having a viscosity of 20 mPa · s. The energy curable resin is cured by energy such as heat or radiation. The viscosity of the coating liquid W is preferably 0.5 mPa · s or more and 200.0 mPa · s or less, more preferably 5.0 mPa · s or more and 150 mPa · s or less, further preferably 10.0 mPa · s or more and 100 mPa · s or less. With this viscosity, the amount of the coating liquid W applied to the resin film (F) can be adjusted. One surface of the resin film F coated with the coating liquid W is referred to as a coating surface of the resin film F and a surface of the resin film F is referred to as a coating surface of the resin film F, The opposite surface may be referred to as the back surface of the resin film F. [ The gravure roll 31 has a cylindrical shape in which a spiral concave portion is formed on the roll surface. The gravure roll 31 is rotated at a constant angular velocity in the direction opposite to the conveying direction of the resin film F. [ The liquid supply fan 32 is provided below the gravure roll 31. [ The lower end portion of the gravure roll 31 is immersed in the coating liquid W in the liquid supply pan 32. [ One guide roll 33 is provided on the upstream side and the downstream side of the gravure roll 31 in the vicinity of the gravure roll 31. The resin film (F) is pressed against the gravure roll (31) by a guide roll (33). The gravure roll 31 scrapes the coating liquid W from the liquid supply pan 32 by the concave portion of the surface and applies the coating liquid W to the coated surface of the resin film F being conveyed successively by a predetermined amount do. As the application device 3, another application device capable of applying the application liquid W continuously on the resin film (F) such as a Meyer bar type may be used.

The drying device 6 blows hot air directly to the coating liquid W applied on the resin film F by the coating device 3 to heat the coating liquid W. [ The resin film F on which the coating liquid W is applied and the coating film is formed is passed through the drying apparatus 6 to be contained in the coating film applied on the portion of the resin film F that has passed through the drying apparatus 6 Most of the organic solvents were volatilized. The drying device 6 may be any device capable of volatilizing the organic solvent contained in the coating film. For example, a heating device for indirect heating may be used. The energy curable resin remains on the coated surface of the resin film (F), and an energy curable resin coating film is formed on the coated surface of the resin film (F) by volatilizing the organic solvent contained in the coated film.

When a thermosetting resin is used as the light energy curable resin, the thermosetting resin can be cured by heating, and when the photocurable resin is used, irradiation with ionizing radiation such as ultraviolet rays or electron beams is performed It is possible to cure the photocurable resin. The photocurable resin is easy to cure because of ionizing radiation. The light irradiation device 7 for irradiating ultraviolet rays irradiates light onto the energy curable resin coating film formed on the transferred resin film F to cure the energy curable water map film. The cured energy curable resin coating film becomes a coat layer (energy curing resin layer), and the resin film F in which the coat layer is laminated becomes a laminated film. In place of the light irradiation device 7, a thermosetting resin can be cured by providing a heating device.

The light irradiation device 7 is provided with a box-shaped chamber 71 having one side opened, an ultraviolet lamp 72, a conditioning roll 73, and a guide roll 74 for guiding the resin film F . The chamber 71 is disposed on the side of the coated surface of the resin film F to be transported. The opening of the chamber 71 has a rectangular shape defined by four edges. The chamber 71 is arranged such that the opening is close to the conveying path. Therefore, the resin film (F) passes near the opening of the chamber (71).

The ultraviolet lamp 72 irradiates the energy curable resin coating film formed on the resin film F with light. The ultraviolet lamp 72 is disposed in the chamber 71. The ultraviolet lamp 72 is a single lamp extended in the width direction of the resin film F (in a direction orthogonal to the paper surface in FIG. 1, hereinafter sometimes simply referred to as "width direction"). The length of the ultraviolet lamp 72 in the extending direction is substantially the same as the width of the resin film F. When a resin curable by light other than ultraviolet ray is used as the energy curable resin included in the coating liquid W and the coating film, a lamp which irradiates the corresponding light may be used. The dressing roll 73 faces the ultraviolet lamp 72 with the conveying path therebetween and is disposed on the back side of the resin film F. [ An inert gas discharging means for discharging (discharging) an inert gas such as nitrogen gas may be provided in the chamber 71.

