Method for manufacturing and managing a stack

Abstract

The present application provides a method for manufacturing a laminate, which can stably manufacture a laminate including a coating layer having a desired thickness. A method for manufacturing a laminate according to one embodiment includes: a coating step of coating a coating agent on a substrate being conveyed using a coating roll to form a coating layer on the substrate, the coating agent being coated on the substrate based on a ratio of a rotation speed of the coating roll to a conveyance speed of the substrate, i.e., a coating draw ratio; a thickness acquisition step of acquiring a thickness of the coating layer; a calculation step of calculating a difference between the thickness of the coating layer and a prescribed thickness; and a change step of changing the coating draw ratio in the coating step based on the difference between the thickness of the coating layer and the prescribed thickness, the coating step, the thickness acquisition step, the calculation step, and the change step being repeatedly performed while automatically implementing the coating step, the thickness acquisition step, the calculation step, and the change step.

Description

Technical Field

[0001] This invention relates to a method for manufacturing and managing laminates. Background Technology

[0002] Patent document 1 discloses a technique of applying a coating liquid (coating agent) to a sheet (substrate) using a rotating roller (coating roller) while transporting the sheet. This produces a laminate having a substrate and a coating layer.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2000-024565 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In a laminate having a substrate and a coating layer, if the coating layer is an adhesive layer formed by an adhesive, for example, to manufacture a product containing the laminate, the laminate is bonded to other components. In this case, if the thickness of the coating layer deviates from the desired thickness (or is uneven), the same undesirable situation occurs in the product, resulting in the product potentially failing to achieve the desired performance. Alternatively, depending on the material of the coating layer, the laminate itself is sometimes sold as a product. In this case, if the thickness of the coating layer deviates from the desired thickness (or is uneven), the appearance of the product may be impaired. Therefore, it is necessary to manage the coating state of the coating agent in a way that achieves the desired thickness. The thickness of the coating layer is determined by the ratio of the rotation speed of the coating roller to the transport speed of the substrate (hereinafter referred to as the "coating traction ratio").

[0008] Traditionally, coating thickness was managed, for example, as shown below. A coating agent was applied to a substrate using a coating roller, and the resulting coating thickness was measured. Using this measurement result, the user (the manufacturer of the laminate) determined a new coating draw ratio based on experience, thereby managing the coating thickness.

[0009] However, because users determine the coating pull ratio that should be changed based on experience, it is sometimes impossible to consistently achieve the desired thickness.

[0010] One aspect of the present invention aims to provide a method for manufacturing a laminate that can stably manufacture a laminate comprising a coating layer having a desired thickness. Another aspect of the present invention aims to provide a management method that manages the coating pull ratio in a manner that stably forms a coating layer having a desired thickness.

[0011] means for solving problems

[0012] A method for manufacturing a laminate according to one aspect of the present invention includes: a coating step in which a coating agent is applied to a transported substrate using a coating roller to form a coating layer on the substrate, and the coating agent is applied to the substrate based on a coating traction ratio, which is the ratio of the rotational speed of the coating roller to the transport speed of the substrate; a thickness acquisition step in which the thickness of the coating layer is acquired; a calculation step in which the difference between the thickness of the coating layer and a predetermined thickness is calculated; and a modification step in which the coating traction ratio in the coating step is modified based on the difference between the thickness of the coating layer and the predetermined thickness, and the coating step, the thickness acquisition step, the calculation step, and the modification step are performed repeatedly while the coating step, the thickness acquisition step, the calculation step, and the modification step are performed automatically.

[0013] In the above manufacturing method, the coating pull ratio in the coating process is changed based on the difference between the thickness of the coating layer and the specified thickness. Furthermore, the coating process, the thickness acquisition process, the calculation process, and the change process are performed automatically. Therefore, it is possible to stably manufacture a laminate containing a coating layer with the desired thickness.

[0014] The thickness of the coating layer can be the average thickness of the coating layer within a specified range along the transport direction of the substrate. Even coating layers applied with the same coating draw ratio exhibit some variation in thickness in reality. By using the aforementioned average thickness, the coating draw ratio can be varied to reduce the impact of these variationes.

