JP2007268384A - Applicator, application method and manufacturing method of optical film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an applicator and an application method by which vibration of a movable slot die can be effectively suppressed and to provide a manufacturing method of an optical film including a coating film obtained by the applicator and the application method. <P>SOLUTION: The applicator has a die support part 98 for supporting a die coater 18, a moving table 100, a stopper reception part 122, a ball screw 123 which moves a support pedestal according to rotation, a table position detector 125 for detecting a position of the moving table 100, a servomotor 124 for controlling rotation of the ball screw 123 based on detection result of the table position detector 125 and two or more stoppers 110, 112 which restrict movement of the support pedestal by contact with the stopper reception part 122. When the die coater 18 arranged at a predetermined application position ejects a coating solution to carry out application, the stopper reception part 122 is pressed to the stoppers 110, 112. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a coating apparatus, a coating method, and an optical film manufacturing method, and more particularly to a technique for suppressing vibration of the coating apparatus.

  Conventionally, as a coating device for coating a coating film (film) with a desired thickness on the surface of a web (support), a device using a die coater (slot die) for discharging a coating solution from a manifold through a slot has been widely used. Has been. There are various types of die coaters such as a slide coater, a fountain coater, an extrusion coater, and the like, and a high quality coating film is formed on the web by using a die coater according to the application.

  In order to form a high-quality coating film on the web, it is important to accurately adjust the distance between the die coater and the web and to apply the coating liquid from the die coater onto the web with high accuracy. For this reason, several devices and methods for adjusting the distance between the coating unit such as a die coater and the web have been proposed.

For example, Patent Document 1 discloses a moving device used in a curtain coating type coating device, and an AC servo, a positioner, and a position feedback mechanism are provided to realize the moving device. Patent Document 2 discloses a moving mechanism using a linear motor and an air slide. By this moving mechanism, the die cradle that supports the die head moves relative to the base. Patent Document 3 discloses a method for positioning a coating apparatus. In this positioning method, the movement position adjustment of the table is feedback controlled by a ball screw, a servo motor, and a position detection device. Further, Patent Document 4 discloses a die moving structure in a die coating apparatus, and the interval between the die and the base material is adjusted by a temporary stop disposed at a position where the die can be temporarily stopped.
JP-A-6-226179 JP 2003-62506 A JP 2004-223467 A JP-A-3-38272

  The above-described apparatus for adjusting the distance between the coating unit such as the die coater and the web has a mechanism for moving the movable unit such as the die, but the movable unit is more likely to vibrate than the fixed unit. The vibration of the movable part at the time of applying the coating liquid is not preferable because it may cause surface defects such as unevenness of the coating film formed on the web.

  For example, in each device described in Patent Documents 1 to 3, the position of a movable part such as a die coater is adjusted by a motor. In such an apparatus, the movable part is stopped and fixed by simply stopping the motor. However, from the viewpoint of accurately forming the coating film by suppressing vibration, such a method is effective for the movable part. The degree of fixation may be insufficient.

  Moreover, although the stop tool is used in the apparatus described in Patent Document 4, this stop tool is only used to stop the movement of the die, and is used to fix the position of the die. It is not something that can be done. Therefore, in this apparatus, it is difficult to accurately form the coating film by sufficiently suppressing the vibration of the die.

  In this way, even if the moving table supporting the die coater or the like is accurately moved to a predetermined position, it cannot sufficiently prevent the vibration of the moving table thereafter, and in the coating film formed on the web In some cases, surface defects such as step unevenness are conspicuous.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a coating apparatus and a coating method that can effectively suppress vibration of a movable slot die, and such a coating apparatus and a coating method. The manufacturing method of the optical film containing the coating film obtained by this is provided.

  In order to achieve the above object, one aspect of the present invention provides a support base that supports a slot die, a ball screw that moves the support base in response to rotation, and a support base position detection device that detects the position of the support base. And a servo motor for controlling the rotation of the ball screw based on the detection result of the support base position detection device, and two or more stoppers for restricting the movement of the support base by contact with the support base. Further, the present invention relates to a coating apparatus, wherein when the coating liquid is ejected from the slot die arranged at a predetermined coating position and coating is performed, the support base is pressed against the stopper.

  According to the coating apparatus, the slot die supported on the support base by the ball screw and the servo motor can be accurately moved, and the support base can be accurately arranged and fixed by the stopper. In particular, the coating liquid is discharged from the slot die arranged at a predetermined coating position, and the support base is pressed against the stopper when the coating is applied, so that the support base is appropriately supported and fixed. Can be effectively suppressed.

  Here, the “slot die” is a concept that can include all the applicators in which the coating liquid is discharged through a relatively narrow slot. The “stopper” is not particularly limited, but may have a highly rigid material or a material or structure excellent in damping properties from the viewpoint of suppressing vibration that may occur when contacting the support base.

  The support table is further arranged to face the stopper via the support table, and further includes a pressing unit that presses the support table. When the coating liquid is discharged from the slot die and applied, the support table is the pressing unit. It is preferable that it is pressed by the stopper and pressed against the stopper.

  In this case, when the coating liquid is discharged from the slot die and applied, the support base can be surely pressed against the stopper by the pressing portion, and the amount of vibration is suppressed by strengthening the fixing of the support base. Can do. In particular, since the support table is sandwiched between the stopper and the pressing portion, it is possible to effectively prevent the positional shift between the support table and the slot die.

  The “pressing part” may be anything as long as it can properly press the support base, and is mechanically driven using a hydraulic drive system, an air pressure (pneumatic) drive system, a motor, a spring, or the like. Any method such as a method can be applied. In addition, the pressing direction of the pressing portion with respect to the support base may be any direction as long as the support base can be accurately pressed against the stopper.

  In another aspect of the present invention, a support base that supports a slot die, two or more stoppers that limit movement of the support base by contact with the support base, and the stopper via the support base. And a pressing portion that presses the support base, and when the coating liquid is discharged from the slot die disposed at a predetermined application position and applied, the support base is pressed by the pressing portion. In addition, the present invention relates to a coating apparatus that is pressed against the stopper.

  According to the coating apparatus, the pressing unit can reliably discharge the coating liquid from the slot die and press the support base against the stopper when coating. Moreover, a support stand can be supported by three or more places by a press part and a stopper. In this way, the fixing of the support base can be strengthened, and the amount of vibration can be suppressed.

  The plurality of stoppers preferably include stoppers disposed on the left side and the right side in the horizontal direction.

  In this case, since the support base is pressed against the stoppers arranged on the left and right sides in a balanced manner, the support base can be more accurately supported and fixed by the stopper, and the amount of vibration can be suppressed. The “horizontal direction” is a direction perpendicular to the moving direction of the support base and the slot die, and is, for example, parallel to the longitudinal direction of the support base and the ground (ground) on which the coating apparatus is installed. Can be true.

  It is preferable to further include a slide part that moves the support base, and the slide part moves the slide part using at least one of a rolling bearing type guide, an air slide, and a slide metal.

  In this case, the support base can be smoothly moved through the slide portion, and it can be surely pressed against the stopper with a constant thrust, so that stability is improved.

  The slot die is preferably a die coater or a slide coater.

  In the case of using a die coater or a slide coater, it is preferable to reduce the vibration in order to apply the coating liquid with high accuracy, and thus the above-described coating apparatus according to the present invention is particularly useful.

  It is preferable to further include a stopper moving mechanism for moving the plurality of stoppers.

  In this case, the stopper can be moved to adjust the position of the stopper, and the support base can be more accurately supported and fixed by the stopper.

  Preferably, the stopper moving mechanism moves the plurality of stoppers using at least one of motor drive, hydraulic drive, and air drive.

  It further comprises a movement control device that controls movement of the support base and movement of the stopper, and the movement control device moves the support base to a predetermined position based on a detection result of the support base position detection device. It is preferable that the slot die is arranged at a predetermined application position by moving the stopper and pressing it against the support base.