The coating film controlling device 4 extends from the vicinity of the coating device 3 to the vicinity of the drying device 6 along the conveying path. The coating film control device 4 includes six backup rolls 41, a cover member 42 covering one side of the resin film F coated with the coating liquid W, And four exhaust means (43) for exhausting the gas between the members (42) to the outside of the cover member (42).

Each of the six backup rolls 41 is arranged along the conveying path on the back side of the resin film F to guide the resin film F. The resin film F is wound around the backup roll 41 disposed at the most upstream side and the most downstream side among the six backup rolls 41 by about 90 degrees. By the backup roll 41 disposed at the most upstream side, the conveying direction of the resin film F changes from a substantially horizontal direction to a substantially vertical direction. Further, by the backup roll 41 disposed at the most downstream side, the conveying direction of the resin film F changes from a substantially vertical direction to a substantially horizontal direction.

The cover member 42 extends along the conveying path from the vicinity of the application position where the application device 3 applies the application liquid W to the vicinity of the drying device 6. The application position in the present embodiment is the position where the gravure roll 31 and the resin film F are in contact with each other. The clearance between the cover members adjacent to each other is blocked by the clearance blocking member 422. There are two types of cover member 42: at least one through-hole cover member 420 provided with a hole and at least one no-cover cover member 421 without a hole. 1, three cover members 42 on the downstream side in the conveying direction close to the drying apparatus 6 are the perforated cover members 420 and are arranged upstream of the drying apparatus 6 (in the vicinity of the coating apparatus 3) The two cover members 42 on the side of the cover member 421 are the non-cover members 421. In addition, the perforated cover member 420 may be disposed closer to the drying apparatus 6, so that the total area of the perforations per unit area becomes larger. Of the one cover member 42, the total area of the holes per unit area may be larger than the upstream side in the conveying direction on the downstream side in the conveying direction. The position of the perforated cover member 420 and the non-covered cover member 421 may be appropriately changed. For example, the cover member 42 on the most upstream side in the transport direction closest to the application device 3 may be disposed on the non- The perforated cover member 420 and the non-porous cover member 421 may alternately be arranged in the order of the perforated cover member 420 and the non-covered cover member 421 in the transport direction. Further, depending on the composition of the coating liquid (for example, when a coating liquid having a low viscosity is used or when a solvent having a low boiling point is used), the perforated cover member 420 may be provided on the upstream side or immediately after the coating position .

The temperature difference between the drying temperature of the drying device 6 and the drying temperature in a specific line of the resin film F having the cover member 42 of either the non-covered cover member 421 or the perforated cover member 420 is Deg.] C or lower. This makes it difficult for dolby to occur in the drying apparatus 6, and as a result, it is difficult to cause a problem of whitening in the laminated film. The drying temperature of the drying apparatus 6 is preferably within the range of 30 to 200 占 폚, and more preferably 50 to 150 占 폚, depending on the kind of the resin film to be conveyed (heat-resistant temperature). The drying temperature in a specific line of the resin film F having the cover member 42 of either the non-covered cover member 421 or the perforated cover member 420 is preferably within a range of 10 ° C to 100 ° C, Deg.] C to 50 [deg.] C.

These cover members 42 allow the gas outside the cover member 42 to flow into the space between the resin film F and the cover member 42 (hereinafter sometimes referred to as the inside of the cover member 42) Is regulated. This action can also be obtained when the perforated cover member 420 is used. This is because the perforated cover member 420 is connected to the exhaust means 43. The cover member 42 on the most upstream side and the downstream side is detachably mounted on a frame (not shown) provided in the coating film controller 4. [ Further, although the cover members adjacent to each other are closed by the clearance blocking member, the clearance blocking member can be removed, and the adjacent cover members are detachably mounted. By arranging the cover members 42 to be removable in this way, the arrangement of the cover members can be easily changed. For example, the types of the coating liquids can be changed and the conveyance path can be changed flexibly. That is, the positional relationship between the perforated cover member 420 and the non-covered cover member 421 can be easily changed. The clearance blocking member 422 restricts the flow of gas outside the cover member 42 from the clearance between the cover members 42 into the cover member 42. [ In addition, when the clearance between the cover members 42 is narrow, the clearance blocking member 422 may be omitted. For example, when the both ends of each cover member are formed in a jig shape (comb shape) and the concave portions of adjacent cover members are staggered, the gap between adjacent cover members can be narrowed Therefore, the clearance blocking member can be omitted. That is, the cover members adjacent to each other are only required to be connected so as to restrict the inflow of the gas. As the means for achieving this, a method of using the clearance blocking member as described above, or a method in which both end portions of the cover member are jig- And a method of making the contents of the cover member staggered.

