JP-7855918-B2 - Coating method, method for manufacturing multilayered material, coating apparatus, and multilayered material manufacturing apparatus

Inventors

• 平野 祐哉

Assignees

• 日本ゼオン株式会社

Dates

Publication Date

20260511

Application Date

20220516

Claims (18)

1. A method for applying a coating solution to a long web having a first surface and a second surface, The process includes a transport step of continuously transporting the web along a transport path, and a coating step (A) of using a bar (A) that rotates around an axis (A) to guide a coating liquid (A) to the first surface at a coating position (A) along the transport path, and continuously applying the coating liquid (A) to the first surface. In the coating process (A), the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web. The coating step (A) includes pressing the bar (A) against the first surface and applying pressure to the web from the second surface side to the first surface side in a pressurized region (A) including the coating position (A) of the transport path, The pressurization step (Ap) is a coating method comprising blowing a gas onto the second surface .
2. The coating method according to claim 1 , wherein the pressurization step (Ap) is performed by a floating conveying device that has a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface has a porous material surface.
3. The coating method according to claim 1, wherein the pressurizing step (Ap) is performed by pressurizing devices (Ap) provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region ( A ) are on the same plane.
4. The coating method according to claim 1, wherein the coating step (A) further includes a separation step (As) in which pressure is applied to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A).
5. The coating method according to claim 1, wherein the bar (A) is a gravure roll, and the coating step (A) includes scraping off the coating liquid from the gravure roll with a blade.
6. A method for manufacturing a multilayered material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, A coating step (A) comprising applying the coating liquid (A) continuously to the first surface of the web by the coating method described in any one of claims 1 to 5 to form a coating film (A), and a curing step (A) of curing the coating film (A). A method for manufacturing a multilayered material, including the method described above.
7. A coating step (B) is performed in which, at a coating position (B) downstream of the coating position (A) in the transport path, a bar (B) that rotates around an axis (B) is used to guide the coating liquid (B) to the second surface, and the coating liquid (B) is continuously applied to the second surface to form a coating film (B); and a curing step (B) is performed to cure the coating film (B). It further includes, In the coating process (B), the extension direction of the axis (B) at the coating position (B) is at an angle of 5° to 30° with respect to the width direction of the web. The method for manufacturing a multilayer material according to claim 6, wherein the coating step (B) includes pressing the bar (B) against the second surface and applying pressure to the web from the first surface side to the second surface side in a pressurized region (B) of the transport path that includes the coating position (B ) .
8. The method for manufacturing a multilayer material according to claim 7 , wherein the curing step (A) and the curing step (B) are performed in a curing apparatus provided at a position downstream of the coating position (B) in the transport path.
9. The curing step (A) is performed in a curing device (A) located downstream of the coating position (A) and upstream of the coating position (B) in the transport path. The method for manufacturing a multilayer material according to claim 7 , wherein the curing step (B) is performed in a curing device (B) located downstream of the coating position (B) in the transport path.
10. A coating apparatus for applying a coating liquid to a long web having a first surface and a second surface, A conveying device that continuously conveys the aforementioned web along a conveying path, A bar (A) provided at the coating position (A) of the transport path, which rotates about an axis (A) to guide the coating liquid (A) to the first surface and continuously coats the coating liquid (A) to the first surface, wherein the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web and is provided so as to be in contact with the first surface, and a pressurizing device (Ap) provided in the pressurizing region (A) of the transport path including the coating position (A), which applies pressure to the web from the second surface side to the first surface side . The pressurizing device (Ap) is a coating device that blows gas onto the second surface .
11. The coating apparatus according to claim 10 , wherein the pressurizing device (Ap) is a floating conveying device comprising a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface is the surface of a porous material.
12. The coating apparatus according to claim 10, wherein the pressurizing device (Ap) is provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying device is provided such that the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region ( A ) are on the same plane.
13. The coating apparatus according to claim 10, further comprising a separation device (As) that applies pressure to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A).
14. The coating apparatus according to claim 10 , wherein the bar (A) is a gravure roll, and further comprises a blade capable of scraping the coating liquid off the gravure roll.
15. A multilayer manufacturing apparatus for producing a multilayer material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, A coating apparatus according to any one of claims 10 to 14 , comprising: a coating apparatus (A) for continuously applying the coating liquid (A) to the first surface of the web to form a coating film (A); and a curing apparatus (A) provided downstream of the coating apparatus (A) for curing the coating film (A). A multilayer manufacturing apparatus, including a multilayer material manufacturing apparatus.
16. Located downstream of the coating device (A) in the aforementioned transport path, A coating device (B) for continuously applying a coating liquid (B) to the second surface of the web to form a coating film (B), and a curing device (B) provided downstream of the coating device (B) for curing the coating film (B). Furthermore, The coating apparatus (B) is A bar (B) provided at a coating position (B) downstream of coating position (A) in the transport path, which rotates about an axis (B) to guide the coating liquid (B) to the second surface and continuously coats the coating liquid (B) to the second surface, wherein the extension direction of the axis (B) is at an angle of 5° to 30° with respect to the width direction of the web, and the bar (B) is provided so as to be in contact with the second surface, and a pressurizing device (Bp) is provided in the pressurizing region (B) of the transport path including the coating position (B), which applies pressure to the web from the first surface side to the second surface side. The multilayer manufacturing apparatus according to claim 15 .
17. The multilayer manufacturing apparatus according to claim 16 , further comprising a curing device that serves as both the curing device (A) and the curing device (B), and is provided at a position downstream of the coating position (B) in the transport path.
18. The curing device (A) is provided as a curing device (A) located downstream of the coating position (A) in the transport path and upstream of the coating position (B), The multilayer manufacturing apparatus according to claim 16 , further comprising a curing device (B) provided at a position downstream of the coating position (B) in the transport path.