  A stopper position detecting device for detecting the positions of the plurality of stoppers; and a movement control device for controlling the movement of the support base and the movement of the stopper, wherein the movement control device detects the stopper position detecting device. After moving the plurality of stoppers to a predetermined position based on the result, it is preferable that the slot die is arranged at a predetermined application position by moving the support base and pressing it against the plurality of stoppers.

  In these cases, the stopper can be accurately pressed against the support base, and the slot die can be accurately arranged at a predetermined application position.

  The movement control device further includes a movement control device that controls movement of the support base and movement of the stopper, and the movement control device simultaneously moves the stopper and the support base in a state where the support base is pressed against the stopper. It is preferable that the support table can be finely moved.

  In this case, the position of the support base can be finely adjusted by the stopper and the support base, and the slot die can be accurately arranged at a predetermined application position.

  Another aspect of the present invention relates to a coating method for coating a coating solution on a support using the above-described coating apparatus.

  According to the coating method, the support base can be accurately arranged and fixed by the stopper, so that the coating liquid can be accurately applied onto the support from the slot die supported by the support base.

  Another aspect of the present invention is a coating method in which a ball screw is rotated by a servo motor, and a coating liquid is discharged and applied from a slot die supported by a support base that moves as the ball screw rotates. The slot is moved to a predetermined application position by moving the support base to a predetermined position, moving a plurality of stoppers, and pressing the plurality of stoppers against the support base arranged at the predetermined position. It is related with the application | coating method characterized by arrange | positioning.

  Another aspect of the present invention is a coating method in which a ball screw is rotated by a servo motor, and a coating liquid is discharged from a slot die supported by a support base that moves as the ball screw rotates. A plurality of stoppers are moved to a predetermined position, the support table is moved, and the support die is pressed against the plurality of stoppers arranged at the predetermined position, thereby applying the slot die to a predetermined coating The present invention relates to a coating method characterized by being disposed at a position.

  According to these aspects, the stopper can be accurately pressed against the support base, and the slot die can be accurately arranged at a predetermined application position.

  Another aspect of the present invention relates to an optical film manufacturing method in which a coating film is formed on a support by the above-described coating apparatus, and an optical film is manufactured using the coating film.

  In this case, the coating film formed on the support with high accuracy by the coating apparatus is used, and a high-quality optical film can be manufactured.

  The optical film is preferably an antireflection film.

  In the case of producing such a highly functional film such as an antireflection film, the coating apparatus and the coating method according to the present invention described above are particularly suitable because it is necessary to produce the film with high accuracy.

  According to the coating liquid coating apparatus and coating method of the present invention, the support base can be accurately arranged and fixed by the stopper, so that vibrations generated in the slot die supported by the support base can be suppressed. Moreover, a high quality optical film can be manufactured by using the coating film manufactured with such a coating device and the coating method.

  Embodiments of the present invention will be described below with reference to the drawings.

First Embodiment FIG. 1 is a diagram showing an overall configuration of an optical film production line (slot die coater coating system 10). The arrows in the figure indicate the traveling direction of the web 14. In order to show the slot die coater type coating system 10 succinctly, only the pass rollers 68 arranged at representative positions are shown for the plurality of pass rollers 68 for transporting the web 14.

  In the slot die coater type coating system 10 of the present embodiment, from the upstream side toward the downstream side, the feeder 66, the dust remover 74, the backup roller 12, the extrusion type die coater (slot die) 18, the drying device 76, and the heating device. 78, the ultraviolet irradiation device 80, and the winder 82 are sequentially installed. Note that “upstream” and “downstream” here are based on the traveling direction of the web 14.

  The feeder 66 sequentially feeds the web 14 which is a transparent support having a polymer layer formed in advance to the downstream side. The dust remover 74 removes foreign matters such as dust adhering to the web 14. Although details of the die coater 18 and the backup roller 12 will be described later, the coating liquid is discharged from the die coater 18 toward the web 14 conveyed and supported by the backup roller 12, and a coating film is formed on the web 14.

  The drying device 76 and the heating device 78 form a zone for drying the coating film formed on the web 14. The drying device 76 evaporates the solvent in a state where the surface of the coating film (coating layer) on the web 14 is suppressed while being sealed with a gas layer. As a seal on the surface of the coating film by the gas layer, the gas may be moved along the surface of the coating film at a relative speed of −0.1 m / second to +0.1 m / second with respect to the moving speed of the coating film. preferable. When evaporating in a state where the solvent is suppressed, it is preferable to dry the coating film while the decreasing rate of the solvent content in the coating film is proportional to the time. The heating device 78 may be used to remove the solvent by heating as necessary, or to cure the coating film.

  The solvent is preferably dried by the drying device 76 and the heating device 78 in a state where a cover is provided. Further, as the drying air, a rectified air, a homogeneous air, or the like can be used. Further, the evaporated solvent may be condensed and removed by a cooling condensing plate installed facing the coating film surface.

  The ultraviolet irradiation device 80 irradiates the coating film monomer or the like with ultraviolet light using an ultraviolet lamp, and crosslinks the coating film monomer or the like to form a desired polymer. The winder 82 winds and collects the web 14 on which the polymerized coating film (coating layer) is laminated in a roll shape.

  In addition, according to the component of a coating film, the heat processing zone for hardening a coating film with a heat | fever can also be provided, and hardening and bridge | crosslinking of a desired coating film may be performed. Further, the coating film on the web 14 may be subjected to other processing such as heat treatment in a process different from the system 10.

  A plurality of pass rollers 68 are provided between the devices of the slot die coater type coating system 10, and the web 14 is fed from the upstream side to the downstream side by these pass rollers 68. The position and number of the pass rollers 68, the distance between the rotation centers of the adjacent pass rollers 68, and the like are appropriately adjusted as necessary.

  In the slot die coater type coating system 10 described above, the backup roller 12 and the pass roller 68 serve as guide rollers for conveying the web 14. In addition, other devices can be introduced into the slot die coater type coating system 10 as necessary. For example, in the optical compensation film, a rubbing treatment device for adjusting the orientation of the liquid crystal portion of the coating film can be installed before and after the dust remover 74.

  Next, the die coater 18 and the backup roller 12 will be described.

  FIG. 2 is a configuration diagram of the die coater 18, the backup roller 12, and the periphery thereof. The arrows in the vicinity of the backup roller 12 and the web 14 in the drawing indicate the “conveying direction of the web 14 by the backup roller 12”, that is, the “traveling direction of the web 14” in this embodiment. For ease of understanding, the size and orientation of each device shown in FIG. 2 do not necessarily match the actual device, but each device shown in FIG. 2 is the device shown in FIG. Corresponding to the kind.

  In this embodiment, the coating liquid is discharged from the slot 24 of the die coater 18 toward the surface of the web (support) 14 that continuously runs while being supported by the backup roller 12, and the coating is applied between the die coater 18 and the web 14. The liquid bead 20 is liquid cross-linked. Then, the coating liquid of the bead 20 is applied to the surface of the continuously running web 14 in a state where the pressure in the decompression chamber 26, which is a space adjacent to the upstream side of the bead 20, is reduced, and a coating film (application) is applied on the web 14. Layer) is formed.

  With reference to the position where the coating liquid is applied by the die coater 18 (hereinafter also referred to as “application position”), the portion preceding the application position with respect to the traveling direction of the web 14 is referred to as “web upstream”, and the latter stage. The portion is referred to as “web downstream”. Therefore, in the horizontal die coater 18 shown in FIG. 2, the lower side of the bead 20 is the “web upstream side” and the upper side of the bead 20 is the “web downstream side”. A web width direction perpendicular to the web conveyance direction is referred to as a “web width direction”.

  FIG. 3 is a perspective view showing a state in which a part of the die coater 18 is cut.