In the coating film controller 4 shown in Fig. 1, the lengths of the respective cover members in the film transport direction are different, but the lengths of the cover members may be substantially the same. By doing so, the arrangement of the cover member can be more easily changed, and it is possible to flexibly cope with the change of the kind of the coating liquid and the change of the conveying path. Also, the concept of substantially the same is also a concept including the completely same. The length of each cover member may be set to approximately integer multiples. By doing so, it is possible to change the arrangement of the cover member, and to cope more flexibly by changing the kind of coating liquid, changing the conveyance path, and the like.

The shape of the cover member is not particularly limited. Examples of the shape include a flat plate shape, a curved surface shape, a concavo-convex shape, and the like. It is also possible to adjust the volatilization amount of the solvent by changing the shape of the cover member. As the non-porous cover member for further allowing the volatile solvent to remain, the surface area may be increased. For example, a multilayer structure plate in which a plurality of metal meshes are stacked in multiple layers to form a non-porous structure, Shaped irregular shape or the like.

2 (a) is a cross-sectional view of the perforated cover member 420 taken along the line A-A in Fig. Fig. 2 (b) is a sectional view taken along the line B-B in Fig. 1, and is a cross-sectional view of the non-transparent cover member 421. Fig. In Fig. 2, the resin film (F) is shown by a thick solid line.

The cover member 42 includes a base plate 42a in the form of a flat plate disposed to face the application surface of the resin film F and two side plates 42b projecting from the base plate 42a toward the resin film F. [ . The base plate 42a and the side plate 42b are made of a transparent acrylic plate so that the resin film F can be seen from the outside of the base plate 42a and the side plate 42b. The base plate 42a is formed to have a width larger than the width of the resin film (F). The base plate 42a is disposed along the conveying path at a position spaced by about 10 mm from the coated surface of the resin film F. The gap between the base plate 42a and the coated surface of the resin film F is preferably as narrow as possible within a range in which the coating liquid W applied to the resin film F is reliably prevented from contacting the base plate 42a, For example, 5 mm or more and 15 mm or less.

As shown in FIG. 2A, a plurality of holes 42c are provided in the base plate 42a of the perforated cover member 420. As shown in FIG. On the other hand, as shown in Fig. 2 (b), the base plate 42a of the non-covered cover member 421 is not provided with a hole.

It is also possible to reduce the distance between the base plate 42a and the coated surface of the resin film F or to change the shape of the non-covered cover member so that the amount of the organic solvent Can be limited. The limitation of the volatilization amount will be described later in detail.

The side plates 42b are formed in the vicinity of both end portions in the width direction of the base plate 42a. The side plate 42b projects from the base plate 42a up to the back side of the resin film F so as to cover the thick portions at both ends in the width direction of the resin film F and to cover the backup roll 41. [ The distance in the width direction between the widthwise end of the backup roll 41 and the side plate 42b is about 10 mm. This interval is preferably as narrow as possible in the range in which the side plate 42b does not contact the widthwise end of the resin film F and the widthwise end of the backup roll 41. For example, desirable.

As shown in Fig. 1, the exhaust means 43 is mounted on the downstream side portion of the perforated cover member 420. As shown in Fig. The exhausting means 43 sucks the base body between the resin film F and the cover member 42 (hereinafter sometimes referred to as the atmosphere inside the cover) in a direction substantially perpendicular to the application surface of the resin film F , And the cover member (42). The atmosphere in the cover can be evenly sucked and can be exhausted to the outside of the cover member 42 by sucking it in the substantially vertical direction. The direction in which the exhaust means 43 sucks the atmosphere in the cover may be a direction crossing the application surface of the resin film (F). By sucking in the direction crossing the application surface of the resin film (F), the atmosphere in the cover can be sucked substantially evenly. However, in order to more uniformly suck, it is preferable to suck the resin film (F) in a direction perpendicular to the coated surface. The uniformity of the concentration of the organic solvent in the coating liquid W applied to the resin film (F) can be uniformly lowered, and the coating film can be uniformly controlled.

