WO2023286645A1 - 機能層の製造方法、及びその製造装置 - Google Patents

機能層の製造方法、及びその製造装置 Download PDF

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Publication number
WO2023286645A1
WO2023286645A1 PCT/JP2022/026561 JP2022026561W WO2023286645A1 WO 2023286645 A1 WO2023286645 A1 WO 2023286645A1 JP 2022026561 W JP2022026561 W JP 2022026561W WO 2023286645 A1 WO2023286645 A1 WO 2023286645A1
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Prior art keywords
protective film
functional layer
peeling
treated
processed
Prior art date
Application number
PCT/JP2022/026561
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English (en)
French (fr)
Japanese (ja)
Inventor
幸雄 西條
悟志 大亀
誠司 近藤
正洋 村上
渉 長竹
Original Assignee
日東電工株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 日東電工株式会社 filed Critical 日東電工株式会社
Priority to CN202280043368.9A priority Critical patent/CN117561127A/zh
Priority to KR1020237041152A priority patent/KR20240031953A/ko
Publication of WO2023286645A1 publication Critical patent/WO2023286645A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C13/00—Means for manipulating or holding work, e.g. for separate articles
    • B05C13/02—Means for manipulating or holding work, e.g. for separate articles for particular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
    • B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H20/00—Advancing webs
    • B65H20/10—Advancing webs by a feed band against which web is held by fluid pressure, e.g. suction or air blast
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H41/00—Machines for separating superposed webs

Definitions

  • the present invention relates to a method and apparatus for continuously forming functional layers on a long strip-shaped material to be processed.
  • a coating liquid (a solution that forms a functional layer) is applied to the surface of the material to be treated while the material is being transported. It is known to coat the In this method, in some cases, the material to be treated is conveyed with a protective film affixed thereon in order to prevent damage.
  • Patent Document 1 a long polycarbonate film (material to be treated) in which a surface on which a hard coat layer (functional layer) is to be formed and a surface opposite to the surface are each protected by a protective film, While transporting the film in the length direction through guide rolls from the feeder, the protective film on the surface on which the hard coat layer is to be formed is peeled off to expose the surface, and the exposed surface is coated with the hard coat material.
  • a method for forming a hard coat layer on a polycarbonate film by drying is disclosed.
  • a functional layer is formed by applying a coating liquid to the surface of the long belt-shaped material to be treated after peeling off the protective film during the process of transporting the material.
  • a continuous film-like functional layer can be formed in the longitudinal direction of the material to be treated.
  • a functional layer having an optical function is required to have high thickness accuracy, it is necessary to improve the manufacturing method of the functional layer.
  • An object of the present invention is to provide a functional layer manufacturing method and apparatus capable of continuously manufacturing a functional layer having a substantially uniform thickness.
  • the inventors diligently investigated the cause of the formation of a functional layer with non-uniform thickness. It was presumed that the reason for this was that the conveying speed of the material to be coated varied when the coating liquid was applied. It is presumed that this variation in the conveying speed of the material to be treated is caused by the fact that the force generated at the branch point when peeling off the protective film has a component in the conveying direction of the material to be treated. Fluctuations in the conveying speed of the material to be treated that occur when the protective film is peeled off (hereafter, fluctuations in conveying speed are referred to as “speed fluctuations”) affect the material to be treated that exists near the coating device, resulting in It is presumed that uneven coating of the working liquid (uneven coating thickness) occurs. Accordingly, the present inventors have found that a functional layer having a substantially uniform thickness can be continuously formed by suppressing the speed variation of the material to be processed, and completed the present invention.
  • the production method of the present invention includes a step of conveying a long strip-shaped material having a long strip-shaped material to be treated and a protective film attached to the surface of the material to be treated, and conveying the original fabric. a step of peeling the protective film from the material to be treated by pulling out the protective film from a separation member arranged in a path; applying a coating liquid to the surface of the material to be treated exposed by peeling the protective film;
  • the separation member has an arcuate surface portion having a radius of curvature of 30 mm or less, and the protective film is pulled out along the arcuate surface portion of the separation member.
  • a preferable manufacturing method of the present invention is the manufacturing method of [1], wherein the separation member is a roll having a radius of 30 mm or less.
  • a preferred manufacturing method of the present invention is the manufacturing method of [1], wherein the separation member has a protruding end portion, and the protruding end portion includes the arc surface portion.
  • a preferable manufacturing method of the present invention is the manufacturing method according to any one of [1] to [3], wherein the angle formed by the conveying direction of the material to be treated and the drawing direction of the protective film is 60 degrees or more and 180 degrees.
  • a preferable manufacturing method of the present invention is that, in the manufacturing method of any one of [1] to [4], the conveying length from immediately after peeling off the protective film to immediately before applying the coating liquid is 1 m or more.
  • a preferable manufacturing method of the present invention is that, in the manufacturing method of any one of [1] to [5], the above-described The conveying direction of the material to be treated is changed while preventing the surface of the material to be treated exposed by peeling off the protective film from coming into contact with foreign matter.
  • a preferable production method of the present invention is the production method according to any one of [1] to [6], wherein the material to be treated is a stretched film, and the coating liquid contains a liquid crystal compound.
  • a preferred manufacturing method of the present invention is the manufacturing method according to any one of [1] to [7] above, wherein the protective film is controlled so that the fluctuation width of the tension of the protective film is equal to or less than a predetermined value. pull out
  • the manufacturing apparatus of the present invention includes a conveying device that conveys a raw material having a long strip-shaped material to be processed and a protective film attached to the surface of the material to be processed, and a separation A peeling device for peeling the protective film from the material to be treated by pulling out the protective film from a member, and a coating liquid for coating the surface of the material to be treated exposed by peeling the protective film. and a processing device, wherein the separation member has an arcuate surface portion having a radius of curvature of 30 mm or less, and the protective film is pulled out along the arcuate surface portion of the separation member.
  • a preferable manufacturing apparatus of the present invention is the manufacturing apparatus according to [9], wherein the separation member is a roll having a radius of 30 mm or less.
  • a preferable manufacturing apparatus of the present invention is the manufacturing apparatus according to [9], wherein the separation member has a protruding end portion, and the protruding end portion includes the arc surface portion.
  • a preferred manufacturing apparatus of the present invention is the manufacturing apparatus according to any one of [9] to [11] above, wherein the peeling device has a The protective film is pulled out from the material to be treated so that the angle is 60 degrees or more and 180 degrees or less.
  • a preferable manufacturing apparatus of the present invention is the manufacturing apparatus according to any one of [9] to [12], wherein the conveying length from the peeling device to the coating device is 1 m or more.
  • a preferred manufacturing apparatus of the present invention is the manufacturing apparatus according to any one of [9] to [13], wherein the conveying device is provided between the peeling device and the coating device in a non-contact manner. It has a converting section, and the non-contact conveying converting section changes the conveying direction of the material to be treated without contacting the surface of the material to be treated exposed by peeling off the protective film from foreign matter.