[0015] The thickness acquisition process can be performed at specified intervals, and the calculation process can be performed each time the thickness acquisition process is performed. The coating process, the thickness acquisition process, the calculation process, and the modification process can be repeated in cycles longer than the specified interval. The modification process in each cycle changes the coating pull ratio in the coating process based on the difference between the thickness of the coating layer calculated in the last calculation process among the multiple calculation processes performed in the cycle and the specified thickness.

[0016] In the above method, since the change process is carried out at a period longer than the specified interval, the next coating traction ratio can be calculated based on the thickness of the coating layer in a stable state after the coating traction ratio is changed.

[0017] In the above-mentioned modification process, the traction ratio adjustment value can be calculated by multiplying the difference between the thickness of the coating layer and the specified thickness by a specified adjustment ratio. When the coating traction ratio in the first coating process is set as the initial coating traction ratio, in the Nth modification process (N is an integer of 2 or more), a new coating traction ratio is set in the form of the sum of the (N-1) traction ratio adjustment values ​​calculated in the modification processes up to the (N-1)th modification process, the traction ratio adjustment value calculated in the Nth modification process, and the initial coating traction ratio.

[0018] When the coating traction ratio before the change of the above-mentioned change process is set as the first coating traction ratio, and the coating traction ratio changed in the above-mentioned change process is set as the second coating traction ratio, in the above-mentioned change process, the second coating traction ratio can be set in the form of the sum of the traction ratio adjustment value obtained by multiplying the difference between the thickness of the above-mentioned coating layer and the specified thickness by the specified adjustment ratio and the first coating traction ratio.

[0019] Another aspect of the present invention is a management method for managing the coating traction ratio, which is the ratio of the rotational speed of the coating roller to the transport speed of the substrate, used in the coating process. The coating process is a process of applying a coating agent onto a transported substrate using a coating roller to form a coating layer on the substrate. The management method includes: a thickness acquisition step, which acquires the thickness of the coating layer formed by the coating process; a calculation step, which calculates the difference between the thickness of the coating layer and a predetermined thickness; and a modification step, which modifies the coating traction ratio in the coating process based on the difference between the thickness of the coating layer and the predetermined thickness. The thickness acquisition step, the calculation step, and the modification step are performed automatically.

[0020] In the above management method, the coating pull ratio in the coating process is changed based on the difference between the thickness of the coating layer and the specified thickness. Furthermore, the thickness acquisition step, the calculation step, and the change step are performed automatically. Therefore, the coating pull ratio can be managed to stably form a coating layer with the desired thickness.

[0021] The thickness of the coating layer can be the average thickness of the coating layer within a specified range along the transport direction of the substrate. Even coating layers applied with the same coating draw ratio exhibit some variation in thickness in reality. By using the aforementioned average thickness, the coating draw ratio can be varied to reduce the impact of these variationes.

[0022] When repeatedly performing the above-mentioned coating process, thickness acquisition process, calculation process, and modification process, the thickness acquisition process can be performed at specified intervals, and the calculation process can be performed each time the thickness acquisition process is performed. The coating process, thickness acquisition process, calculation process, and modification process can be repeatedly performed at a period longer than the specified interval. The modification process in each period is based on the difference between the thickness of the coating layer calculated in the last calculation process among the multiple calculation processes performed in the period and the specified thickness, and the coating pull ratio in the coating process is changed.

[0023] In the above method, since the change process is carried out at a period longer than the specified interval, the next coating traction ratio can be calculated based on the thickness of the coating layer in a stable state after the coating traction ratio is changed.