3 is an exploded perspective view showing the exhaust means. Although one of the two exhaust means 43 is shown in Fig. 3, the other of the exhaust means 43 has the same configuration. In Fig. 3, the exhaust direction by the exhaust fan 436 is indicated by an arrow.

3, the exhaust means 43 includes a suction portion 430, four exhaust tubes 434, a buffer container 435, and two exhaust fans 436. The suction portion 430 includes a punching plate 431, a mesh member 432 in mesh form, and an exhaust cover 433. This suction portion 430 is disposed on the downstream side of the smoothing position described later. The perforated cover member 420 is provided with a rectangular hole 420c which penetrates the base plate 420a in the plate thickness direction. Each of the punching plate 431 and the mesh member 432 is formed in a substantially rectangular shape substantially identical to the edge portion defining the rectangular hole 420c and sandwiched in the rectangular hole 420c. The exhaust cover 433 is box-shaped with one opening slightly larger than the rectangular hole 420c. The exhaust cover 433 is fixed to the base plate 420a by adhering the edge portion defining the opening to the base plate 420a so that the punching plate 431 and the mesh member 432 are inserted into the rectangular hole (420c). 3, the punching plate 431 is described. However, by providing a plurality of holes in the base plate 420a in the direction of the thickness of the base plate, the base plate 420a has the function of a punching plate You can. When a plurality of holes are provided in the base plate 420a, the punching plate 431 may not be stacked on the base plate 420a.

Each of the four exhaust tubes 434 connects the exhaust cover 433 and the buffer container 435. Further, any number of exhaust tubes 434 may be used. The buffer container 435 is equipped with an exhaust fan 436. The exhaust fan 436 exhausts the gas in the buffer container 435 to the outside of the buffer container 435. The air in the exhaust cover 433 is depressurized through the buffer container 435 and the exhaust tube 434 by the operation of the exhaust fan 436 and the atmosphere in the cover is sucked into the exhaust cover 433, As shown in Fig. Turbulence may be generated around the exhaust fan 436 due to the operation of the exhaust fan 436. In the present embodiment, since the air pressure in the exhaust cover 433 is reduced through the buffer container 435 and the exhaust tube 434, turbulence can be prevented from affecting the flow of the gas in the atmosphere in the cover . In addition, since the buffer container 435 can be disposed apart from the conveying path, the atmosphere in the cover exhausted by the exhaust fan 436 can be prevented from flowing into the cover member 42. It is also possible to change the exhaust amount for each exhaust tube 434. For example, in the exhaust tube 434 shown in Fig. 3, the drawing when from the left to the exhaust tube (434a, 434b, 434c, 434d ), the exhaust tubes (434a and 434d) of the displacement of the 0 ~ 5m ³ / min, exhaust It can be the displacement of the tube (434b and 434c) to 10 ~ 20m ³ / min. Thereby, it is possible to partially control the drying state in the width direction of the resin film (F), and also to improve the curl problem after the curing step by adjusting more detailed conditions.

The punching plate 431 is an acrylic plate in which a plurality of through holes 431a are formed in the plate thickness direction. By providing the punching plate 431, the rectifying effect when sucking the atmosphere in the cover is enhanced, and the atmosphere in the cover can be sucked substantially uniformly through the entire rectangular hole 420c. The mesh member 432 is made of stainless steel of 300 mesh. By providing the mesh member 432, the effect of rectifying when the atmosphere in the cover is sucked is higher, and the atmosphere in the cover can be more uniformly suctioned into the entire rectangular hole 420c. The number of meshes of the mesh member 432 is preferably 100 mesh or more and 1000 mesh or less, more preferably 200 mesh or more and 1000 mesh or less, and still more preferably 300 mesh or more and 1000 mesh or less. The larger the number of meshes, the higher the rectifying effect, and the atmosphere in the cover can be absorbed more uniformly through the entire rectangular hole 420c. However, if the number of meshes exceeds 1000, the gap between the meshes becomes too narrow and the suction efficiency decreases. Therefore, it is preferable that the mesh size is 1000 mesh or less. In addition, the number of meshes is the number of eyes per inch (25.4 mm). The punching plate 431 and the mesh member 432 of the present embodiment correspond to an example of the rectifying member in the present invention. Either one of the punching plate 431 and the mesh member 432 may be omitted. In the case of omitting either one, it is preferable to omit the punching plate 431 having a small number of holes and a relatively low rectifying effect.