  • the manufacturing method and the manufacturing apparatus of the present invention since the speed fluctuation of the material to be treated can be suppressed, uneven coating of the coating liquid on the surface of the material to be treated is less likely to occur, and a functional layer having a substantially uniform thickness can be formed. It can be formed continuously.
  • FIG. 1 is a schematic side view of a functional layer manufacturing apparatus according to a first embodiment
  • FIG. The top view seen from the arrow II direction of FIG. (a) to (d) are enlarged side views showing the layer structure of the raw fabric.
  • (a) is a perspective view of a non-contact transfer conversion section (air turn bar), and
  • (b) is a schematic side view enlarging the vicinity of the non-contact transfer conversion section.
  • FIG. 2 is a perspective view of the separation member (roll) of the first embodiment;
  • FIG. 4 is an enlarged side view of a state in which a protective film is peeled off from an original fabric having a certain layer structure;
  • FIG. 4 is an enlarged side view of a state in which a protective film is peeled off from a raw fabric having another layer structure;
  • the enlarged side view which expanded the vicinity of the separation member of the same manufacturing apparatus.
  • the downstream side relates to the transportation of the raw material, the material to be processed, the protective film, etc., and means the leading side of their transportation, and the upstream side means the opposite side. Also, if there are multiple numerical ranges expressed separately from the lower limit to the upper limit, select an arbitrary lower limit and an arbitrary upper limit, and enter "Any lower limit to an upper limit”. shall be configurable.
  • a functional layer is continuously formed on the surface of the material to be treated after peeling off the protective film in the process of conveying a long strip-shaped material having the material to be treated and the protective film.
  • the protective film is peeled off, the surface of the material to be treated is exposed, and the functional layer can be formed on the surface of the material to be treated by coating the surface with a coating liquid.
  • the separation member is used as a fulcrum for pulling out the protective film.
  • the protective film is pulled out along the arc surface portion having a radius of curvature of 30 mm or less of the separation member.
  • the radius of curvature of the arcuate portion is preferably 25 mm or less, more preferably 20 mm or less, still more preferably 10 mm or less, and particularly preferably 7 mm or less.
  • the lower limit of the radius of curvature of the arcuate portion exceeds zero, but if it is too small, the protective film may be scraped off when pulled out along the arcuate portion. From this point of view, the lower limit of the radius of curvature of the arcuate portion is 1 mm or more, preferably 3 mm or more.
  • FIG. 1 is a schematic side view of a functional layer manufacturing apparatus A according to the first embodiment
  • FIG. 2 is a plan view of the periphery of a separation member c1 as seen from the upper side of the paper.
  • the thick arrow indicates the transport direction of the original fabric 1
  • the white arrow indicates the drawing direction of the protective film 2
  • the thin arrow indicates the rotation direction of various rolls, winding units, and the like.
  • the functional layer manufacturing apparatus A includes a conveying device B that conveys a long belt-shaped raw material 1 in the longitudinal direction, a peeling device C that is arranged on the conveying route of the raw cloth 1 and peels off the protective film 2, and the peeling.
  • the manufacturing apparatus A includes a curing device E such as a drying processing unit e1 that dries the coating liquid, a curing processing unit e2 that cures the coating liquid, and a bonding unit F that bonds any appropriate film. etc.
  • the raw fabric 1 has a material to be treated 3 and a protective film 2, and may have any suitable film and/or layer as necessary.
  • the material 3 to be treated is an object to be coated with the coating liquid.
  • the material 3 to be treated is in the form of a long thin film (also referred to as a web).
  • the term “long belt shape” refers to a generally rectangular shape in plan view, the length of which is sufficiently longer in the longitudinal direction than in the width direction.
  • the length in the longitudinal direction is, for example, five times or more, preferably ten times or more, the length in the width direction.
  • the width direction is a direction orthogonal to the longitudinal direction.
  • the material to be treated 3 itself may have sufficient mechanical strength to be transported in the longitudinal direction by the transport device B, or may itself not have the above mechanical strength. If the material to be treated 3 does not have the above mechanical strength, the material to be treated 3 is conveyed by the conveying device B while being laminated on a support film (film having the above mechanical strength).
  • a support film film having the above mechanical strength.
  • the former when it is necessary to distinguish between the material to be processed having the mechanical strength and the material to be processed having no mechanical strength, the former will be referred to as the "first material to be treated 31" and the latter as the "second material to be treated”. 2 to be treated 32", and simply referred to as "to be treated 3" when both are included.
  • the material to be treated 3 has two large surface areas.
  • the surface of the material to be treated 3 is one of the two large-area surfaces and is the surface to which the coating liquid is applied (surface to be treated).
  • the surface opposite to the surface of the material 3 to be treated is referred to as the "opposite surface" of the material 3 to be treated.
  • the protective film 2 is a film that prevents the surface of the material 3 to be treated from being damaged.
  • the protective film 2 is attached to the surface of the material 3 to be treated in a detachable state.
  • the protective film 2 has at least a film substrate.
  • the protective film 2 may have a bonding adhesive layer on one surface of the film substrate, if necessary. Also, the protective film 2 may have any suitable film and/or layer.
  • FIG. 3 illustrates some of the layer configurations of the raw fabric 1 .
  • FIGS. 3(a) and 3(b) are examples of the raw material 1 having a first material 31 to be processed (the material 3 to be processed having a strength capable of being transported in the longitudinal direction by the transport device B).
  • the original fabric 1 in FIG. 1A has, in order from the upper side of the paper surface, a first processed material 31 and a protective film 2 having a bonding adhesive layer 22 and a film substrate 21 .
  • the original fabric 1 in FIG. 4B has, in order from the upper side of the paper surface, a suitable film 41, a first processed material 31, and a protective film 2 having a bonding adhesive layer 22 and a film substrate 21. .
  • the protective film 2 of the raw fabric 1 is detachably attached to the material to be treated 3 via the bonding adhesive layer 22 . Therefore, when the protective film 2 is pulled out, it is peeled off at the boundary between the surface of the first processed material 31 and the bonding adhesive layer 22, and as a result, the surface of the first processed material 31 is exposed.
  • the protective film 2 may be directly attached to the surface of the first processed material 31 in a detachable state by means such as pseudo-adhering the film substrate 21 to the first processed material 31. can.
  • the protective film 2 in such a case does not have the bonding adhesive layer (not shown).
  • FIGS. 3(c) and 3(d) are examples of the original fabric 1 having a second processed material 32 (the processed material 3 which does not have the strength to be transported in the longitudinal direction by the transport device B).
  • the original fabric 1 in FIG. 1(c) includes, in order from the upper side of the paper surface, a support film 42, a second processed material 32, and a protective film 2 having a film substrate 21 and not having a bonding adhesive layer.
  • the original fabric 1 in FIG. 4(d) has, in order from the upper side of the paper surface, an appropriate film 41, a support film 42, a second material to be treated 32, and a film substrate 21, and has an adhesive layer for bonding.
  • the support film 42 is a film that supports the second material 32 to be processed so that the second material 32 to be processed can be transported by the transport device B. As shown in FIG. As the support film 42, a film having mechanical strength capable of being transported in the longitudinal direction by the transport device B is used.