[0024] In the above-mentioned modification process, the traction ratio adjustment value can be calculated by multiplying the difference between the thickness of the coating layer and the specified thickness by a specified adjustment ratio. When the above-mentioned coating process, the above-mentioned thickness acquisition process, the above-mentioned calculation process and the above-mentioned modification process are repeatedly performed, when the coating traction ratio in the first coating process is set as the initial coating traction ratio, in the Nth modification process (N is an integer of 2 or more), a new coating traction ratio is set in the form of the sum of the (N-1) traction ratio adjustment values ​​calculated in the modification processes up to the (N-1)th modification process, the traction ratio adjustment value calculated in the Nth modification process, and the initial coating traction ratio.

[0025] When the coating traction ratio before the change of the above-mentioned change process is set as the first coating traction ratio, and the coating traction ratio changed in the above-mentioned change process is set as the second coating traction ratio, the second coating traction ratio can be set in the form of the sum of the traction ratio adjustment value obtained by multiplying the difference between the thickness of the above-mentioned coating layer and the specified thickness by a specified adjustment ratio and the first coating traction ratio.

[0026] Invention Effects

[0027] According to one aspect of the invention, a method for manufacturing a laminate can be provided, which is capable of stably manufacturing a laminate comprising a coating layer having a desired thickness. According to another aspect of the invention, a management method can be provided, which manages the coating pull ratio in a manner that stably forms a coating layer having a desired thickness. Attached Figure Description

[0028] Figure 1 This is a conceptual diagram illustrating an example of a method for manufacturing a laminate according to one embodiment.

[0029] Figure 2 This is a flowchart of an example of a method for manufacturing a laminate according to one implementation.

[0030] Figure 3 This is a chart illustrating an example of data used to change the coating pull ratio in a method for manufacturing a laminate in one embodiment.

[0031] Figure 4 This is a chart illustrating an example of data used to change the coating pull ratio in a method for manufacturing a laminate in one embodiment.

[0032] Figure 5 This is a chart illustrating an example of data used to change the coating pull ratio in a method for manufacturing a laminate in one embodiment.

[0033] Figure 6 It means Figures 3-5 The thickness t of the coating layer in ave A graph showing the change in the traction ratio adjustment value.

[0034] Figure 7 It means Figures 3-5 The curves showing the changes in coating pull ratio and coating thickness t1.

[0035] Figure 8 It is a graph representing the results of the verification experiment.

[0036] Explanation of reference numerals in the attached figures

[0037] 10-layer laminate, 11-substrate, 12-coating layer, 12a-coating agent, 22-coating roller, 30-control device. Detailed Implementation

[0038] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The same symbols are used for the same elements, and repeated descriptions are omitted. The scale of the drawings may not necessarily be the same as that in the description.

[0039] Figure 1 This is a conceptual diagram illustrating a method for manufacturing a laminate in one embodiment. Figure 1 In the manufacturing method of the laminate 10 shown, a strip of substrate 11 is transported using a conveying device (not shown) while a coating agent 12a is applied to the substrate 11. Thus, a laminate 10 having a substrate 11 and a coating layer 12 formed by the coating agent 12a can be obtained.

[0040] The substrate 11 is, for example, a resin film. In this case, the substrate 11 formed by extrusion molding can be transported continuously, for example. The substrate 11 can also be transported continuously as it is released from a roll of substrate 11. The substrate 11 can be a flexible material, a single-layer resin film, or a laminate of resin films. Examples of substrate 11 include triacetyl cellulose (TAC), polyethylene terephthalate (PET), and polycyclic cyclic olefins (COP). The substrate 11 can also be an optical laminate such as a polarizer, a retardation plate, a circular polarizer (including an elliptical polarizer) obtained by bonding a retardation plate and a polarizer with an adhesive layer, or a laminate obtained by laminating a protective film onto a polarizer or retardation plate. The aforementioned polarizer can, for example, be a laminate obtained by laminating a polarizing film (polarizing film layer) with a protective film. Similarly, the aforementioned retardation plate can, for example, be a laminate obtained by laminating a retardation film (retardation sublayer) with a protective film. Examples of the thickness of the substrate 11 are 10 μm to 200 μm.