The coating liquid W applied to the resin film F forms a coating film on the resin film F and the surface tension of the coating liquid W causes the width of the resin film F Leveling which tends to make the coating film uniform in the direction and flow direction occurs. Further, the organic solvent in the coating liquid W contained in the coating film after the application gradually volatilizes. When the organic solvent in the applied coating liquid W volatilizes and the concentration of the organic solvent decreases, the viscosity of the coating film becomes high, and the fluidity of the coating film lowers, making leveling difficult. On the other hand, if the concentration of the organic solvent component in the coating film is high, the leveling is promoted and the thickness tends to be uniform in the width direction of the resin film (F).

In the present embodiment, the coated surface of the resin film (F) and the thicknesswise portions at both ends in the width direction of the resin film (F) are coated with the resin film (F) from the vicinity of the application position where the coating solution (W) And the cover member 42 is covered to the downstream side from the homogenizing position where the thickness becomes uniform in the flow direction. The thickness uniformizing position of the coating film depends on all the conditions such as the component contained in the coating liquid W and the conveying speed of the resin film F. However, the experiment is performed based on the coating liquid W to be used and the desired conveying speed . As described above, the suction portion 430 is disposed on the downstream side of the uniformization position. The upstream side of the position where the suction unit 430 is disposed is the volatilization suppression zone Z1 shown in Fig. 1 and the suction unit 430 is disposed in the coating film control unit 4 And the downstream side becomes the drying zone Z2 shown in Fig.

Next, the operation of the present embodiment will be described.

4 is a flowchart showing a laminated film production process by the laminated film production apparatus shown in Fig. The flow chart of Fig. 4 shows the process of focusing attention on a specific line in the width direction of the resin film (F) during operation of the laminated film production apparatus 1. Fig.

When the laminated film production apparatus 1 is started, a specific line of the resin film F is fed out from the feed roll 2 after a predetermined initial operation (step S1). When the specific line of the resin film F is transported to a position where it is wound on the gravure roll 31, the application liquid W is applied to a specific line of the resin film F by the application device 3 and the application step is performed (Step S2).

A specific line of the resin film (F) coated with the coating liquid (W) is conveyed into the volatilization suppression zone (Z1) of the coating film controlling device (4) immediately after the coating. In the volatilization suppressing zone Z1, the cover member 42 restricts the flow of gas outside the cover member 42 into the cover member 42, and the organic solvent volatilized from the coating film is prevented from flowing into the cover member 42 Stay. As a result, the concentration of the organic solvent in the atmosphere in the cover is increased, and the organic solvent is hardly volatilized from the coating film. Further, after the concentration of the organic solvent in the atmosphere in the cover is saturated, the organic solvent in the coating film does not volatilize. That is, by appropriately setting the volume of the atmosphere in the cover determined by the gap between the cover member 42 and the coating surface of the resin film F, the volatilization amount of the organic solvent from the coating film in the coating film control device 4 is limited can do.

In the present embodiment, the coated surface of the resin film F and the thickness portions at both ends in the width direction of the resin film F are bonded to the cover member 42 to a position where the coated film has a uniform thickness in the width direction of the resin film (F) , The concentration of the organic solvent component in the coating film is prevented from being lowered. By doing so, the viscosity of the coating film is prevented from increasing, and leveling is promoted. A specific line of the resin film (F) passes through the volatilization-inhibiting zone (Z1), and a uniformizing process is performed to make the coating film uniform in thickness on a specific line of the resin film (F3) (step S3).