  • the first processed material 31 examples include a resin film.
  • the first material to be treated 31 is not particularly limited, and examples thereof include polyvinyl alcohol-based resin, cycloolefin-based resin, polycarbonate-based resin, polyvinyl acetal-based resin, polyimide-based resin, acrylic-based resin, and cellulose ester. resins, cellulose resins, polyester resins, polyester carbonate resins, olefin resins, polyurethane resins, and the like.
  • a resin film containing one or more of polycarbonate resin, polyvinyl acetal resin, cellulose ester resin, polyester resin, polyester carbonate resin and the like is used. These can be used singly or in combination of two or more.
  • the first processed material 31 may be a film having an optical function such as an optically anisotropic film, an optically isotropic film, or the like.
  • the film having optical functions include a polarizing film, a retardation film, a light diffusion film, a brightness enhancement film, an antiglare film, and a light reflection film.
  • the first processed material 31 may be a film having an orientation regulating force, and examples of such a film include a stretched film stretched in a predetermined direction.
  • the thickness of the first material to be treated 31 is not particularly limited, and is, for example, 10 ⁇ m to 200 ⁇ m, preferably 12 ⁇ m to 100 ⁇ m.
  • Examples of the second processed material 32 include an adhesive layer, an antiglare layer, an antireflection layer, and a hard coat layer.
  • the thickness of the second processed material 32 is not particularly limited.
  • the second treated material 32 is an adhesive layer, its thickness is, for example, 0.5 ⁇ m to 50 ⁇ m, preferably 1 ⁇ m to 30 ⁇ m.
  • the film substrate 21 constituting the protective film 2 examples include resin film, synthetic paper, and paper.
  • the film substrate 21 is preferably a resin film having excellent transparency, and more preferably a resin film having excellent transparency and optical isotropy.
  • its material is not particularly limited. Examples include vinyl chloride resins such as vinyl chloride and vinyl chloride copolymers, polymethylpentene, polyurethane, and ethylene-vinyl acetate copolymers. These can be used singly or in combination of two or more.
  • the thickness of the film substrate 21 is not particularly limited, and is, for example, 5 ⁇ m to 200 ⁇ m, preferably 10 ⁇ m to 100 ⁇ m.
  • the adhesive layer 22 for bonding may be, for example, a colorless and transparent acrylic adhesive, a rubber adhesive, a silicone adhesive, a urethane adhesive, or a vinyl adhesive.
  • Alkyl ether-based adhesives, polyvinylpyrrolidone-based adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, and the like are included.
  • the thickness of the bonding adhesive layer 22 is not particularly limited, and is, for example, 0.1 ⁇ m to 50 ⁇ m, preferably 1 ⁇ m to 30 ⁇ m.
  • the appropriate film 41 may have a single-layer structure, or may have a multi-layer structure of two or more layers. Moreover, when the appropriate film 41 has a multi-layer structure, it may contain any appropriate layer (for example, the bonding adhesive layer 22, etc.). Moreover, the appropriate film 41 may be a film having an optical function as described above, or may be an optically isotropic film.
  • the support film 42 is not particularly limited as long as it is a film having mechanical strength. Examples of the support film 42 include a resin film, synthetic paper, and paper. As the support film 42, it is preferable to use a highly transparent resin film such as that exemplified as the protective film 2. As shown in FIG. The thickness of the support film 42 is not particularly limited, and is, for example, 5 ⁇ m to 200 ⁇ m, preferably 10 ⁇ m to 100 ⁇ m.
  • conveying device B is a device for conveying raw fabric 1 in the longitudinal direction.
  • the conveying device B conveys the original fabric 1 by a roll-to-roll method.
  • the layer structure of the original fabric 1 changes after the protective film 2 is peeled off and after the functional layer is formed on the surface of the material 3 to be treated. Even if the layer structure changes in this way, the original fabric 1 always includes the material to be treated 3 over the entire conveying path.
  • the raw material 1 from after peeling off the protective film 2 to forming the functional layer will be referred to as the “processing raw material 11", and the material 3 to be processed.
  • the raw roll 1 after forming the functional layer on the surface is called “product raw roll 12", and the period from unwinding to winding is collectively called "raw roll 1".
  • the conveying device B includes an unwinding section b1 in which the roll-shaped material 1 is set, a winding section b2 for winding the product material 12, and a winding section b2 for winding the product material 12 from the unwinding section b1. and a conveying section b3 for continuously conveying the raw fabric 1 in the longitudinal direction to the section b2.
  • the original fabric 1 unwound from the unwinding section b1 is changed from the original fabric 11 for processing into the original fabric 12 while being conveyed along the conveying route of the conveying section b3, and then wound up by the winding section b2.
  • the unwinding section b1 of the conveying device B uses an actuator such as a motor with a brake having an unwinding shaft
  • the winding portion b2 uses an actuator such as a motor with a clutch having a winding shaft
  • the transport section b3 of the transport device B has an upstream feed roll b31, a plurality of guide rolls b32, a downstream feed roll b33, and a tension detector (not shown) such as a tension pickup roll.
  • the transport section b3 of the transport device B may further have feed rolls other than those shown, or may have dancer rolls (not shown).
  • the conveying device B for the original web 1 conveys the original web 1 in the longitudinal direction while controlling the fluctuation width of the tension of the original web 1 to be equal to or less than a predetermined value. In other words, the conveying device B is controlled so that the fluctuation range of the tension of the original web 1 being conveyed becomes small.
  • speed control is performed based on the tension of the original web 1 measured by a tension detector (for example, the difference in peripheral speed between two feed rolls is changed), or/and For example, performing torque control (for example, changing the torque of the unwinding portion b1).
  • the transport section b3 may have a non-contact transport conversion section b34 for changing the transport direction of the processing material 11 including the material 3 to be processed, if necessary.
  • the non-contact transfer conversion section b34 is provided between the peeling device C and the coating device D. As shown in FIG.
  • the non-contact transport conversion part b34 is a portion that changes the transport direction of the processing material 11 including the material to be processed 3 without bringing the surface of the material to be processed 3 exposed by peeling off the protective film 2 into contact with foreign matter. is.
  • the foreign matter includes, for example, machine parts such as guide rolls.
  • the raw material 11 for processing including the material to be processed 3 whose surface is exposed is in contact with the guide roll b32 on the opposite side, and after the direction is changed, the surface is non-removable.
  • the direction is changed without coming into contact with the contact transfer conversion part b34.
  • the processing material 11 (the material to be processed 3) is turned into a hairpin shape at the non-contact transfer conversion unit b34, and the direction is changed.
  • an air turn bar can be used as the non-contact transfer conversion unit b34.
  • FIG. 4(a) shows an example of an air turn bar.
  • the air turn bar which is the non-contact transfer conversion part b34, has a hollow case body b342 in which countless blowout holes b341 are formed, and a supply port b343 for supplying air into the case body b342. As indicated by the arrow in FIG. 3B, the air supplied from the supply port b343 is blown out from the outer surface of the case body b342 through the blowing hole b341, so that the surface of the material to be treated 3 contacts the air turn bar b34. Instead, the processing material 11 including the material 3 to be processed is turned.