  The die coater 18 has a manifold 22 provided inside the main body and a slot 24 extending from the manifold 22 to the tip of the die coater 18. The die coater 18 includes two blocks, an upstream die block 18A and a downstream die block 18B. The manifold 22 and the slot 24 are part of the boundary between the upstream die block 18A and the downstream die block 18B. It has become. Thus, the die coater 18 having a multi-block structure increases the manufacturing accuracy of the die coater 18 and facilitates post-processing such as cleaning. The specific shape and size of the die coater 18 are determined based on its own weight, the environment during use, the temperature of the coating solution, the manufacturing specification limit, and the like.

  The manifold 22 is a liquid reservoir that spreads the coating liquid supplied to the die coater 18 in the coating width direction (web width direction), and extends in the web width direction. The manifold 22 of this embodiment has a substantially circular cross-sectional shape, and constitutes a hollow portion having substantially the same cross-sectional shape along the web width direction. The effective length of the manifold 22 in the web width direction is set equal to or slightly longer than the coating width for the web 14. The manifold 22 is also referred to as “pocket”.

  Closing plates 54 are provided at both ends in the web width direction of the main body of the die coater 18 to prevent leakage of the coating liquid from the manifold 22 to the outside. The manifold 22 is connected to a coating liquid discharge pipe 52 for extracting the coating liquid from the manifold 22. The coating liquid supply pipe 46 and the coating liquid discharge pipe 52 pass through the closing plate 54 and communicate with the manifold 22. In the present embodiment, the supply of the coating liquid to the manifold 22 is performed via the coating liquid supply pipe 46 and the coating liquid discharge pipe 52, but the present invention is not limited to this.

  The slot 24 constitutes a narrow flow path for the coating liquid from the manifold 22 to the tip of the slot, and discharges the coating liquid from the opening 24A at the tip of the die coater 18 so that the coating liquid is between the die coater 18 and the web 14. A bead 20 consisting of The slot 24 usually has an opening width of about 0.01 mm to 0.5 mm, and generally has a length approximately equal to or greater than the coating width of the coating liquid applied to the web 14 in the web width direction. The tip of the slot 24 is disposed so as to form an angle of 30 ° or more and 90 ° or less with the tangent line of the backup roller 12 in the web traveling direction. The flow path length of the slot 24 extending from the manifold 22 toward the web 14 can be set based on various conditions such as the liquid composition of the coating liquid, physical properties, supply flow rate, supply liquid pressure, and the like. It is preferable to set the flow path length of the slot 24 so that the coating liquid discharged from the section 24A has a substantially uniform flow rate and liquid pressure in the web width direction.

  Width restricting plates 60 are inserted at both ends of the slot 24 in the web width direction, and each width restricting plate 60 is in close contact with the upstream die block 18A and the downstream die block 18B constituting the wall portion of the slot 24. ing. The width regulating plate 60 is a member that regulates the coating width of the coating liquid discharged from the opening 24A of the slot 24, and is arranged and adjusted so that the opening 24A is substantially equal to or less than the coating width in the web width direction. Yes. Further, from the viewpoint of stabilizing the application state of the coating liquid in the vicinity of the width regulating plate 60, a specific material or surface treatment is adopted for the width regulating plate 60 to adjust the wettability of the coating liquid with respect to the width regulating plate 60. It is preferable. For example, the width regulating plate 60 is formed of a material such as Teflon (registered trademark) or Newlite, or a metal plate coated with a polymer such as a fluororesin is used as the width regulating plate 60. It is preferable that the contact angle with respect to 60 coating liquid is adjusted to be 30 ° or more.

  A tip portion of the die coater 18 is formed in a tapered shape as shown in FIG. 2, and the tip is called a lip land 16. The lip land 16 on the web upstream side (lower side in FIG. 2) of the slot 24 is referred to as upstream lip land 16A, and the lip land 16 on the downstream side (upper side in FIG. 2) is referred to as downstream lip land 16B.

  A coating liquid tank 44 that stores the coating liquid is connected to the manifold 22 via a coating liquid supply pipe 46, and a coating liquid pump 42 that sends the coating liquid from the coating liquid tank 44 to the manifold 22 is connected to the coating liquid supply pipe 46. Is provided.

  A decompression chamber 26 for decompressing the space upstream of the web of the bead 20 is provided below the tip portion of the die coater 18 having the above-described configuration. The decompression chamber 26 is configured by a back plate 26A, two side plates 26B, a rear plate 26C, and a bottom plate 26D in a box shape that forms a space therein.

  The decompression chamber 26 preferably has a sufficiently large volume.

  The back plate 26 </ b> A is located on the most upstream side in the web conveyance direction in the decompression chamber 26 and is disposed so as to extend in the width direction of the web 14. The two side plates 26 </ b> B are arranged so as to be perpendicular to the back plate 26 </ b> A and constitute both side walls of the decompression chamber 26. An edge portion (not shown) of the side plate 26 </ b> B adjacent to the backup roller 12 has substantially the same curvature as the backup roller 12. The rear plate 26C is disposed below the die coater 18 and substantially parallel to the back plate 26A. The bottom plate 26D constitutes the bottom portion of the decompression chamber 26 and is joined to the back plate 26A, the side plate 26B, and the rear plate 26C at the edge portion.

  A suction port 40 is formed in the bottom plate 26 </ b> D, and an air pipe (decompression tube) 28 is connected to the suction port 40. The decompression chamber 26 is connected to a blower (decompression means) 30 via a suction port 40 and an air pipe 28, and a buffer device 33 is provided in the air pipe 28 between the decompression chamber 26 and the blower 30. An orifice 32 is provided in the air pipe 28 between the buffer device 33 and the buffer device 33. Therefore, the decompression chamber 26, the orifice 32, the buffer device 33, and the blower 30 are sequentially provided via the air pipe 28, and these constitute a decompression device.

  Next, a mechanism for adjusting the distance between the die coater 18 and the backup roller 12 (web 14) will be described.

  FIG. 4 is a diagram illustrating a configuration of the die coater 18 and the backup roller 12 according to the first embodiment viewed from the side. FIG. 5 is a front view of the stoppers 110 and 112 and their surroundings. For ease of understanding, the die coater 18 and the like are omitted in FIG.

  The die coater 18, the backup roller 12, and members such as stoppers 110 and 112 that adjust the distance between the die coater 18 and the backup roller 12 (web 14) are provided on the foundation 140 serving as a base.

  The backup roller 12 around which the web 14 is wound is fixedly supported on the base portion 140 via a roller mount 130.

  Between the die coater 18 and the base portion 140, a lower frame 102, a slide guide portion 106, a slide portion 104, a moving table 100, and a die support portion 98 are sequentially provided.

  The lower pedestal 102 is a pedestal for realizing stable fixed support on the foundation part 140, and is directly provided on the foundation part 140. The slide guide unit 106 is a member that guides the slide movement of the slide unit 104. Two slide guide portions 106 of the present embodiment are juxtaposed in a direction perpendicular to the moving direction of the die coater 18 (see arrow A in FIG. 4) on the lower frame 102, and each extends in the moving direction of the die coater 18. To do. Two slide portions 104 are juxtaposed in a direction perpendicular to the moving direction of the die coater 18 (see the arrow in FIG. 4) at a position corresponding to the slide guide portion 106 at the lower part of the moving table 100. Each slide portion 104 is slidably fitted to the corresponding slide guide portion 106 and slides along the slide guide portion 106 together with the moving table 100.

  Note that any method can be used as the slide method (mechanism) of the moving table 100 realized by the slide unit 104 and the slide guide unit 106. For example, a rolling bearing guide method, an air slide method, a slide metal method, or the like can be adopted as the slide moving mechanism of the moving table 100.

  The moving table 100 is a table that fixedly supports the die coater 18 via the die support part 98, and slides together with the slide part 104. The die support part 98 is a member that fixes the die coater 18 to the moving table 100.

  Below the moving table 100, a driving device that is a driving source for sliding the die coater 18 is provided. This driving device includes a stopper receiving portion 122 fixed to the moving table 100, a ball screw 123 that passes through the stopper receiving portion 122, and a servo motor 124 that rotates the ball screw 123 about its axis.