The specific line of the resin film (F) subjected to the homogenization process is continuously conveyed into the drying zone (Z2). At the upstream portion of the drying zone Z2, the atmosphere in the cover in which the organic solvent is saturated or the concentration of the organic solvent is high is discharged from the suction portion 430 so that the organic solvent concentration is low or the organic solvent Gas that does not contain gas is introduced and ventilation is performed. As a result, the drying of the coated film is promoted, and the natural drying process is carried out in a specific line of the resin film (F) passing through the drying zone (Z2) (step S4). This natural drying step corresponds to an example of the drying step in the present invention. In this natural drying step, the atmosphere in the cover is sucked in a direction crossing one side of the resin film (F), so that the atmosphere in the cover can be sucked substantially evenly and the coating film can be uniformly controlled. In addition, once the air is ventilated, a gas containing mostly organic solvents becomes the atmosphere inside the cover. Therefore, the organic solvent in the coating film is volatilized until the concentration of the organic solvent becomes saturated in the downstream portion of the drying zone Z2, that is, the portion where the suction portion 430 is not disposed, .

Thereafter, the specific line of the resin film (F) is conveyed to the drying device (6), and the main drying step is performed (step S5). In this main drying step, the coating liquid W applied to a specific line of the resin film (F) is heated by the drying device (6). By heating, the organic solvent in the coating film on the specific line of the resin film (F) is completely volatilized, and an energy curable resin coating film is formed on a specific line of the resin film (F).

Next, a specific line of the resin film (F) is transported to the light irradiation device 7, and a light irradiation step is performed (step S6). This light irradiation step is a step of irradiating ultraviolet rays from the ultraviolet lamp 72 onto the photocurable resin coating film formed in the form of a resin film (F), thereby curing the photocurable waterproofing film. When a thermosetting resin is used instead of a photocurable resin, a heating device may be provided in place of the light irradiation device.

Lastly, a winding process is performed in which a specific line of the resin film F on which the coat layer formed by curing the energy-curable resin coating film is laminated is conveyed to the winding roll 8 and is wound around the winding roll 8 (step S7) .

Next, a material preferably used in the present embodiment will be described.

As the resin film (F), it is preferable to use polyethylene terephthalate (PET), triacetyl cellulose (TAC), polyethylene naphthalate (PEN), polymethyl methacrylate (PMMA), polycarbonate (PC), polyimide (PI), polyethylene (PE), polypropylene (PP), polyvinyl alcohol (PVA), polyvinyl chloride (PVC), cycloolefin copolymer (COC), norbornene norbornene resin, acrylic resin, polyethersulfone, cellophane, aromatic polyamide, and the like can be preferably used. In the case of producing a laminated film for use in a plasma display (PDP) or a liquid crystal display (LCD), it is more preferable to use one selected from a PET film, a TAC film and a Hamnobonen resin film.

The transparency of these resin films is better as the transparency is better, but for optical applications, the total light transmittance (JIS K7105) is preferably 80% or more, and more preferably 90% or more.

The surface of the resin film may be treated with a treatment such as alkali treatment, corona treatment, plasma treatment or sputter treatment, primer coating such as surfactant, silane coupling agent, It is possible to improve the adhesion between the resin film and the coat layer and improve the chemical resistance in the physical strength of the coat layer. A resin film in which another layer is provided on the coat layer side of the resin film may also be used. In this case, too, the physical strength and chemical resistance of the hard coat layer can be improved by improving the adhesion of each layer interface by the same method.

The resin component contained in the coating liquid W is not particularly limited, but an ionizing radiation curable resin that can be efficiently cured by a simple and easy processing operation in a curing treatment by ultraviolet irradiation is preferable. Examples of the ionizing radiation curable resin include radically polymerizable functional groups such as acryloyl group, methacryloyl group, acryloyloxy group and methacryloyloxy group, cationic polymerizable functional groups such as epoxy group, vinyl ether group and oxetane group A monomer, an oligomer, a prepolymer, or a polymer having a polymerizable unsaturated bond may be used alone or in a suitable mixture. Examples of the monomer include, but are not limited to, methyl acrylate, methyl methacrylate, methoxypolyethylene methacrylate, cyclohexyl methacrylate, phenoxyethyl methacrylate, ethylene glycol methacrylate, dipentaerythritol hexaacrylate, trimethylolpropane tri Methacrylate, pentaerythritol triacrylate, and the like. Examples of oligomers and prepolymers include acrylate compounds such as polyester acrylates, polyurethane acrylates, polyfunctional urethane acrylates, epoxy acrylates, polyether acrylates, alkyd acrylates, melamine acrylates and silicone acrylates, unsaturated poly Such as esters, tetramethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, neopentyl glycol diglycidyl ether, bisphenol A diglycidyl ether and various alicyclic (cycloaliphatic) (3-ethyl-3-oxetanyl) methoxy} methyl} benzene , di [1-ethyl (3-oxetanyl) ] Methyl ether And the like. Examples of the polymer include polyacrylate, polyurethane acrylate, and polyester acrylate. These may be used alone or in combination.