  • the peeling device C is a device for peeling the protective film 2 from the material to be processed 3 (original fabric 1) while the original fabric 1 is being conveyed in the longitudinal direction.
  • the surface of the material 3 to be treated is exposed by peeling off the protective film 2, and the raw material 11 for processing, in which the surface of the material 3 to be treated is exposed, is transported in the longitudinal direction by the transport device B. As shown in FIG.
  • the peeling device C includes a separating member c1 used as a fulcrum, a tension control unit c2 for pulling out the protective film 2 while controlling the fluctuation width of the tension of the protective film 2 to be equal to or less than a predetermined value, a guide roll c3, and a collecting part c4 for winding and collecting the pulled-out protective film 2.
  • - ⁇ A peeling device C including the separating member c1 is arranged in the conveying path of the raw sheet 1. As shown in FIG. As described above, the separation member c1 has the arcuate surface c12 having a radius of curvature of 30 mm or less, and the arcuate surface c12 extends in the width direction of the original fabric 1 . The arc surface portion c12 of the separation member c1 is arranged in contact with the protective film 2 .
  • FIG. 5 is a perspective view of a roll c111 having a radius of 30 mm or less, which is the separation member c1.
  • the roll used as the separation member c1 will be referred to as a "separation roll c111" in order to distinguish it from guide rolls and the like.
  • the separation roll c111 has, for example, a cylindrical portion c112 and a pair of shaft portions c113 provided on both sides of the cylindrical portion c112. As shown in FIG. 2, the shaft c113 of the separation roll c111 is attached to the bearing c114 fixed to the frame of the manufacturing apparatus A or the like.
  • the cylindrical portion c112 includes a cylindrical body whose peripheral surface is made of metal such as stainless steel, and a cylindrical body whose peripheral surface is made of rubber (including elastomer) or synthetic resin.
  • the columnar portion c112 of the separation roll c111 extends parallel to the width direction and is in contact with the protective film 2 of the original roll 1 .
  • the columnar portion c112 of the separation roll c111 forms an arcuate surface portion c12 having a radius of curvature of 30 mm or less at any point on its peripheral surface (because it is circular when viewed from the side).
  • the radius of the cylindrical portion c112 of the separation roll c111 is preferably 25 mm or less, more preferably 20 mm or less.
  • the lower limit of the radius of the columnar portion c112 of the separation roll c111 exceeds zero, but the practical numerical value is 1 mm or more, preferably 3 mm or more.
  • the separation roll c111 may be rotatable (rotatable) or non-rotatable. In order to pull out the protective film 2 smoothly, the separation roll c111 is preferably rotatable. In this case, the shaft portion c113 of the separation roll c111 may be rotatably supported by the bearing c114, or the shaft portion c113 may be fixed to the bearing c114 and the cylindrical portion c112 may be rotatably attached to the shaft portion c113. may have been
  • the tension control unit c2 includes a driving roll c21 arranged in a path for pulling out the protective film 2, and a tension detector c22 arranged between the separating member c1 and the driving roll c21 and measuring the tension of the protective film 2. and a controller (not shown) including a computer that controls the tension of the protective film 2 based on the tension measured by the tension detector c22.
  • the drive roll c21 is not particularly limited, and for example, a suction roll, a nip roll, or the like can be used.
  • FIG. 1 illustrates a case where a suction roll is used as the drive roll c21.
  • the suction roll is a roll having numerous suction holes on its peripheral surface, through which the protective film 2 can be pulled out while being sucked.
  • the drive roll c21 such as a suction roll or a nip roll is also called a tension cut roll.
  • the tension controller c2 draws out the protective film 2 while controlling the variation width of the tension of the protective film 2 to be equal to or less than a predetermined value.
  • the pulled-out protective film 2 is conveyed through the pulling-out route and finally wound up on the collection section c4.
  • the tension of the protective film 2 to be controlled is the tension of the protective film 2 between the separating member c1 and the drive roll c21.
  • the length of the protective film 2 from the separating member c1 to the driving roll c21 (path length between the separating member c1 and the driving roll c21) can be set as appropriate. The longer the distance from the separating member c1 to the driving roll c21, the more uniform the thickness of the functional layer can be formed.
  • the length of the protective film 2 from the separating member c1 to the driving roll c21 is long.
  • the length of the protective film 2 between the separating member c1 and the drive roll c21 is 1 m or longer, preferably 5 m or longer, and more preferably 10 m or longer.
  • a realistic numerical value is, for example, 30 m or less.
  • a method for controlling the tension of the protective film 2 includes changing the rotation speed of the drive roll c21 based on the tension of the protective film 2 measured by the tension detector c22.
  • the rotational speed of the feed roll b31 on the upstream side is controlled by the conveying device B for the original fabric 1. As shown in FIG.
  • the control unit (not shown) of the protective film 2 changes the rotation speed of the drive roll c21 based on the measured tension of the protective film 2 (that is, the peripheral speed of the drive roll c21 and the upstream side By changing the difference in the peripheral speed of the feed roll b31), the tension of the protective film 2 is changed, and the fluctuation range is controlled to be equal to or less than a predetermined value.
  • the drive roller c21 is a nip roll
  • the drive roller c21 (nip roll) can also serve as the separation member c1. That is, a driving roller or a driven roller of a nip roll can be used as the separating member c1.
  • the length of the protective film 2 between the separating member c1 and the driving roll c21 is 0 m.
  • the guide roll c3 is arranged in the path for pulling out the protective film 2 between the separation member c1 and the recovery section c4.
  • One guide roll c3 may be arranged at an appropriate location, but usually two or more are arranged at an appropriate location.
  • at least the guide roll c3 in contact with the bonding adhesive layer 22 is preferably a non-adhesive guide roll.
  • the guide roll c31 among the guide rolls c3 is in contact with the adhesive layer 22 for bonding.
  • a non-adhesive guide roll refers to a roll to which an adhesive does not or hardly adheres to its peripheral surface.
  • Non-adhesive guide rolls include, for example, a roll whose peripheral surface is coated with silicone rubber, a roll whose peripheral surface is coated with silicone resin, a roll whose peripheral surface is coated with fluororesin, and a sandblasted peripheral surface. A roll or the like roughened by can be used.
  • the collection part c4 is a part for winding the pulled out protective film 2, and for example, an actuator such as a geared motor having a winding shaft is used.
  • the raw material 1 is separated into the processing raw material 11 including the material to be processed 3 and the protective film 2 on the delivery side of the arc surface portion c12 of the separation member c1 (separation roll c111). separated into The pulled-out protective film 2 is wound up from the drive roll c21 to the collecting portion c4 while curving along the peripheral surface of the circular arc surface portion c12.
  • the raw material 11 for processing is transported by the transport device B. As shown in FIG.
  • the withdrawal speed (recovery speed) of the protective film 2 is substantially equal to the transport speed of the original film 1 .
  • an angle (this angle is referred to as a "peeling angle") formed by the conveying direction of the processing material 11 and the drawing direction of the protective film 2 is appropriately set.