[0041] A coating layer 12 is formed on a substrate 11. The thickness of the coating layer 12 is typically 0.1 μm to 10 μm, preferably 0.5 μm to 5 μm, and more preferably 1 μm to 3 μm. Examples of the coating agent 12a used as the material for the coating layer 12 are adhesives or binders. The adhesive or binder can be a material known in the art of this disclosure. Examples of adhesives include UV-curable resins and other active energy ray-curable adhesives, and aqueous adhesives such as polyvinyl alcohol-based resin aqueous solutions. Examples of binders include binder compositions with (meth)acrylic resins, rubber resins, urethane resins, ester resins, silicone resins, and polyvinyl ether resins as main components.

[0042] Figure 2 This is a flowchart illustrating an example of a method for manufacturing a laminate 10. The method for manufacturing the laminate 10 includes a coating step S01, a thickness acquisition step S02, a calculation step S03, and a modification step S04. The thickness acquisition step S02, the calculation step S03, and the modification step S04 constitute a method for managing the thickness of the coating layer 12 in one embodiment. The laminate 10 is manufactured by repeatedly performing the coating step S01, the thickness acquisition step S02, the calculation step S03, and the modification step S04 as a basic cycle. Figure 2 The diagram below shows the steps involved in the basic cycle described above. Each step is explained.

[0043] [Coating Process]

[0044] In coating process S01, such as Figure 1As shown, a coating agent 12a is applied to a transported substrate 11 using a coating apparatus 20. Specifically, the coating agent 12a in the coating agent supply section 21 of the coating apparatus 20 is applied to the substrate 11 using a coating roller 22. An example of the coating apparatus 20 is a known gravure coating apparatus. In this case, the coating roller 22 is a gravure roller. The coating roller 22 is as follows... Figure 1 As shown, for example, it rotates in a direction opposite to the transport direction of the substrate 11.

[0045] In the coating process S01, the coating agent 12a is applied to the substrate 11 based on the coating draw ratio (%) set (or saved) in the control device 30. The coating draw ratio is the ratio (V1 / V2) of the rotational speed V1 of the coating roller 22 to the conveying speed V2 of the substrate 11. For example, when the rotational speed V1 is 60 m / min and the conveying speed V2 is 30 m / min, the coating draw ratio is 200%. In this embodiment, the control device 30 controls the rotational speed V1 of the coating roller 22, thereby adjusting the coating draw ratio. As described later, the coating draw ratio is appropriately changed using the change process S04. The initial coating draw ratio at the start of manufacturing of the laminate 10 can be pre-input into the control device 30 by the user.

[0046] [Thickness Acquisition Process]

[0047] In the thickness acquisition process S02, the thickness t of the coating layer 12 is obtained. ave The thickness t of the coating layer 12 obtained in the thickness obtaining process S02 of this embodiment. ave It is the average thickness of the coating layer 12 within a specified range of the substrate 11. The specified range is defined as a region of a certain length along the transport direction of the substrate 11 (or a region of a certain length passing below the measuring device M1 or the measuring device M2).

[0048] In the thickness acquisition process S02, such as Figure 1 As shown, in the transport direction of the substrate 11, the control device 30 obtains the thickness t of the coating layer 12 by utilizing the measurement results of the measuring instruments M1 and M2 disposed upstream and downstream of the coating apparatus 20. ave The measuring instruments M1 and M2 are described below.

[0049] Measuring device M1 measures the thickness t0 of substrate 11. Measuring device M2 measures the thickness t2 of laminate 10 including coating layer 12. Therefore, the manufacturing method of laminate 10 in one embodiment may have a step of obtaining the thickness of substrate 11 before coating step S01, and a step of measuring the thickness of laminate 10 after coating step S01.

[0050] There are no limitations on whether measuring devices M1 and M2 can measure the thickness of the objects being measured (substrate 11 and laminate 10). An example of measuring device M1 and M2 is a spectroscopic interferometric laser displacement meter (e.g., KEYENCE SI-T series). Measuring devices M1 and M2 input the measurement results (thickness t0, thickness t2) to the control device 30. There are no limitations on the input method. For example, the measurement results can be input to the control device 30 via wired or wireless means.