  The stopper receiving portion 122 is screwed to the ball screw 123 and moves in the moving direction of the die coater 18 (the direction of arrow A in FIG. 4) as the ball screw 123 rotates. The ball screw 123 extends in the moving direction of the die coater 18, and moves the stopper receiving portion 122, the moving table 100, the die support portion 98, and the die coater 18 in the direction of arrow A according to the rotation of the shaft. The servo motor 124 is controlled by a control device 160, which will be described later, and controls the amount of shaft rotation of the ball screw 123 based on the position of the moving table 100 and the positions of the stoppers 110 and 112, and the positions of the moving table 100, the die coater 18, and the like. Control precisely. The configuration of the drive device is not limited to this.

  A first stopper 110 and a second stopper 112 that restrict movement of the stopper receiving part 122 by contact with the stopper receiving part 122 are provided on the lower frame 102 separately from the moving table 100 and the stopper receiving part 122. ing. The first stopper 110 and the second stopper 112 are arranged on the backup roller 12 side (the right side in FIG. 4) with respect to the stopper receiving portion 122. The first stopper 110 and the second stopper 112 are juxtaposed on the left side and the right side in the horizontal direction in the direction perpendicular to the moving direction of the stopper receiving portion 122 (the direction of arrow A in FIG. 4). In this example, the stoppers 110 and 112 are positioned between the pair of slide portions 104 (see FIG. 5), but the distance between the stoppers 110 and 112 can be appropriately changed.

  Each of the first stopper 110 and the second stopper 112 includes a stopper pedestal 114 attached to the lower pedestal 102, a stopper support 116 and a contact support 117 attached to the stopper pedestal 114, and a contact support 117. And a contact portion 118 attached to the surface on the stopper receiving portion 122 side. Since the contact portion 118 is a portion that is in direct contact with the stopper receiving portion 122, it is desirable that the material and structure have high rigidity, but it is also possible to use a member such as rubber having high damping performance.

  Further, the first stopper 110 and the second stopper 112 of this embodiment are provided with a stopper moving mechanism 119. The stopper moving mechanism 119 can slide each of the first stopper 110 and the second stopper 112 in the same direction as the movement direction of the die coater 18 (the direction of arrow B in FIG. 4). The position of the portion 118 can be adjusted. The stopper moving mechanism 119 can employ any driving method, such as a motor driving method, a hydraulic driving method, an air driving method, a screw or spring driving method, or the like. It is. The stopper moving mechanism 119 may be of any type as long as it can appropriately move the contact portion 118 to a desired position. For example, sliding movement between the lower frame 102 and the stopper frame 114, The movement of the contact portion 118 in the arrow B direction can be realized by sliding movement between the stopper pedestal 114 and the stopper support portion 116 or sliding movement between the stopper support portion 116 and the contact support portion 117. . In this embodiment, an example in which a stopper moving mechanism 119 that slides between the lower frame 102 and the stopper frame 114 is employed will be described. Therefore, in the present embodiment, the first stopper 110 and the second stopper 112 are configured to move integrally. In addition, the structure which moves the 1st stopper 110 and the 2nd stopper 112 separately may be sufficient.

  A servo motor 124 that is a movement drive source of the stopper receiving portion 122, the movement table 100, and the die coater 18, and a stopper movement mechanism 119 that is a movement drive source of the stoppers 110 and 112 are connected to the control device 160. The control device 160 is also connected with a table position detecting device 125 for detecting the actual position of the moving table 100 and a stopper position detecting device 126 for detecting the actual positions of the stoppers 110 and 112. The data is sent from the position detection device 125 and the stopper position detection device 126 to the control device 160. An arbitrary device capable of detecting the position of the moving table 100 can be used as the table position detecting device 125, and the attachment position is not particularly limited, and the table position detecting device 125 is set at an appropriate position according to the detection method. Can be arranged. Similarly, any device that can detect the positions of the stoppers 110 and 112 can be used as the stopper position detection device 126. The attachment position is not particularly limited, and the stopper position is detected at an appropriate position according to the detection method. A device 126 can be arranged.

  The control device 160 controls the servo motor 124 and the stopper moving mechanism 119 based on the detection result of the table position detection device 125 and the detection result of the stopper position detection device 126, and moves the stopper receiving portion 122 and the stoppers 110 and 112. Control movement.

  The “support portion” of the present invention includes the “stopper receiving portion 122”, the “moving table 100”, and the “die support portion 98” of the present embodiment.

  According to the mechanism having the above-described configuration, the “distance between the die coater 18 and the backup roller 12 (web 14)” is appropriately adjusted by the control device 160.

  For example, the control device 160 can control the servo motor 124 based on the detection result of the table position detection device 125 to move the moving table 100 to a predetermined position. Thereafter, the control device 160 controls the stopper moving mechanism 119 to move the stoppers 110 and 112 and presses the stoppers 110 and 112 against the stopper receiving portion 122. As a result, as shown in FIG. 6, the die coater 18 can be disposed at a predetermined application position close to the web 14 wound around the backup roller 12.

  In addition, the control device 160 can control the stopper moving mechanism 119 based on the detection result of the stopper position detection device 126 and move the stoppers 110 and 112 to predetermined positions. Thereafter, the control device 160 controls the servo motor 124 to move the stopper receiving portion 122 and presses the stopper receiving portion 122 against the stoppers 110 and 112. Also in this case, as shown in FIG. 6, the die coater 18 can be disposed at a predetermined application position close to the web 14 wound around the backup roller 12.

  Further, as shown in FIG. 6, the control device 160 controls the servo motor 124 and the stopper moving mechanism 119 in a state where the stoppers 110 and 112 are pressed against the stopper receiving portion 122, so that the stoppers 110 and 112 The stopper receiving part 122 can also be moved simultaneously. By finely moving the stopper receiving portion 122 in this way, the position of the die coater 18 can be finely adjusted, and the die coater 18 can be disposed at an accurate application position. For example, the die coater 18 can be disposed at a very accurate application position by finely moving the stopper receiving portion 122 at a level of several μm.

  In this way, when the coating liquid is discharged from the die coater 18 and applied, the stopper receiving portion 122 is pressed against the stoppers 110 and 112, so that vibration of the die coater 18 due to the movement is suppressed and the die coater 18 is suppressed. Can be prevented from being displaced. In particular, the stoppers 110 and 112 and the stopper receiving part 122 are not simply in contact with each other, but the stopper receiving part 122 is pressed against the stoppers 110 and 112 so that they are pressed against each other and brought about by movement. Vibration and positional deviation can be effectively suppressed.

  Therefore, according to such a slot die coater type coating system 10, vibrations of the die coater 18 and the like are effectively suppressed, and surface defects such as unevenness of the coating film coated on the web 14 are reduced, resulting in high quality. A coating film can be provided. Since the coating film provided by such an apparatus has a very good surface shape, it is particularly useful in the field of optical films such as antireflection films.

Second Embodiment In this embodiment, members that are the same as or similar to those in the first embodiment are given the same reference numerals, and descriptions thereof are omitted.

  FIG. 7 is a diagram illustrating a configuration of the die coater 18 and the backup roller 12 according to the second embodiment viewed from the side.

  In the present embodiment, a hydraulic device 150 is provided that is disposed so as to face the stoppers 110 and 112 via the stopper receiving portion 122 after the die coater 18 is disposed at a predetermined application position. The hydraulic device 150 plays a role of pressing the stopper receiving portion 122 toward the stoppers 110 and 112 and reliably pressing the stopper receiving portion 122 against the stoppers 110 and 112.

  Other configurations are substantially the same as those of the first embodiment.

  In the present embodiment, when the coating liquid is discharged from the die coater 18 and applied, the hydraulic device 150 presses the stopper receiving portion 122, so that the stopper receiving portion 122 is reliably pressed against the stoppers 110 and 112. Therefore, vibrations and positional shifts caused by movement can be more reliably suppressed.

Third Embodiment In this embodiment, members that are the same as or similar to those in the first embodiment are given the same reference numerals, and descriptions thereof are omitted.