  • the conveying direction of the processing material 11 including the material 3 to be processed is indicated by a two-dot chain line
  • the drawing direction of the protective film 2 is indicated by a one-dot chain line
  • the peeling angle is indicated by the symbol ⁇ .
  • the peeling angle increases, the speed fluctuation of the material to be processed 3 (raw material 11 for processing) can be more suppressed. Therefore, it is preferable that the peeling angle is large.
  • the lower limit of the peeling angle ⁇ is, for example, 45 degrees or more, preferably 60 degrees or more, and more preferably 70 degrees or more.
  • the upper limit of the peeling angle ⁇ is, for example, 180 degrees or less, preferably 150 degrees or less, and more preferably 120 degrees or less.
  • the peeling angle ⁇ can be adjusted (the peeling angle can be increased or decreased), for example, by changing the position of the drive roll c21.
  • the example shown in FIG. 1 shows the case where the peeling angle is approximately 90 degrees.
  • one or more guide rolls may be arranged between the separating member c1 and the drive roll c21 (not shown). When the guide rolls are arranged in this manner, the peeling angle can be adjusted by changing the position of the guide roll on the side closer to the separation member c1.
  • the coating device D is a device that applies a coating liquid to the exposed surface of the material 3 to be treated.
  • the coating device D is not particularly limited as long as it can coat the surface of the material 3 to be treated with the coating liquid.
  • a slot die coater d1 is illustrated as the coating device D.
  • a die lip of the slot die coater d1 is arranged to face the surface of the material 3 to be treated.
  • a back roll d2 is arranged on the opposite side of the die lip with the processing material 11 interposed therebetween.
  • the conveying length of the material to be treated 3 (raw material 11 for treatment) from the peeling device C to the coating device D can be appropriately set.
  • the conveying length is also called path length.
  • the conveying length is 1 m or more, preferably 5 m or more, and more preferably 10 m or more.
  • a realistic numerical value is, for example, 20 m or less.
  • the non-contact transport conversion unit b34 By providing the , it is possible to prevent an increase in the size of the apparatus while ensuring a relatively long conveying length.
  • the non-contact transfer conversion part b34 while the material to be treated 3 (original fabric 11 for treatment) is being conveyed from the peeling device C to the coating device D, the surface of the material to be treated 3 is brought into contact with foreign matter. can be prevented. Therefore, a functional layer having a substantially uniform thickness can be formed by coating the surface of the material 3 to be treated with the coating liquid without damaging the surface thereof.
  • the curing device E is arranged downstream of the coating device D as required.
  • a curing device E is provided to change the coating liquid from a liquid state to a solid state. If the coating liquid naturally changes to a solid state while the processing material 11 after being coated with the coating liquid is conveyed, the curing device E may be omitted. good.
  • the curing device E has, for example, a drying processing section e1.
  • the drying processing section e1 is not particularly limited as long as it can dry the coating liquid, and for example, a blower that blows hot air or normal temperature air, a far-infrared heater, or the like is used.
  • the curing device E has a curing processing section e2 that irradiates light such as ultraviolet rays.
  • the bonding portion F is a portion where an appropriate film 43 such as a protective film is attached to the original product 12 (processing original 11 on which the functional layer is formed).
  • the bonding section F has a supply roll f1 for unwinding a suitable film 43 and a nip roll f2 for bonding the film 43 to the original product 12 .
  • the manufacturing method of the functional layer includes a step of conveying a long strip-shaped original fabric 1 having a material to be processed 3 and a protective film 2, and separating the protective film 2 by a separating member c1 arranged in a conveying path of the original fabric 1. It has a step of peeling the protective film 2 from the material to be treated 3 by pulling it out, and a step of applying a coating liquid to the surface of the material to be treated 3 exposed by peeling the protective film 2 .
  • the manufacturing method of the present invention is carried out using, for example, a manufacturing apparatus A as shown in FIG.
  • the raw fabric 1 is unwound from the unwinding section b1 and conveyed by the conveying section b3.
  • the conveying speed of the original fabric 1 is not particularly limited, and is, for example, 3 m/min or more and 30 m/min or less, preferably 5 m/min or more and 20 m/min or less.
  • the original fabric 1 is conveyed while controlling the fluctuation width of the tension of the original fabric 1 to be equal to or less than a predetermined value. From the viewpoint of suppressing the speed fluctuation of the material 3 to be processed (raw material 11 for processing), it is preferable that the fluctuation width of the tension of the material 1 is as small as possible.
  • the variation width of the tension refers to the variation width of the tension of the original fabric 1 in a time shorter than the transport time of the entire length of the original fabric 1 to be controlled.
  • time means the length of time between certain points in time (length of time).
  • the total length of the raw fabric 1 to be controlled is the length in the longitudinal direction of the raw fabric 1 conveyed from the start of the tension control to the end of the control.
  • the ⁇ overall length of the original fabric to be controlled'' is referred to as the ⁇ control length of the original fabric''
  • the ⁇ period from the start of the tension control to the end of the control'' is referred to as the ⁇ entire control period''.
  • a specific value of the fluctuation width of the tension of the original fabric 1 can be represented by, for example, a standard deviation within a predetermined period of time.
  • the standard deviation (SD1-1) of the tension of the raw fabric 1 for the first time is 0.04 MPa or less, preferably 0.02 MPa or less, and more preferably 0.01 MPa or less.
  • the standard deviation (SD2-1) of the tension of the raw fabric 1 at the second time is 0.04 MPa or less, preferably 0.02 MPa or less, and more preferably 0.01 MPa or less.
  • the lower limits of the standard deviations (SD1-1) and (SD2-1) are theoretically zero, but usually exceed zero.
  • the first time means a fixed time from the start of tension control of the original fabric 1 .
  • the first time is a time corresponding to a length of 2% or more and 5% or less of the control length of the original fabric 1 from the start of tension control of the original fabric 1 .
  • the second time means a fixed time until the control of the tension of the raw material 1 is finished.
  • the second time is a time corresponding to 2% or more and 5% or less of the control length of the material 1 until the tension control of the material 1 is finished.
  • the tension value does not stabilize immediately after starting the control of the tension of the raw material 1, the time when the control is started is not the time when the control is started in a strict sense, but means the time when the operation is stabilized after the start of the control.
  • the original fabric 1 is conveyed while controlling the tension so that the tension of the original fabric 1 is substantially constant during the entire control period.
  • the expression that the tension is substantially constant means that when the entire control period is equally divided into a plurality of times, each average tension in the plurality of times exhibits substantially the same value.
  • the expression that each of the average tensions exhibits substantially the same value means, for example, that the absolute value of the difference between the maximum value and the minimum value of the average tensions at the plurality of times is 0.2 MPa or less, preferably 0.09 MPa. Examples include the following cases.
  • control is performed so that the absolute value of the difference between the average tension of the raw fabric 1 at the first time and the average tension of the raw fabric 1 at the second time is 0.09 MPa or less, preferably 0.05 MPa or less. It is Note that the lower limit of the absolute value is zero. If the difference between the average tension in the first period of time, which is a certain period of time from the start of control, and the average tension in the second period of time, which is a period of time until the end of control, is a small value as described above, the entire control period It can be estimated that the tension of the original fabric 1 is substantially constant at .