[0051] In this embodiment, the control device 30 controls the measuring devices M1 and M2. Specifically, the control device 30 controls the measuring devices M1 and M2 to perform measurements at predetermined intervals. Thus, the measurement results of the measuring devices M1 and M2 are sequentially input into the control device 30 at the predetermined intervals. Regarding the predetermined intervals, in order to calculate the difference Δd1 (described later) at the specified intervals, the intervals can be the same as or smaller than the specified intervals. The predetermined intervals are input into the control device 30 by the user beforehand.

[0052] For the thickness t using control device 30 ave An example of the calculation method will be used to illustrate this.

[0053] The control device 30 calculates the difference Δd1 between the measurement results of measuring device M2 and measuring device M1. The difference Δd1 is the difference between the measurement results of measuring device M2 and measuring device M1 at the same location on the substrate 11 (referred to as "measurement position x" for ease of explanation). The difference Δd1 can be calculated using the measurement results at measurement position x, based on the setting distance between measuring devices M1 and M2 and the transport speed of the substrate 11, respectively. The difference Δd1 is the thickness t1 of the coating layer 12 at measurement position x on the substrate 11. The control device 30 calculates the difference Δd1 at each specified interval. The specified interval is pre-input by the user into the control device 30. The control device 30 obtains the thickness t1 by averaging multiple differences Δd1 within a specified range that are sequentially calculated from the start of manufacturing of the laminate 10. ave In this embodiment, the specified range is a region having a certain length (the length along the transport direction of the substrate 11) pre-input by the user into the control device 30. The average difference Δd1 used is determined by the length of the specified range and the number of times the difference Δd1 is updated (equivalent to a specified interval in this embodiment).

[0054] [Calculate the process steps]

[0055] In process S02, the control device 30 calculates the thickness t. aveThe difference Δd2 between the thickness and the target thickness (the specified thickness). For example, the calculation process S02 is performed each time the thickness acquisition process S02 is performed.

[0056] [Change of work process]

[0057] In the change process S04, the control device 30, based on the difference Δd2, adjusts the thickness t. ave In accordance with the target thickness, the coating pull ratio in coating process S01 is changed. In this embodiment, the control device 30 performs the change process S04 at a period larger than the specified interval of the calculated difference Δd1 (hereinafter referred to as the "correction period"). For example, the correction period can be a natural number multiple of 2 or more of the specified interval (e.g., 3 times, 4 times, etc.). The correction period can be pre-input into the control device 30 by the user. For example, the change process S04 can be performed each time the calculation process S03 is performed.

[0058] For example, the control device 30 can adjust the traction ratio based on the difference Δd2 by multiplying it by a preset correction gain (adjustment ratio) to adjust the thickness t. ave The coating pull ratio in coating process S01 is changed in a manner consistent with the target thickness. The aforementioned correction gain can be pre-input by the user into the control device 30. The aforementioned correction gain can be changed by the user during the manufacturing of the laminate 10 according to the manufacturing conditions. The correction gain can be 1x, but is preferably 10 to 70x, more preferably 20 to 50x, and even more preferably 30 to 40x.

[0059] An example of a method for changing the coating traction ratio using the aforementioned traction ratio adjustment value will be described. In this example, in the Nth change step S04 (where N is an integer of 2 or more), the sum of the (N-1) traction ratio adjustment values ​​calculated up to the (N-1)th change step S04 and the traction ratio adjustment value calculated in the Nth change step is further calculated as a correction value. A new coating traction ratio is set in the form of the sum of the aforementioned correction value and the initial coating traction ratio (the coating traction ratio set for implementing the first coating step S01).

[0060] Another example of a method for changing the coating traction ratio using the aforementioned traction ratio adjustment value will be described. For ease of explanation, the coating traction ratio before the change will be referred to as the first coating traction ratio, and the coating traction ratio after the change will be referred to as the second coating traction ratio. In this example, the control device 30 sets the second coating traction ratio as the sum of the traction ratio adjustment value and the first coating traction ratio.