Description

This invention relates to a method for applying a coating solution to a long, conveyed web, a method for manufacturing a multilayered material using this coating method, and a coating apparatus and a multilayered material manufacturing apparatus for the same purpose. In most cases, a cylindrical bar is used to apply coating liquid to a web, maintaining contact with the web surface. A typical example of such a bar is the bar used in a bar coater. In a typical bar coater, a portion of the bar is immersed in the stored coating liquid, while another portion is pressed against the web. The bar rotates around its axis, thereby guiding the coating liquid to the web surface and continuously applying it over a wide area. Furthermore, not limited to bar coaters, the gravure rolls in gravure coaters also guide the stored coating liquid to the web surface through a similar mechanism, and can therefore be considered a form of bar. Generally, a long web, such as a film, is continuously transported from upstream to downstream along a transport path. A coating solution is applied using a coating device installed along the transport path, forming a coating film on the web. This film is then cured by drying or other means, creating a layer of cured material. For this type of coating, there is a need for methods that achieve more uniform coating than conventional methods, for the purpose of improving quality. Therefore, modifications to existing manufacturing equipment are sometimes made. On the other hand, when modifying such manufacturing equipment, it is also necessary to utilize existing manufacturing equipment as much as possible and reduce the cost of modifying the manufacturing process. For example, a coating device called a vertical kiss-reverse system is known for achieving homogeneous coating, but this device can only coat webs that are conveyed in a vertical direction (i.e., parallel to the direction of gravity). In contrast, conventional coating devices using bar coaters generally coat webs that are conveyed in a horizontal direction (i.e., perpendicular to the direction of gravity) or a direction close to it. Therefore, from the perspective of utilizing existing manufacturing equipment as much as possible, there is a need for a coating device that can coat webs that are conveyed in a horizontal direction or a direction close to it, similar to conventional bar coaters, and that also offers improved coating homogeneity. In the application of a coating solution to a web using a bar, the bar's axis is usually positioned parallel to the web's width. However, it has also been proposed to position the bar's axis at an angle opposite to the web's width. For example, Patent Document 1 discloses a method in which a bar for scraping off the coating solution is positioned at an angle opposite to the web's width, and this angle is changed to adjust the coating thickness. Japanese Patent Application Publication No. 6-170313 Figure 1 is a schematic side view showing an example of a coating method of the present invention, a coating apparatus and manufacturing apparatus for carrying out the coating method of the present invention including the coating method, and a coating method and manufacturing method for a multilayered material using the same.Figure 2 is a top view showing a schematic, enlarged view of the coating apparatus 100A, which is a component of the manufacturing apparatus 10 shown in Figure 1.Figure 3 is a side view showing a cross-section of the coating apparatus 100A, obtained by cutting it with a plane perpendicular to the direction of arrow R3 in Figure 2.Figure 4 is a schematic top view showing the relationship between the pressurizing device (Ap), the bar (A), and the web when a free roll is used as the pressurizing device (Ap).Figure 5 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 4, combined from three cross-sections perpendicular to the direction of arrow R5 in Figure 4.Figure 6 is a schematic top view showing the relationship between the pressurizing device (Ap), the bar (A), and the web when a levitation conveying device is used as the pressurizing device (Ap).Figure 7 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 6, combined from three cross-sections perpendicular to the direction of arrow R6 in Figure 6.Figure 8 is a side view showing the bar 110A, the levitation conveying devices 151OA and 151DA, and the web 11 as observed from the direction of arrow R9U, as shown in Figure 2. The present invention will be described in detail below with reference to embodiments and examples, but the present invention is not limited to the embodiments and examples shown below, and may be modified and implemented as desired without departing from the scope of the claims and equivalents of the present invention. In this application, the "parallel" orientation of the components of the member for carrying out the method of the present invention