  • the tension per unit cross-sectional area of the original fabric 1 during transportation is not particularly limited, and is set, for example, in the range of 0.5 MPa or more and 2.9 MPa or less, preferably 0.8 MPa or more and 2.6 MPa or less. is set within
  • each unit "MPa" of the tension, the average tension, and the standard deviation of the tension of the raw fabric 1 represents the tension per unit cross-sectional area of the cross section of the raw fabric perpendicular to the thickness direction.
  • FIG. 6 shows a state in which the protective film 2 is peeled off from the raw fabric 1 having the layer structure shown in FIG. 3(a) at the separation member c1, and FIG. It shows a state in which the protective film 2 is peeled off from the roll 1 by the separation member c1.
  • the protective film 2 has the bonding adhesive layer 22 and the film substrate 21 .
  • the protective film 2 when the protective film 2 is pulled out, it is separated at the interface between the bonding adhesive layer 22 and the material to be treated 3 (first material to be treated 31) on the output side of the separation member c1.
  • the protective film 2 does not have the bonding adhesive layer 22 . Therefore, when the protective film 2 is pulled out, it is separated at the interface between the protective film 2 (film substrate 21) and the material to be treated 3 (second material to be treated 32) on the output side of the separation member c1.
  • the material to be treated 3 (the first material to be treated 31 and the second material to be treated 32) is not particularly limited.
  • a film having an orientation regulating force such as a stretched film
  • an adhesive layer can be used as the second material 32 to be treated.
  • the stretched film which is a film having the orientation regulating force, is not particularly limited, and may be a cycloolefin resin film, a cellulose resin film, a polyester, a polyarylate, an ester resin film having an ester bond in the main chain such as a polycarbonate, or an acrylic film. resin film, styrene resin film, and the like.
  • the stretching method of the stretched film is not particularly limited.
  • a method of uniaxially stretching the film before stretching in the longitudinal direction (longitudinal uniaxial stretching method), a method of uniaxially stretching the film before stretching in the width direction (horizontal uniaxial stretching method).
  • a uniaxial stretching method such as; a simultaneous biaxial stretching method in which the film before stretching is stretched in the longitudinal direction and in the width direction at the same time, and a sequential biaxial stretching method in which the film before stretching is stretched in one of the longitudinal direction and the width direction and then stretched in the other direction.
  • biaxial stretching method such as stretching method; method of stretching the film before stretching in an oblique direction neither parallel nor perpendicular to the width direction (diagonal stretching method); and the like.
  • a stretched film generally has an orientation regulating force for homogeneously orienting a liquid crystal compound in a direction parallel to the stretching direction.
  • a coating liquid containing a liquid crystal compound is applied to the surface of such a stretched film, a functional layer is formed in which the liquid crystal compound is oriented parallel to the stretching direction.
  • a stretched film a known film or a film that became known after the present invention can be used.
  • a stretched film described in JP-A-2020-183980 can be used.
  • JP-A-2020-183980 for details of the stretched film, refer to the above-mentioned publication.
  • the adhesive layer which is the second material to be treated 32, is made of a transparent adhesive material.
  • adhesive base materials that form the adhesive layer include acrylic adhesives, rubber adhesives, silicone adhesives, polyester adhesives, urethane adhesives, epoxy adhesives, and polyether adhesives. Adhesives and the like can be mentioned. From the viewpoint of transparency, workability, durability, etc., it is preferable to use an acrylic pressure-sensitive adhesive.
  • the pressure-sensitive adhesive layer a known pressure-sensitive adhesive layer or a pressure-sensitive adhesive layer that became known after the present invention can be used.
  • the base adhesive section described in Japanese Patent No. 6194358 can be used as the adhesive layer (second treated material 32) of the present invention.
  • the base pressure-sensitive adhesive category refer to the above publication.
  • the protective film 2 is pulled out along the arc surface portion c12 of the separation member c1.
  • the protective film 2 and the material to be treated 3 are separated at one point (branching point S) on the peripheral surface of the arc surface portion c12 of the separation member c1, and the surface of the material to be treated 3 is exposed.
  • a blank 11 and a protective film 2 are produced.
  • the raw material 11 for processing is conveyed to the coating device D by the conveying device B, and the protective film 2 that has been peeled off is pulled out along the arc surface portion c12 of the separating member c1 and collected in the collecting portion c4. .
  • the protective film 2 is pulled out while controlling the fluctuation range of the tension of the protective film 2 to be equal to or less than a predetermined value.
  • the tension of the protective film 2 to be controlled refers to the tension of the protective film 2 between the separation member c1 and the drive roll c21. From the viewpoint of suppressing the speed fluctuation of the material to be treated 3 (raw material 11 for treatment), it is preferable that the fluctuation width of the tension of the protective film 2 is as small as possible.
  • the variation width of the tension refers to the variation width of the tension of the protective film 2 in a time period shorter than the pulling-out time of the entire length of the protective film 2 to be controlled.
  • the total length of the protective film 2 to be controlled is the longitudinal length of the protective film 2 pulled out from the start of tension control to the end of the control.
  • the "total length of the protective film to be controlled” will be referred to as the “control length of the protective film”
  • the period from the start of the tension control to the end of the control will be referred to as the "entire control period”.
  • a specific value of the fluctuation width of the tension of the protective film 2 can be represented by a standard deviation within a predetermined time, for example.
  • the standard deviation (SD1-2) of the tension of the protective film 2 for the first hour is 0.01 MPa or less, preferably 0.008 MPa or less, and more preferably 0.007 MPa or less.
  • the standard deviation (SD2-2) of the tension of the protective film 2 for the second time is 0.01 MPa or less, preferably 0.008 MPa or less, and more preferably 0.007 MPa or less.
  • the lower limits of the standard deviations (SD1-2) and (SD2-2) are theoretically zero, but usually exceed zero.
  • the absolute value of the difference between the standard deviation of the tension of the protective film 2 for the first time (SD1-2) and the standard deviation of the tension of the protective film 2 for the second time (SD2-2) is, for example, It is 0.005 MPa or less, preferably 0.003 MPa or less. With such a difference, the fluctuation width of the tension between the first time and the second time does not substantially change, and the protective film can be pulled out stably.
  • the first time means a certain time from the start of tension control of the protective film 2 .
  • the first time is a time corresponding to a length of 2% or more and 5% or less of the control length of the protective film 2 from the start of tension control of the protective film 2 .
  • the second time means a certain time until the control of the tension of the protective film 2 is finished.
  • the second time is a time corresponding to 2% or more and 5% or less of the controlled length of the protective film 2 until the control of the tension of the protective film 2 is completed.
  • the tension value does not stabilize immediately after starting the control of the tension of the protective film 2
  • the time when the control is started is not the time when the control is started in a strict sense, but the time when the operation stabilizes after the start of the control.