  FIG. 8 is a diagram illustrating a configuration of the die coater 18 and the backup roller 12 according to the third embodiment viewed from the side.

  In the present embodiment, instead of the ball screw 123 and the servo motor 124, the hydraulic device 150 serves as a movement driving source for the stopper receiving portion 122, the moving table 100, the die support portion 98, and the die coater 18. The hydraulic device 150 is disposed so as to face the stoppers 110 and 112 via the stopper receiving portion 122. The hydraulic device 150 is controlled by the control device 160 and moves the stopper receiving portion 122, the moving table 100, the die support portion 98, and the die coater 18 by pressing the stopper receiving portion 122 toward the stoppers 110 and 112. Let

  Other configurations are substantially the same as those of the first embodiment.

  Also in this embodiment, the die coater 18 can be moved to a predetermined application position by the hydraulic device 150, and the application liquid can be applied from the die coater 18 toward the web 14 with high accuracy. In particular, when the coating liquid is discharged from the die coater 18 disposed at the coating position and applied, the stopper device 122 is pressed against the stoppers 110 and 112 by the hydraulic device 150, so that the vibration of the die coater 18 accompanying the movement occurs. Can be suppressed, and displacement of the die coater 18 can also be prevented.

  In each of the slot die coater type coating systems 10 according to the first to third embodiments described above, various types of coating solutions and webs 14 can be used depending on the purpose.

  Next, a specific configuration example of the optical film that can be realized by the present invention will be described.

[Optical compensation sheet for LCD]
Hereinafter, a liquid crystal display device in which an optical compensation sheet in which an optically anisotropic layer made of a discotic compound is coated on a cellulose acylate film transparent support (web 14) is directly used as a protective film for a polarizing plate will be described. The optical film to which the present invention can be applied is not limited to this.

  Discotic compounds are described in detail in JP-A-7-267902, JP-A-7-281028, and JP-A-7-306317. According to them, the optically anisotropic layer is a layer formed from a compound having a discotic structural unit. That is, the optically anisotropic layer is a polymer layer obtained by polymerization (curing) of a low molecular weight liquid crystal discotic compound layer such as a monomer or a polymerizable liquid crystal discotic compound.

  Further, the cellulose acylate film is preferably used as a support (web 14) for the alignment film. As those, those described in detail in JP-A-9-152509 can be applied. That is, the alignment film can be disposed on the cellulose acylate film or an undercoat layer coated on the cellulose acylate film, and defines the alignment direction of the liquid crystalline discotic compound provided thereon. To function. Such an alignment film may be any layer as long as it can impart orientation to the optically anisotropic layer. In addition, it is preferable that the polymer used for the alignment film and the liquid crystalline compound of the optically anisotropic layer are chemically bonded via an interface between these layers.

  The cellulose acylate film is an optical compensation sheet having a basic structure described in detail in JP-A-8-5837, JP-A-7-191217, JP-A-8-50206, and JP-A-7-281028. Can be used. A cellulose acylate film and an optical compensation sheet composed of an optically anisotropic layer provided thereon are application examples, and the optically anisotropic layer is a layer formed from a compound having a discotic structural unit. As an application example to LCD, the optical compensation sheet is bonded to one side of a polarizing plate via an adhesive, or the optical compensation sheet as a protective film is bonded to one side of a polarizing element via an adhesive or the like. Is preferred. The optically anisotropic element preferably has at least a discotic structural unit (preferably a discotic liquid crystal).

  The production method of the optical compensatory sheet to which the cellulose acylate film is applied is described in detail in, for example, JP-A-9-73081, JP-A-8-160431, and JP-A-9-73016. However, it is not limited to these.

[Application method of optical compensation sheet for LCD]
Next, the example which applies a cellulose acylate film to a panel is shown. They are described in detail in JP-A-8-95034, JP-A-9-197397, and JP-A-11-316378. The optical compensation sheets described in the above publications are advantageously used for liquid crystal display devices, particularly transmissive liquid crystal display devices. The transmissive liquid crystal display device includes a liquid crystal cell and two polarizing plates disposed on both sides thereof. A liquid crystal cell carries a liquid crystal between two electrode substrates. One optical compensation sheet can be disposed between the liquid crystal cell and one polarizing plate, or two optical compensation sheets can be disposed between the liquid crystal cell and both polarizing plates. The mode of the liquid crystal cell is preferably a VA mode, a TN mode, or an OCB mode.

[Anti-glare film, anti-reflection film]
The cellulose acylate film can be preferably applied to an antiglare film and an antireflection film. For the purpose of improving the visibility of flat panel displays such as LCD, PDP, CRT, and EL, either or both of an antiglare layer and an antireflection layer can be provided on one or both sides of the cellulose acylate film. A film imparted with such a function is called an antiglare film or an antireflection film, and a film having both an antiglare layer and an antireflection layer is sometimes called an antiglare antireflection film. Generally, an anti-glare film is composed of a transparent support and an anti-glare layer, and an anti-reflection film is provided with an anti-reflection layer consisting of a single layer or multiple light interference layers on the outermost surface of the transparent support. Accordingly, a hard coat layer or an antiglare layer is provided between the support and the light interference layer.

  As the transparent support, a cellulose acylate film is preferable for LCD applications, and cellulose acetate is particularly preferable. When the antiglare and antireflection film according to the present invention is used in an LCD, it can be disposed on the outermost surface of the display or the interface with the air inside the display by providing an adhesive layer on one side. Since cellulose triacetate is used as a protective film for protecting the polarizer of the polarizing plate, it is preferable to use the antiglare and antireflection film according to the present invention as it is for the protective film from the viewpoints of cost and display thinning.

  The antiglare and antireflection film according to the present invention can be provided with a hard coat layer as necessary. The compound used for the hard coat layer is preferably a polymer having a saturated hydrocarbon or polyether as the main chain, and preferably has a crosslinked structure. In order to obtain a polymer having a crosslinked structure, it is preferable to crosslink a monomer having two or more ethylenically unsaturated groups with ionizing radiation or heat.

  As a means for imparting antiglare performance to the film, a method of forming matte particles having a particle size that scatters visible light in a binder to form an antiglare layer having surface irregularities, embossing, sandblasting, etc. on the support surface. Various methods such as a method for imparting irregularities and a method for imparting irregularities to the surface by the phase separation structure of the coating composition have been disclosed in published patent publications. Generally, however, mat particles are dispersed in a binder. The method has been put into practical use.

  For the formation of the antiglare layer, fine particles (matting agent) made of a resin or an inorganic compound may be used in addition to a binder made of a resin compound for the purpose of imparting antiglare properties by forming surface irregularities. The average particle size is preferably 1.0 μm to 10.0 μm, more preferably 1.5 μm to 5.0 μm. Further, it is preferable that fine particles having a particle diameter smaller than the binder film thickness of the antiglare layer is less than 50% of the whole fine particles. The particle size distribution can be measured by the Coulter counter method, but the distribution can be considered in terms of the particle number distribution. The film thickness of the antiglare layer is preferably 0.5 μm to 10 μm, more preferably 1 μm to 5 μm.

  For the resin binder used for forming the antiglare layer, a material for forming the hard coat layer is preferably used from the viewpoint of film strength and transparency. When combined with an antireflection layer, the refractive index of the layer is increased from 1.50 to 2.00 by using a high refractive index monomer or high refractive index inorganic fine particles in combination with the hard coat material. In some cases, the antireflection performance can be improved.

  When unevenness is imparted to the support surface by embossing, it is preferable to form the unevenness on the surface after forming all of the multiple optical interference layers. When forming a plurality of optical interference layers by wet coating after forming the surface irregularities, it may cause a significant deterioration of the antireflection performance due to the unevenness of the thickness of each layer caused by the coating liquid collecting in the recesses, It is not preferable. By performing the embossing process after forming the entire optical interference layer, the film thickness of the optical interference layer becomes substantially uniform. Here, “substantially uniform” means that the central film thickness is within ± 3%.