A thickening agent may be added to the coating liquid W, but a coating liquid which does not contain a thickening agent is preferable because it is difficult to thinly coat the resin film F and time for leveling increases. A high boiling point solvent may be added to the coating liquid W, but a coating liquid not containing a high boiling point solvent is preferable because the drying time is increased.

When the ionizing radiation curable resin is cured by ultraviolet irradiation, it is necessary to add a photopolymerization initiator. The radiation to be used may be ultraviolet rays, visible rays or infrared rays. These radiation may be polarized light or unpolarized light.

Examples of the photopolymerization initiator include radical polymerization initiators such as acetophenone type, benzophenone type, thioxanthone type, benzoin and benzoin methyl ether, and cations such as aromatic diazonium salts, aromatic sulfonium salts, aromatic iodonium salts and metallocene compounds The polymerization initiator may be used alone or in appropriate combination.

In addition, additives such as a leveling agent and an antistatic agent may be added to the energy-curable resin. The leveling agent has a function of correcting the defects before forming the coating film by promoting tension uniformity of the coating film surface.

The resin composition may contain light-transmitting fine particles. An energy curable resin to which a solvent is added to the resin composition is applied on a resin film and then the energy curable resin is cured to form a hard coat layer. By adding the light-transmitting fine particles to the resin composition, it is easy to adjust the shape and the number of the surface irregularities of the hard coat layer (antiglare layer) having the antifogging property. When the antiglare layer is formed, the portion where the fine particles exist is increased, but the thickness becomes uniform in the portion where no fine particles exist, so that the present invention can be applied.

Examples of the light-transmitting fine particles include organic light-transmitting resin fine particles made of acrylic resin, polystyrene resin, styrene-acrylic copolymer, polyethylene resin, epoxy resin, silicone resin, polyvinylidene fluoride, polyfluorinated ethylene resin, Light-transmitting fine particles such as titanium dioxide, zirconium oxide, calcium oxide, tin oxide, phosphorus oxide, and antimony oxide may be used. The refractive index of the light-transmitting fine particles is preferably 1.40 to 1.75, and when the refractive index is less than 1.40 or more than 1.75, the difference in refractive index between the resin film and the resin matrix becomes too large and the total light transmittance decreases. The difference in refractive index between the light transmitting fine particles and the resin is preferably 0.2 or less. The average particle diameter of the light-transmitting fine particles is preferably in the range of 0.3 to 10 mu m, more preferably 1 to 7 mu m, and even more preferably 2 to 6 mu m.

When the particle size is smaller than 0.3 탆, the antireflection property is deteriorated. When the particle diameter is larger than 10 탆, flashing occurs and the degree of surface irregularity becomes too large and the surface becomes whitish. The ratio of the light-transmitting fine particles contained in the resin is not particularly limited. However, it is preferable that the ratio of the light-transmitting fine particles contained in the resin is 0.1 to 20 parts by mass based on 100 parts by mass of the resin composition in order to satisfy the anti- It is easy to control the fine uneven shape and haze value of the layer surface. Here, the " refractive index " indicates a measurement value according to JIS K-7142. The " average particle diameter " indicates an average value of the diameters of 100 particles measured by an electron microscope.

The refractive index (n) of the energy-curable resin is generally in the range of 1.40 to 1.60. When it is desired to lower the refractive index or to increase the refractive index, a desired refractive index can be obtained by adding ultra fine particles having a particle diameter of 100 nm or less. As the ultra-fine particles of high refractive index, for example, TiO ₂ (refractive index: n = 2.3 ~ 2.7), CeO 2 (n = 1.95), ZnO (n = 1.9), Sb 2 O 5 (n = 1.71), SnO 2 (n = 1.95), ITO (n = 1.95), Y 2 O 3 (n = 1.87), La 2 O 3 (n = 1.95), ZrO 2 (n = 2.05), Al 2 O 3 (n = 1.63), HfO ₂ (n = 2.00), and Ta ₂ O ₅ can be used. As the ultra-fine particles having a low refractive index, it is preferable to use hollow ultrafine particles in which the interior of the ultra-fine particles is empty.