  • the standard deviation of the tension of the protective film 2 at any given time during the tension control of the protective film 2 is 0.01 MPa or less (preferably 0.008 MPa or less, more preferably 0.007 MPa or less). It is more preferable to pull out the protective film 2 .
  • the arbitrary fixed time is, for example, a time corresponding to a length of 2% or more and 5% or less of the control length of the protective film 2, and the starting point of the time is while the protective film 2 is being controlled. It means that any point in time is acceptable.
  • the arbitrary fixed time may be the above-described first time, or the above-described second time, or other time. If the standard deviation of the tension of the protective film 2 at any given time during the tension control of the protective film 2 is 0.01 MPa or less, the fluctuation range of the tension throughout the control is substantially unchanged, and the protective film is stably stretched. pulled out.
  • the protective film 2 is pulled out while controlling the tension so that the tension of the protective film 2 is substantially constant during the entire control period.
  • the expression that the tension is substantially constant means that when the entire control period is equally divided into a plurality of times, each average tension in the plurality of times exhibits substantially the same value.
  • the expression that each of the average tensions exhibits substantially the same value is, for example, the case where the absolute value of the difference between the maximum value and the minimum value of each of the average tensions at the plurality of times is 0.3 MPa or less. be done.
  • the absolute value of the difference between the average tension of the protective film 2 for the first time and the average tension of the protective film 2 for the second time is 0.3 MPa or less, preferably 0.1 MPa or less, more preferably 0.1 MPa or less. It is controlled to be 05 MPa. Note that the lower limit of the absolute value is zero. If the difference between the average tension in the first period of time, which is a certain period of time from the start of control, and the average tension in the second period of time, which is a period of time until the end of control, is a small value as described above, the entire control period , it can be estimated that the tension of the protective film 2 is substantially constant.
  • the tension per unit cross-sectional area of the protective film 2 to be controlled is not particularly limited.
  • each unit “MPa" of the tension, the average tension and the standard deviation of the tension of the protective film 2 represents the tension per unit cross-sectional area of the film cross section perpendicular to the thickness direction.
  • the protective film 2 pulled out by the drive roll c21 is wound up on the collection part c4. Since the drive roll c21 is a tension cut roll, the tension of the protective film 2 between the drive roll c21 and the recovery section c4 does not affect the tension between the drive roll c21 and the separation member c1. Therefore, the tension of the protective film 2 between the driving roll c21 and the collection part c4 may or may not be controlled.
  • the collection part c4 should be able to wind the protective film 2 pulled out by the drive roll c21. For example, the recovery part c4 winds up the protective film 2 with a constant torque.
  • the processing material 11 with the exposed surface of the material 3 to be processed is conveyed downstream.
  • the processing material 11 is conveyed to the coating device D via the non-contact conveying conversion section b34.
  • a coating liquid is applied to the surface of the material to be treated 3 by a coating device D.
  • the coating liquid is not particularly limited, and any suitable one can be used according to the functional layer to be formed.
  • a coating liquid containing a liquid crystal compound is used.
  • the liquid crystal compound is preferably a polymerizable liquid crystal compound, and as an example of such a polymerizable liquid crystal compound, for example, a polymerizable liquid crystal compound described in JP-A-2020-183980 can be used.
  • a polymerizable liquid crystal compound described in JP-A-2020-183980 can be used for the details of the polymerizable liquid crystal compound, the coating liquid containing the same, and the alignment method of the polymerizable liquid crystal compound, etc., reference is made to the above publication.
  • a coating liquid containing a refractive index adjusting material is used.
  • a coating liquid containing a refractive index adjusting material for example, a dispersion liquid in which a high refractive index material described in Japanese Patent No. 6194358 is dispersed in a solvent can be used.
  • the coating thickness (thickness of the coating film) of the coating liquid is not particularly limited, and is, for example, 5 nm or more and 30 ⁇ m.
  • the coating thickness is, for example, 0.5 ⁇ m or more and 30 ⁇ m or less, preferably 1 ⁇ m or more and 15 ⁇ m or less.
  • the coating thickness is, for example, 5 nm or more and 10 ⁇ m or less, preferably 10 nm or more and 5 ⁇ m or less.
  • the coating film is dried in the drying processing section e1, if necessary.
  • the drying method is not particularly limited, and includes natural drying, heat drying, reduced pressure drying and the like.
  • light such as ultraviolet light is irradiated in the curing processing section e2.
  • a functional layer is formed on the surface of the material 3 to be treated. This functional layer is continuously formed in the longitudinal direction of the material 3 to be treated as the raw material 1 is conveyed.
  • the material 3 to be treated is a film having the alignment regulating force and the coating liquid contains the liquid crystal compound
  • a retardation layer (functional layer) is formed on the surface of the material 3 to be treated.
  • the material 3 to be treated is the adhesive layer and the coating liquid contains the refractive index adjusting material
  • a partition layer for adjusting the refractive index is formed.
  • a film 43 (protective film or the like) is bonded at a bonding portion F to the surface of the functional layer of the original product 12 on which the functional layer is formed.
  • the obtained raw product fabric 12 is wound on the winding part b2.
  • the speed fluctuation of the material 3 to be processed when the protective film 2 is peeled off from the material 3 to be processed is suppressed. can.
  • the branch point S (the dividing point between the protective film 2 and the material to be treated 3) is less likely to shift toward the drawer side of the protective film 2. .
  • the branch point S shifts to the drawer side of the protective film 2 (in FIGS.
  • the force component in the conveying direction generated in the material to be processed at the branch point S due to the pulling of the protective film 2 is maximized. becomes smaller. Therefore, it is possible to suppress the speed fluctuation of the material to be processed 3 (raw material 11 for processing). Since the material to be treated 3 (original fabric 11 for treatment) is less likely to cause speed fluctuations, uneven coating of the coating liquid on the surface of the material to be treated 3 is less likely to occur, and a functional layer having a substantially uniform thickness can be formed. In other words, when the conveying speed of the material to be treated is fast, the coating thickness of the coating liquid is thin, and when it is slow, the coating thickness is thick. It can prevent unevenness.
  • the material to be treated follows the protective film and deviates greatly toward the drawer side. It is presumed that the speed fluctuation of the material to be treated increases due to the recoil when the protective film separates. Furthermore, by pulling out the protective film 2 with a peeling angle of 60 degrees or more and 180 degrees or less, it is possible to further suppress speed fluctuations of the material to be treated 3 . In addition, since the conveying length of the material to be treated 3 (raw material 11 for treatment) from immediately after peeling off the protective film 2 to just before applying the coating liquid is set to 1 m or longer, the protective film 2 can be peeled off. Even if the material to be treated 3 slightly fluctuates in speed when the coating is applied, the fluctuation can be prevented from affecting the vicinity of the coating device D.
  • the speed fluctuation of the material 3 to be treated can be effectively suppressed.
  • the tension when the protective film is pulled out varies greatly, the material to be treated is alternately pulled strongly toward the pull-out side and weaker than that due to the variation in tension. Therefore, it is presumed that the velocity fluctuation of the material to be treated increases when the protective film is pulled out.