  The antireflection film can be a single layer of a low refractive index layer or a low refractive index layer and a high refractive index layer so as to have a film thickness, refractive index, and layer structure designed based on the principle of optical interference by an optical thin film. An antireflection layer composed of a plurality of layers is provided. Here, the low refractive index layer and the high refractive index layer refer to a layer having a refractive index lower than the refractive index of the support and a layer having a refractive index higher than the refractive index of the support, respectively. It has a film thickness equal to or less than the wavelength order of the target light. Such a layer having a very thin film thickness is called an optical thin film, and has been put to practical use in various applications as an optical functional layer such as an antireflection film or a reflection film based on the principle of optical interference.

  A low refractive index layer having a refractive index of 1.30 to 1.49 can be selected as a material having a balance between film strength and refractive index. Specifically, as disclosed in JP-A-11-38202 and JP-A-11-326601, etc., a low air gap is formed between fine particles having a particle diameter that is small enough not to cause light scattering. A refractive index layer or a fluorine-containing compound that is crosslinked by heat or ionizing radiation is preferably used.

  For the high refractive index layer, a material preferably used for increasing the refractive index of the antiglare layer is similarly used. A preferable refractive index range is 1.70 to 2.20, and a preferable film thickness range is 5 to 300 nm.

  Each of the hard coat layer, antiglare layer and antireflection layer is formed by dip coating, air knife coating, curtain coating, roller coating, wire bar coating, gravure coating, micro gravure or extrusion coating ( According to US Pat. No. 2,681,294), it can be formed by coating. Two or more layers may be applied simultaneously. The method of simultaneous application is described in US Pat. No. 2,761,789, US Pat. No. 2,941,898, US Pat. No. 3,508,947, US Pat. No. 3,526,528, and Yuji Harasaki, Coating Engineering, page 253, Asakura Shoten (1973). .

  In JP 2003-149413 A, the degree of acetylation is 59.0 in order to provide a liquid crystal display device with excellent display quality, in which contrast reduction, gradation or black-and-white reversal, and hue change are hardly caused by angular change. A light diffusing film having a light diffusing layer containing translucent fine particles in a translucent resin on a cellulose acetate film of 6% to 61.5%, and the thickness of the cellulose acetate film is 20 μm to 70 μm, There is a description of a light diffusion film having a cut-off value per 100 mm of 0.8 mm and an average surface roughness Ra of 0.2 μm or less, and this light diffusion film can also be applied to the present invention.

  The antiglare film and antireflection film of the present invention are polarized light used for each application including LCD by saponifying the back surface of the support by any means before or after formation of the antiglare layer and antireflection layer. In the production of the plate, the polarizer can be directly bonded to one or both sides of the polarizer as a protective film.

  In particular, in the case where a retardation film is disposed between a polarizing plate and a cell in which liquid crystal is encapsulated in order to increase the viewing angle of the LCD, polarized light used on the viewing side among polarizing plates disposed on both sides of the cell. Protect the anti-glare film or anti-reflection film on the protective film on the air interface side of the plate, and the retardation film on the opposite surface, which is formed between the cell and the polarizer, on both sides of the polarizer It can be used as a layer. The polarizing plate having such a structure has a thickness equivalent to that of a conventional polarizing plate, but can provide functions such as a wide viewing angle and low reflection, and is extremely preferable for high-function LCD applications.

  As a multilayer film in which a plurality of transparent thin films of inorganic compounds (metal oxides, etc.) having different refractive indexes are laminated, colloids are produced by chemical vapor deposition (CVD), physical vapor deposition (PVD), and sol-gel methods of metal compounds such as metal alkoxides. And forming a thin film by post-processing (ultraviolet irradiation: JP-A-9-157855, plasma processing: JP-A-2002-327310) after forming the metal oxide particle film. On the other hand, various antireflection films formed by laminating thin films formed by dispersing inorganic particles in a matrix have been proposed as antireflection films with high productivity.

  An antireflection film composed of an antireflection layer having an antiglare property having a fine uneven shape with respect to the antireflection film by application as described above may also be mentioned.

[Layer structure of coating type antireflection film]
On the substrate, the antireflection film comprising at least a medium refractive index layer, a high refractive index layer, and a low refractive index layer (outermost layer) in the order of “refractive index of high refractive index layer> refractive index of medium refractive index layer” It is designed to have a refractive index satisfying the relationship of “> refractive index of transparent support> refractive index of low refractive index layer”. Further, a hard coat layer may be provided between the transparent support and the medium refractive index layer. Furthermore, the coating type antireflection film may include a medium refractive index hard coat layer, a high refractive index layer, and a low refractive index layer. Other functions may be imparted to each layer, for example, an antifouling low refractive index layer or an antistatic high refractive index layer (eg, JP-A-10-206603, JP-A-2002). -243906 publication etc.) etc. are mentioned.

  An antiglare antireflection film comprising a layer structure in which an antiglare layer and a low refractive index layer are laminated on a substrate is designed to satisfy “refractive index of antiglare layer> refractive index of low refractive index layer”. . Further, a hard coat layer may be provided between the transparent support and the antiglare layer.

  The clear antireflection film having a layer structure in which a hard coat layer is provided on a substrate and a low refractive index layer is laminated is designed to satisfy “refractive index of antiglare layer> refractive index of low refractive index layer”. A hard coat layer may be provided between the transparent support and the antiglare layer. Alternatively, an antiglare antireflection film having a layer structure in which an antiglare layer is provided on a substrate and a high refractive index layer and a low refractive index layer are laminated is expressed as “refractive index of high refractive index layer> refractive index of transparent support> low. It is designed to satisfy the “refractive index of the refractive index layer”. Alternatively, an anti-glare antireflection film having a layer structure in which a hard coat layer is provided on a substrate and a high refractive index layer and a low refractive index layer are laminated is represented by “refractive index of high refractive index layer> refractive index of transparent support> It is designed to satisfy the “refractive index of the low refractive index layer”.

  The layer having a high refractive index of the antireflection film is composed of a curable film containing at least an ultrafine particle of an inorganic compound having a high refractive index having an average particle size of 100 nm or less and a matrix binder. The refractive index of the middle refractive index layer is adjusted to be a value between the refractive index of the low refractive index layer and the refractive index of the high refractive index layer. The low refractive index layer is formed by sequentially laminating on the high refractive index layer, and is preferably constructed as an outermost layer having scratch resistance and antifouling properties.

(Other layers of antireflection film)
Further, a hard coat layer, a forward scattering layer, a primer layer, an antistatic layer, an undercoat layer, a protective layer, and the like may be provided.

(Hard coat layer)
The hard coat layer is provided on the transparent support in order to impart physical strength to the antireflection film. In particular, it is preferably provided between the transparent support and the high refractive index layer. The high refractive index layer can also serve as a hard coat layer. The hard coat layer can also serve as an antiglare layer (described later) provided with particles having an average particle size of 0.2 μm to 10 μm and imparted with an antiglare function (antiglare function). The film thickness of the hard coat layer can be appropriately designed depending on the application.

(Forward scattering layer)
The forward scattering layer is provided to give a viewing angle improvement effect when the viewing angle is inclined in the vertical and horizontal directions when applied to a liquid crystal display device. By dispersing fine particles having different refractive indexes in the hard coat layer, it can also serve as a hard coat function. For example, Japanese Patent Laid-Open No. 11-38208 specifying a forward scattering coefficient, Japanese Patent Laid-Open No. 2000-199809 having a relative refractive index of a transparent resin and fine particles in a specific range, and Japanese Patent Laid-Open No. 2002 specifying a haze value of 40% or more. -107512 publication etc. are mentioned.

(Anti-glare function)
The antireflection film may have an antiglare function that scatters external light. The antiglare function is obtained by forming irregularities on the surface of the antireflection film. The method for forming irregularities on the surface of the antireflection film may be any method as long as these surface shapes can be sufficiently retained.

The above-described slot die coater type coating system 10 is particularly effective for thin layer coating. For example, the wet coating amount is 20 ml / m ² or less (the film thickness during coating is 20 μm or less), and further 10 ml / m ^2. It can be suitably applied to an optical film production line for performing a thin layer coating.