[0061] The laminate 10 manufactured as described above can be bonded to other components, or it can be sold as a product by further curing the coating layer 12.

[0062] The control device 30 described above only needs to be configured to perform all the functions of the control device 30 described in the coating process S01 to the change process S04. The control device 30 may have the function of receiving inputs such as measurement results from measuring instruments M1 and M2 and various data from the user, and displaying various data (thickness t). ave The control device 30 can perform functions such as adjusting the difference Δd2 and the traction ratio. Examples of user-input data include the target thickness and the various parameters mentioned above (e.g., specified interval, correction period, correction gain, etc.). The control device 30 can be a dedicated device for manufacturing laminates. Alternatively, the personal computer can function as the control device 30 by executing a program in the personal computer to perform the various functions mentioned above.

[0063] use Figures 3-5 The method for changing the coating traction ratio of the control device 30 is further explained in detail. Figure 3 This is a chart illustrating an example of data used to change the coating traction ratio in a manufacturing method of a laminate 10 in one embodiment.

[0064] Figures 3-5 The data shown is from a hypothetical case assuming the fabrication of laminate 10 under the following conditions. Figures 3-5 Select the data from the hypothetical case up to 60 seconds have elapsed.

[0065] Target thickness: 1.5μm

[0066] Initial coating pull ratio: 200%

[0067] Length of the specified range: 1.4m

[0068] Specified interval: 1 second

[0069] Delivery speed: 21m / minute (0.35m / second)

[0070] Correction period: 15 seconds (equivalent to a length of 5.25m)

[0071] Corrected gain: 35

[0072] Figures 3-5 The thickness t1 shown is, for example, when using... Figure 1 When measuring instruments M1 and M2 measure thickness t0 and thickness t2, the thickness of the coating layer 12 is calculated as the difference between thickness t2 and thickness t1.

[0073] Since the designated range is assumed to be 1.4m and the transport speed is assumed to be 21m / minute, therefore, Figure 3As shown, at the moment when data up to data No. 5 is obtained, the thickness t is calculated as the average of the differences Δd1 between data No. 1 and No. 5. ave Since the specified range is 1.4m long, therefore in Figure 3 In the example shown, the region of substrate 11 corresponding to data No. 2 to No. 6 is taken as the next specified range, and the thickness t is calculated. ave Subsequently, while shifting the specified range by 0.35m each time (equivalent to 1 second), the thickness t was calculated. ave Each time the thickness t is calculated... ave At that time, the difference Δd2 is calculated, and the traction ratio adjustment value is also calculated. Figure 6 It means Figures 3-5 thickness t ave A graph showing the change in the traction ratio adjustment value. Figure 6 The horizontal axis represents the transport distance of substrate 11. Figure 6 The vertical axis on the left represents the thickness t. ave (μm), with the vertical axis on the right representing the traction ratio adjustment value.

[0074] Since the correction period is 15 seconds, therefore... Figure 3 As shown, at the moment when data No. 15 is obtained, a new coating traction ratio is set based on the traction ratio adjustment value. Specifically, since the moment data No. 15 is obtained is the first change process S04, the traction ratio adjustment value is equivalent to the correction value. Therefore, by adding -22.4, which is the correction value (equivalent to the traction ratio adjustment value), to 200% of the coating traction ratio up to data No. 15, the calculated value of 177.6 is set as the next coating traction ratio. Thereafter, as... Figure 4 As shown, when data No. 30 is obtained, a new coating traction ratio is set based on the traction ratio adjustment value. Specifically, since the traction ratio adjustment value when data No. 30 is obtained during the second change process S04 is -7, -7 is added to the correction value of -22.4 calculated in the first change process S04, and the resulting -29.4 is used as the correction value. -29.4 is added to 200% of the initial coating traction ratio, and the resulting 170.6 is used as the next coating traction ratio. The coating traction ratio is set similarly thereafter.