  • the speed fluctuation of the material to be processed 3 (raw material 11 for processing) when the protective film 2 is pulled out can be effectively suppressed. Furthermore, by conveying the original fabric 1 while controlling the fluctuation range of the tension of the original fabric 1 to be equal to or less than a predetermined value, the speed of the original fabric 1 (processing original fabric 11) when the protective film 2 is pulled out Variation can be suppressed more. In particular, when the tension of the protective film 2 is controlled to be substantially constant over the entire control period, it is possible to further suppress speed fluctuations of the original fabric 1 (processing original fabric 11) when the protective film 2 is pulled out.
  • the length of the protective film 2 from the separation member c1 to the driving roll c21 is set to 1 m or more, even if the protective film 2 flutters due to the driving roll c21, the fluttering is treated. It becomes difficult to propagate to the material 3.
  • the speed fluctuation of the material to be treated 3 (raw material 11 for treatment) can be suppressed, uneven coating of the coating liquid on the surface of the material to be treated 3 is difficult to occur, and the thickness of the material to be treated is substantially uniform. Functional layers can be formed continuously.
  • a roll (separation roll c111) is used as the separation member c1.
  • a separating member c1 having protruding ends may be used.
  • a projecting end c14 of the separation member c1 includes an arcuate surface c12 having a radius of curvature of 30 mm or less.
  • the projecting end portion c14 including the arc surface portion c12 extends in the width direction of the raw fabric 1.
  • the separation member c1 has a plate-like body having a projecting end portion c14 with an arcuate surface portion c12 at the tip.
  • the tip of the projecting end c14 forms an arcuate surface c12 with a radius of curvature of 30 mm or less.
  • the separation member c1 is fixed to the frame of the manufacturing apparatus A or the like.
  • a projecting end portion c14, which is the arc surface portion c12 of the separation member c1 has a small radius of curvature.
  • the thickness W of the projecting end portion c14, which is the circular arc surface portion c12 is 2 mm or more and 5 mm or less, and the radius of curvature thereof is 0.5 mm or more and 5 mm or less.
  • the protective film 2 may be pulled out from the separation member c1 having such a projecting end c14 and peeled off from the material 3 to be processed.
  • FIG. 9 illustrates a case where the protective film 2 is pulled out at a peeling angle ⁇ exceeding 90 degrees by bending and conveying the processing material 11 .
  • the protective film 2 is pulled out by the drive roll c21 while controlling the tension of the protective film 2, but the protective film 2 may be pulled out without controlling the tension.
  • a guide roll c33 (not having the drive roll c21) is arranged between the separation member c1 and the collection section c4.
  • the protective film 2 is pulled out by the winding force of the collection portion c4 and separated from the material to be treated 3 by the separation member c1.
  • the collecting part c4 may be rotated to such an extent that the protective film 2 can be wound up without loosening.
  • the recovery part c4 is rotated with a constant torque.
  • Example 1 [manufacturing device] As shown in FIG. 10, a manufacturing apparatus A equipped with a conveying apparatus B, a peeling apparatus C for peeling, a coating apparatus D, a curing apparatus E and a bonding apparatus F was used. Briefly explaining other than the peeling device, the conveying device uses a device that conveys the original fabric while controlling the tension so that the fluctuation range of the tension of the original fabric is small and the tension of the original fabric is substantially constant. bottom.
  • a coating device an existing slot die coater was used, as a curing device, an existing drying device and an existing ultraviolet irradiation device were used, and as a bonding device, an existing device for bonding separator films was used.
  • the peeling device uses a roll with a radius of 5 mm (a roll in which the peripheral surface of a metal core material is covered with rubber) as a separation member, and as a collection unit, it is peeled off at a constant torque without controlling the tension of the protective film.
  • An existing actuator for winding the protective film on the winding shaft was used.
  • the original fabric includes a bonding adhesive layer (acrylic adhesive), a film substrate (a transparent polyethylene terephthalate film with a thickness of 80 ⁇ m), and a material to be treated (stretched in an oblique direction).
  • a bonding adhesive layer (acrylic adhesive)
  • a film substrate a transparent polyethylene terephthalate film with a thickness of 80 ⁇ m
  • a material to be treated (stretched in an oblique direction).
  • the width of the original fabric was about 1300 mm.
  • the coating liquid the coating liquid containing the liquid crystal compound used in Example A1 of JP-A-2020-183980 was used.
  • Example 2 In the same manner as in Example 1, except that the separation member was changed to a roll with a radius of 25 mm (a roll in which the peripheral surface of a metal core material was coated with rubber), while conveying the original fabric, the protective film was removed. It was peeled off, and the coating liquid was applied to continuously produce a raw product.
  • Example 2 [Evaluation of functional layer in Example 2] Also in Example 2, the functional layer was visually evaluated in the same manner as in Example 1. The functional layer of Example 2 did not show much difference in color shading, but compared with the functional layer of Example 1, there was a slight difference in color shading. Also in Example 2, it could be evaluated that a functional layer having a substantially uniform thickness was formed.
  • Example 3 In the same manner as in Example 1, except that the peeling angle of the protective film was changed to 50 degrees, the protective film was peeled off while the raw material was conveyed, and the coating liquid was applied to continuously produce the product raw material. was made.
  • Example 3 [Evaluation of functional layer of Example 3] Also in Example 3, the functional layer was visually evaluated in the same manner as in Example 1. The functional layer of Example 3 did not show much difference in color shading, but compared with the functional layer of Example 1, there was a slight difference in color shading. Also in Example 3, it could be evaluated that a functional layer having a substantially uniform thickness was formed.
  • a Manufacturing device B Conveying device b34 Non-contact conveying conversion unit C Peeling device c1 Separating member c12 Arc surface portion of separating member c14 Protruding end portion of separating member c2
  • Tension control unit c21 Drive roll D Coating device 1, 11, 12 Original roll 2 Protective film 3, 31, 32 Material to be treated

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating Apparatus (AREA)
PCT/JP2022/026561 2021-07-15 2022-07-04 機能層の製造方法、及びその製造装置 WO2023286645A1 (ja)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013205545A (ja) * 2012-03-28 2013-10-07 Sumitomo Chemical Co Ltd 粘着剤付き光学部材の製造方法
JP2016167075A (ja) * 2012-11-16 2016-09-15 日東電工株式会社 偏光板の製造方法
WO2020138212A1 (ja) * 2018-12-27 2020-07-02 日本ゼオン株式会社 フィルムの製造方法、及び製造装置並びに液晶硬化フィルムの製造方法

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JP4701488B2 (ja) 2000-10-12 2011-06-15 Ｔｄｋ株式会社 ハードコート層付きポリカーボネートフィルムの製造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013205545A (ja) * 2012-03-28 2013-10-07 Sumitomo Chemical Co Ltd 粘着剤付き光学部材の製造方法
JP2016167075A (ja) * 2012-11-16 2016-09-15 日東電工株式会社 偏光板の製造方法
WO2020138212A1 (ja) * 2018-12-27 2020-07-02 日本ゼオン株式会社 フィルムの製造方法、及び製造装置並びに液晶硬化フィルムの製造方法

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