  The slot die coater type coating system 10 may be installed in a clean atmosphere such as a clean room. At that time, the cleanliness is preferably class 1000 or less, more preferably class 100 or less, and still more preferably class 10 or less.

  As described above, according to each embodiment of the present invention, the stopper receiving portion 122 and the die coater 18 can be accurately supported and arranged by appropriately pressing the stopper receiving portion 122 against the stoppers 110 and 112. In addition, vibration can be effectively suppressed. In addition, the servo motor 124 and the stoppers 110 and 112 can suppress vibrations of the stopper receiving portion 122, the die coater 18 and the like while taking advantage of the positioning accuracy of the ball screw 123 and the servo motor 124. As a result, the coating liquid can be accurately applied from the die coater 18 to the web 14, and surface defects such as unevenness in the coating film can be prevented, and a high-quality coating film can be manufactured.

  The above items are examples of each aspect of the present invention, and various modifications such as design changes can be added based on the knowledge of those skilled in the art, or known elements can be applied. Such various embodiments can also be included in the scope of the present invention.

  For example, in each of the above-described embodiments, the example using the extrusion type die coater has been described. However, the present invention is not limited to this, and the present invention is applied to all other coating apparatuses such as a slide coater. can do.

  Further, the backup roller 12, the die coater 18, and the decompression chamber 26 in the slot die coater type coating system 10 may have any arrangement relationship as long as the coating liquid can be properly coated on the web 14. For example, the discharge angle of the coating liquid of the die coater 18 with respect to the web 14, the cross-sectional shape of the manifold 22, the winding state of the web 14 with respect to the backup roller 12, and the winding portion of the web 14 with respect to the backup roller 12 and the die coater 18 and the decompression chamber 26. The relative positional relationship, the overbite amount, and the like can be appropriately adjusted according to the application.

  The supply method of the coating liquid to the manifold 22 may be any method as long as the coating liquid can be appropriately supplied to the manifold 22. For example, not only a method of supplying the coating liquid from one end side of the manifold 22 (see FIG. 3), but also a method of supplying the coating liquid from the central portion of the manifold 22 and a stopper for preventing the coating liquid from leaking out. A method of providing a new coating liquid from one end of the manifold 22 and circulating a part of the coating liquid extracted from the other end to the one end, etc., provided at both ends can also be used. Moreover, the cross-sectional shape of the manifold 22 is not limited to the substantially circular shape shown in each drawing, and may be, for example, a semicircular shape, a rectangular shape such as a trapezoid, or a similar shape.

  In the above-described embodiment, an example in which the coating film is formed as a single layer on the web 14 has been described. However, a coating film having some function such as an antiglare layer or an antireflection layer may be formed in a plurality of layers. Good. When a plurality of coating films are formed on the web 14, the coating liquid for each layer may be sequentially applied on the web 14, or the coating liquid for each layer may be simultaneously applied on the web 14. In addition, when forming sequentially the application | coating on the web 14 (a base material, a film) and forming two or more layers of coating films, it is preferable on production that performing these application | coating processes continuously, and layers (application | coating other than the last layer) It is more preferable to omit the winding process for the film), repeat the coating process and the drying process for each layer, and finally wind up and collect.

Hereinafter, examples using the slot die coater type coating system 10 according to the above-described embodiment will be described, but the present invention is not limited to the following examples.
Example 1
First, an antiglare layer (antiglare film) was produced as a base.

  The coating solution was adjusted as follows. 75 g of a mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, manufactured by Nippon Kayaku Co., Ltd.), zirconium oxide ultrafine particle dispersion having a particle size of about 30 nm (Desolite Z-7401, JSR) 240 g was dissolved in 104 g of methyl ethyl ketone / cyclohexanone = 54/46 wt% mixed solvent.

  10 g of a photopolymerization initiator (Irgacure 907, manufactured by Ciba Fine Chemicals Co., Ltd.) was added to the resulting solution, and after stirring and dissolving, a fluorosurfactant (Megafac F) comprising a 20% by weight fluorine-containing oligomer methyl ethyl ketone solution was added. 0.96 g of -176PF, manufactured by Dainippon Ink Co., Ltd. was added (note that the refractive index of the coating film obtained by applying this solution and curing it with ultraviolet light was 1.65).

  Further, 20 g of crosslinked polystyrene particles having a number average particle diameter of 2.0 μm and a refractive index of 1.61 (SX-200HS, manufactured by Soken Chemical Co., Ltd.) were mixed with 160 g of methyl ethyl ketone / cyclohexanone = 54/46 wt%. Stir and disperse in a solvent with a high-speed disperser at 5000 rpm for 1 hour, using polypropylene filters with pore sizes of 10 μm, 3 μm, and 1 μm (PPE-10, PPE-03, and PPE-01, respectively, manufactured by Fuji Photo Film Co., Ltd.) 29 g of the dispersion obtained by filtration was added and stirred, and then filtered through a polypropylene filter having a pore size of 30 μm to prepare a coating solution for an antiglare layer. This coating solution had a viscosity of 8 mPa · s and a surface tension of 0.030 N / m.

The coating solution obtained in this way is so that the wet film thickness of the coating film applied on the web 14 is 8 μm, the coating amount of the coating liquid on the web 14 is 8 mL / m ² , and the coating width is 1440 mm. And coated on the web 14 by a bar coater. At this time, the web 14 was conveyed at a speed of 10 m / min. The web 14 thus coated with the coating liquid was wound up in a roll shape by the winder 82.

Next, a coating solution for an antireflection film was prepared (preparation of a coating solution for a low refractive index layer). MEK-ST (average particle size of 10 nm to 20 nm, solid content concentration) was added to 93 g of a methyl ethyl ketone solution (JN-7228, manufactured by JSR Corporation) of 6% by weight of a thermally crosslinkable fluoropolymer with a refractive index of 1.42. 30 g% of SiO ₂ sol methyl ethyl ketone dispersion (manufactured by Nissan Chemical Co., Ltd.) 8 g, methyl ethyl ketone 94 g and cyclohexanone 6 g were added. An anti-coating coating solution was prepared. The viscosity of the coating solution for antireflection film was 1 mPa · s, and the surface tension was 0.024 N / m.

The coating solution for the antireflection film thus obtained has a wet film thickness of 4 μm, a coating amount of the coating liquid on the web 14 of 4 mL / m ² , and a coating width of 1490 mm. Then, it was applied on the web 14 by the die coater 18.

  In addition, the web 14 of the 1470 mm width of Fujitac provided with said anti-glare layer was used as the web 14, and this web 14 was conveyed at the speed of 10 m / min. The web 14 thus coated with the coating solution for the antireflection film was wound up into a roll by the winder 82.

  At this time, the stopper receiver 122, the moving table 100, and the die coater 18 are moved and driven by the ball screw 123 and the servo motor 124. The control of the servo motor 124 by the control device 160 is based on the detection result of the table position detecting device 125. Made by feedback control.

  Under the conditions described above, the results shown in Table 1 below could be obtained by changing the presence or absence and position of the stopper and the method of pressing the stoppers 110 and 112 against the stopper receiving portion 122.