[0075] Figure 7 It means Figures 3-5 The curves showing the changes in coating pull ratio and coating thickness t1. Figure 7 The left vertical axis represents the coating pull ratio (%), and the right vertical axis represents the thickness t1 of the coating layer 12.

[0076] like Figures 3-5 and Figure 7 As shown, the coating traction ratio changes for every 5.25m transport distance. Consequently, the thickness t1 of the coating layer 12 also changes, converging to 1.5μm as the target thickness.

[0077] Based on Figures 3-5 The description of the data illustrated explains how to adjust the coating pull ratio using correction values. However, it is also possible to omit this step. Figures 3-5 The coating pull ratio is adjusted according to the correction value shown. The method for adjusting the coating pull ratio in this case is explained.

[0078] Since the pull ratio adjustment value at the time of implementing the initial change process S04 (data No. 15) was -22.4, the next coating pull ratio will be set to 177.6, calculated by adding -22.4 to 200% of the initial coating pull ratio. Since the pull ratio adjustment value at the time of implementing the second change process S04 (data No. 30) was -7, the next coating pull ratio will be set to 170.6, calculated by adding -7 to 177.6. The coating pull ratio will be set similarly thereafter.

[0079] In the manufacturing method of the above-described laminate 10, the thickness of the coating layer 12 is obtained, and the coating pull ratio is changed based on the difference Δd2 between this thickness and the target thickness. In the manufacturing method of the above-described laminate 10, the coating process S01, the thickness acquisition process S02, the calculation process S03, and the change process S04 can be repeatedly performed while the control device 30 automatically performs these processes. That is, the control device 30 can automatically acquire and calculate the data necessary for changing the coating pull ratio. In this case, the thickness of the coating layer 12 (actual thickness or average thickness) can be automatically monitored, and the coating pull ratio can be adjusted based on the obtained thickness of the coating layer 12 (thickness t in this embodiment). ave The coating draw ratio is automatically adjusted. In other words, the coating draw ratio is automatically adjusted to bring the thickness t2 of the coating layer 12 to the target thickness. As a result, a laminate 10 having a coating layer 12 with the target thickness can be stably manufactured. Furthermore, since the coating draw ratio is automatically adjusted to bring the thickness of the coating layer 12 to the target thickness, the thickness fluctuation of the coating layer 12 is also reduced. As a result, the quality of the laminate 10 can be improved.

[0080] Figure 8 It is a graph representing the results of the verification experiment. Figure 8 In use Figure 1 and Figure 2The manufacturing method of the laminate 10 described herein is illustrated with the results of manufacturing the laminate 10 as an example. The multiple drawing points are the results of three manufacturing examples of the laminate 10 manufactured according to this manufacturing method. Specifically, a phase retardation plate with a coating layer 12 on a TAC, a phase retardation plate with a coating layer 12 on a PET, and a laminate with a coating layer 12 on a COP film were manufactured. In each manufacturing example, the coating layer 12 was formed of a UV-curable resin (UV adhesive). The same coating roller and the same UV adhesive were used in each manufacturing example. The target thickness of the coating layer 12 in each manufacturing example was 1.5 μm. Figure 8 In the manufacturing examples of the multiple laminates 10, relative to the use of Figure 1 The standard deviation of the thickness t0 of the substrate 11 measured by the measuring instrument M1 is shown. The standard deviation of the thickness t1 of the coating layer 12 (the difference between the measurement results of measuring instrument M2 and measuring instrument M1) is then plotted. If a thickness distribution occurs within the thickness t0 of the substrate 11, it is considered to affect the thickness distribution of the coating layer 12 at thickness t1. Therefore, in... Figure 8 As described above, the standard deviation of the thickness t1 of the coating layer 12 is plotted relative to the standard deviation of the thickness t0 of the substrate 11.

[0081] Figure 8 The results of the comparative experiment are shown below as a comparative example. In the comparative experiment, the same manufacturing apparatus as that used in manufacturing the laminate 10 of the manufacturing example was used. However, the user (the person responsible for manufacturing the laminate 10) adjusted the coating pull ratio based on experience using the measurement results from measuring instruments M1 and M2. The materials and target thicknesses of the substrate 11 and the coating layer 12 were the same as those used in manufacturing the laminate 10 of the manufacturing example. Figure 8 The results of the three types of laminates 10 manufactured in the comparative experiment are plotted. The meaning of each plotted point is the same as in the example.