Examples of the organic solvent include alcohols such as methanol, ethanol, 1-propanol, 2-propanol, butanol, isopropyl alcohol (IPA) and ISO butanol; Ketones such as acetone, methyl ethyl ketone (MEK), cyclohexanone, and methyl ISO butyl ketone (MIBK); Ketone alcohols such as diacetone alcohol; Aromatic hydrocarbons such as benzene, toluene and xylene; Glycols such as ethylene glycol, propylene glycol and hexylene glycol; Glycol ethers such as ethyl cellosolve, butyl cellosolve, ethyl carbitol, butyl carbitol, diethyl cellosolve, diethyl carbitol and propylene glycol monomethyl ether; Esters such as N-methylpyrrolidone, dimethylformamide, methyl lactate, ethyl lactate, methyl acetate, ethyl acetate and amyl acetate; Ethers such as dimethyl ether and diethyl ether, water and the like. These may be an organic solvent alone or a plurality of organic solvents.

As described above, according to the coating film control apparatus 4 of the present embodiment, the cover member 42 is provided with the resin film F, It is possible to prevent wind from being applied to the coated film. Since the volatilization of the organic solvent in the coating film is suppressed, leveling is promoted and the coating film tends to have a uniform thickness in the width direction and the flow direction of the resin film (F). Since the applied coating liquid W has a uniform thickness in the width direction and the flowing direction of the resin film F and then the gas in the vicinity of the coating liquid W is attracted in the direction crossing the coating surface, It is possible to control the coating film evenly without waving it, and it is possible to produce a laminated film having no wrinkles and having a coat layer of uniform thickness. In addition, since the coating control apparatus of this embodiment is a simple constitution comprising the backup roll 41, the cover member 42, and the exhaust means 43, the apparatus can be constructed at low cost.

The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims. For example, although the above-described embodiment has been described taking the coating film control device 4 provided with two exhaust means 43 as an example, the number of the exhaust means may be one, or three or more. In the embodiment described above, the cover member 42 is composed of at least one through-hole cover member, at least one non-cover member 421 and a plurality of clearance blocking members 422, but the clearance blocking member is omitted , One cover member integrated by connecting one or more through-hole cover members and at least one non-cover cover member, all of the resin film (F) in the coating film control device may be covered.

Further, even if the constituent elements included only in each of the modifications of the above-described embodiments, the constituent elements may be applied to other modifications.

4 Coating film controller 42 Cover member
43 evacuation means 430 suction unit
431 punching plate 432 mesh member
Z1 Volatilization Suppression Zone Z2 Drying Zone
F resin film W coating liquid

Claims (6)

After a coating liquid containing a resin material and a solvent is applied to one side of a film having a long shape and transported in the longitudinal direction to form a coating film, And two or more cover members covering the coating film and the thick portions of both ends in the width direction of the film, until the solvent volatilizing from the coating film is filled in the drying apparatus,
The two or more cover members are connected in the transport direction of the film and include at least one hole cover member provided with a hole and at least one non-hole cover member provided with no hole,
And exhausting means for exhausting the solvent volatilizing from the coating film to the outside through the hole of the hole cover member,
And the position of the cover member can be changed. The method according to claim 1,
Wherein the length of the hole cover member and the length of the non-covered cover member in the transport direction of the film is approximately an integral multiple of an integer. The method according to claim 1,
Wherein the at least two cover members are connected to each other through a clearance blocking member. The method according to claim 1,
Wherein the exhausting means includes a rectifying member having a plurality of through holes penetrating in a direction intersecting with the one surface. The method of claim 4,
Wherein the flow-regulating member is a mesh-shaped member. A coating step of applying a coating liquid containing a resin material and a solvent to one surface of a film of a long length conveyed in the longitudinal direction;
A natural drying step of passing the coating film control device according to any one of claims 1 to 5, wherein an amount and a velocity of a solvent volatilized from the coating film are adjusted,
A main drying step of volatilizing the solvent contained in the coating film,
And a curing step of curing the coating film by applying energy to the coating film.

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