  In Table 1, “table driving method” indicates a driving source for slidingly moving the stopper receiving portion 122, the moving table 100, the die support portion 98, and the die coater 18, and in this example, the “table driving method” is the same as that in the first embodiment. Thus, a drive source in which the ball screw 123 and the servo motor 124 are combined is used (see FIG. 4). “Stopper presence / absence” indicates the presence / absence of the stoppers 110 and 112. Further, “the number of stopper positions” indicates the position and number of the stoppers 110 and 112, and “one central portion” indicates that the stopper is provided only at one location corresponding to the central portion of the stopper receiving portion 122. , “One each on the left and right (two places in total)” is arranged in one place on each of the left and right (two places in total) so that the stoppers 110 and 112 are arranged on both sides of the ball screw 123 as shown in FIG. Indicates. The “stopper driving method” indicates a driving source that presses the stoppers 110 and 112 against the stopper receiving portion 122, and the “servomotor” indicates a case where the rotation of the ball screw 123 is controlled by the servomotor 124. As shown in FIG. 7, “+ hydraulic clamp” indicates a case where the stopper receiver 122 is pressed against the stoppers 110 and 112 by the hydraulic device 150 in addition to the rotation control of the ball screw 123 by the servo motor 124. “Vibration values on table (X, Y, Z)” indicate the maximum displacement (amplitude) of vibration at the upper surface of the moving table 100 after the slide movement of the die coater 18 is stopped, and the X axis direction and Y axis are orthogonal to each other. The maximum displacement in the direction and the Z-axis direction is shown sequentially. The “step uneven surface shape” indicates the surface shape of the coating film formed on the web 14, “◯” means that the surface shape is good, and “Δ” means that the surface shape is normal. This means that “x” means that step unevenness is conspicuous.

  In addition, the measurement of the maximum displacement of the vibration of the moving table 100 was measured using a Rion Co., Ltd. servo acceleration watch LS-10C, and the data was analyzed by a general-purpose FFT. Further, the surface condition of the coating film was visually evaluated.

  As shown in Table 1, when there is no stopper (see “No. 1” in Table 1), the vibration of the moving table 100 is increased, and the surface of the coating film formed in the web 14 is uneven. Remarkable. In addition, when the number of stoppers is one (see “No. 2” in Table 1), compared to the case where there are two (a plurality of) stoppers (see “No. 3 and No. 4” in Table 1), the movement table. The vibration of 100 was slightly increased, and the surface of the coating film formed in the shape of the web 14 was slightly inferior. On the other hand, when one stopper is provided on each of the left and right sides (two in total) (see “No. 3” and “No. 4” in Table 1), the vibration of the moving table 100 is sufficiently suppressed and a good surface shape is obtained. It has been found that a coating film of can be formed on the web 14. In particular, it has been found that when the stopper receiving portion 122 is pressed against the stopper by the hydraulic device 150 (see “No. 4” in Table 1), vibration of the moving table 100 can be further effectively suppressed. .

It is a figure which shows the whole structure of the production line (slot die coater type coating system) of an optical film. It is a block diagram of a die coater, a backup roller, and its periphery. It is a perspective view which shows the state which cut | disconnected a part of die-coater. It is a figure which shows the structure which looked at the die-coater and backup roller of 1st Embodiment from the side. It is a front view of a stopper and its periphery. It is a figure which shows the structure which looked at the die-coater and the backup roller from the side at the time of arrange | positioning a die-coater in the predetermined application | coating position. It is a figure which shows the structure which looked at the die-coater and backup roller of 2nd Embodiment from the side. It is a figure which shows the structure which looked at the die-coater and backup roller of 3rd Embodiment from the side.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Slot die coater type coating system, 12 ... Backup roller, 14 ... Web (support), 16 ... Lip land, 18 ... Die coater (slot die), 20 ... Bead, 22 ... Manifold, 24 ... Slot, 26 ... Vacuum chamber 28 ... Air piping, 30 ... Blower, 32 ... Orifice, 33 ... Buffer device, 34 ... Buffer tank, 35 ... Air suction port, 36 ... Pressure gauge, 38 ... Controller, 40 ... Suction port, 42 ... Coating liquid pump, 44 ... coating liquid tank, 46 ... coating liquid supply pipe, 52 ... coating liquid discharge pipe, 54 ... closing plate, 60 ... width regulating plate, 62 ... front end surface of width regulating plate, 66 ... delivery machine, 68 ... pass roller, 74 ... Dust remover, 76 ... drying device, 78 ... heating device, 80 ... ultraviolet irradiation device, 82 ... winder, 98 ... die support, 100 ... moving table DESCRIPTION OF SYMBOLS 102 ... Lower mount, 104 ... Slide part, 106 ... Slide guide part, 110 ... 1st stopper, 112 ... 2nd stopper, 114 ... Stopper mount, 116 ... Stopper support part, 117 ... Contact support part, 118 ... Contact 119: Stopper moving mechanism, 122 ... Stopper receiving portion, 123 ... Ball screw, 124 ... Servo motor, 125 ... Table position detection device, 126 ... Stopper position detection device, 130 ... Roller mount, 134 ... Pushing device, 136 ... Pressing part, 138 ... Pressing support part, 140 ... Base part, 150 ... Hydraulic device, 160 ... Control device

Claims (16)

A support for supporting the slot die;
A ball screw that moves the support base in response to rotation;
A support base position detection device for detecting the position of the support base;
A servomotor for controlling the rotation of the ball screw based on the detection result of the support base position detection device;
Two or more stoppers for restricting movement of the support table by contact with the support table,
The coating apparatus is characterized in that when the coating liquid is discharged from the slot die disposed at a predetermined coating position and applied, the support base is pressed against the stopper. It is arranged so as to face the stopper via the support base, and further comprises a pressing portion that presses the support base,
The coating apparatus according to claim 1, wherein when the coating liquid is discharged from the slot die and applied, the support base is pressed by the pressing portion and pressed against the stopper. A support for supporting the slot die;
Two or more stoppers that limit movement of the support table by contact with the support table;
A pressing portion that is disposed so as to face the stopper via the support base and presses the support base;
The coating apparatus is characterized in that when the coating liquid is discharged from the slot die disposed at a predetermined coating position and applied, the support base is pressed by the pressing portion and pressed against the stopper.   The coating device according to any one of claims 1 to 3, wherein the plurality of stoppers include stoppers disposed on the left side and the right side in the horizontal direction. A slide part for moving the support base;
5. The slide part according to claim 1, wherein the slide part moves the slide part by using at least one of a rolling bearing type guide, an air slide, and a slide metal. 6. Coating device.   6. The coating apparatus according to claim 1, wherein the slot die is a die coater or a slide coater.   The coating apparatus according to claim 1, further comprising a stopper moving mechanism that moves the plurality of stoppers.   The coating apparatus according to claim 7, wherein the stopper moving mechanism moves the plurality of stoppers using at least one of motor drive, hydraulic drive, and air drive. A movement control device for controlling movement of the support base and movement of the stopper;
The movement control device moves the support base to a predetermined position based on a detection result of the support base position detection device, and then moves the stopper and presses the slot die against the support base. The coating apparatus according to claim 7, wherein the coating apparatus is disposed at a coating position. A stopper position detecting device for detecting the positions of the plurality of stoppers;
A movement control device for controlling movement of the support base and movement of the stopper;
The movement control device moves the support base and presses the plurality of stoppers against the plurality of stoppers after moving the plurality of stoppers to a predetermined position based on the detection result of the stopper position detection device. The coating apparatus according to claim 7, wherein the coating apparatus is disposed at a predetermined coating position. A movement control device for controlling movement of the support base and movement of the stopper;
8. The movement control device can finely move the support base by simultaneously moving the stopper and the support base in a state where the support base is pressed against the stopper. The coating apparatus according to 8.   The coating method which apply | coats a coating liquid on a support body using the coating device in any one of Claims 1 thru | or 11. A coating method in which a ball screw is rotated by a servo motor, and a coating liquid is discharged from a slot die supported by a support that moves as the ball screw rotates.
Move the support to a predetermined position,
A coating method, wherein the slot die is disposed at a predetermined coating position by moving a plurality of stoppers and pressing the support table disposed at the predetermined position against the plurality of stoppers. A coating method in which a ball screw is rotated by a servo motor, and a coating liquid is discharged from a slot die supported by a support that moves as the ball screw rotates.
Move multiple stoppers to a predetermined position,
An application method, wherein the slot die is arranged at a predetermined application position by moving the support table and pressing the support table against the plurality of stoppers arranged at the predetermined position.   The manufacturing method of the optical film which manufactures an optical film with the coating device in any one of Claims 1 thru | or 11. The method of manufacturing an optical film according to claim 15, wherein the optical film is an antireflection film.

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