[0082] according to Figure 8 It can be seen that in the embodiment where the coating pull ratio is automatically adjusted, the thickness fluctuation of the coating layer 12 is smaller. That is, it can be understood that by automatically adjusting the coating pull ratio, a higher quality laminate 10 can be manufactured.

[0083] In the above-mentioned method for manufacturing the laminate 10, compared with the case where the coating traction ratio is varied based on experience, the thickness t1 of the coating layer 12 can be converged to the target thickness more quickly, thus achieving labor saving and enabling efficient use of materials.

[0084] Even with the same coating draw ratio, some fluctuations will occur in the thickness of the coating layer 12 in reality. Therefore, by using thickness t as the average thickness... aveAs for the thickness of the coating layer 12, the coating pull ratio can be adjusted while reducing the impact of the aforementioned fluctuations. By performing the change process S04 at a period longer than the specified interval for thickness measurement, the coating pull ratio can be adjusted based on the thickness of the coating layer 12 in a stable state after changing to a new coating pull ratio. Furthermore, considering the aforementioned stability and follow-through, the length of the specified range, the specified interval, and the correction period can be set in a way that achieves the target thickness of the coating layer 12.

[0085] The embodiments of the present invention have been described above. However, the present invention is not limited to the illustrated embodiments, and is intended to encompass the scope given by the claimed scope, and to include all modifications within the scope and meaning equivalent to the claimed scope.

[0086] For example, the cycle for implementing the change process (correction cycle) can be the same as the interval specified above, and the coating thickness used when calculating the traction ratio adjustment value can be the actual coating thickness. Figure 1 The thickness t1). The material of the coating layer is not limited to adhesives and binders.

[0087] In the above embodiments, for ease of explanation, the method of first calculating the difference Δd2, the traction ratio adjustment value, etc., and then calculating the coating traction ratio that should be changed has been described. However, the control device 30 may also directly calculate the new coating traction ratio based on the measurement results input from the measuring devices M1 and M2. In this case, the calculation of the new coating traction ratio is also based on the difference Δd2, the traction ratio adjustment value, etc.

[0088] To obtain the thickness of coating layer 12, the method of using measuring instruments M1 and M2 has been described. However, for example, the thickness of the coating layer can also be measured directly using a thickness measuring instrument. Alternatively, the thickness of coating layer 12 can be calculated using a pre-set substrate thickness and the measurement result of measuring instrument M2.

[0089] For example, the coating traction ratio can be changed by adjusting the substrate transport speed.

Claims

1. A method for manufacturing a laminate having a coating layer, the method comprising: In the coating process, a coating agent is applied to a transported substrate using a coating roller to form a coating layer on the substrate. The coating agent is applied to the substrate based on the ratio of the rotational speed of the coating roller to the transport speed of the substrate, i.e., the coating traction ratio. The thickness acquisition process is used to obtain the thickness of the coating layer. Calculate the process and the difference between the thickness of the coating layer and the specified thickness; as well as The process is modified by changing the coating pull ratio in the coating process based on the difference between the thickness of the coating layer and the specified thickness. While automatically performing the coating process, the thickness acquisition process, the calculation process, and the modification process, the coating process, the thickness acquisition process, the calculation process, and the modification process are repeatedly performed. The thickness acquisition process is performed at specified intervals. The calculation process is performed each time the thickness acquisition process is performed. The coating process, the thickness acquisition process, the calculation process, and the modification process are repeated at intervals longer than the specified interval. The change process in each cycle is based on the difference between the coating thickness calculated in the last calculation process among the multiple calculation processes performed within the cycle and the specified thickness, thereby changing the coating pull ratio in the coating process. In the modification process, the traction ratio adjustment value is calculated by multiplying the difference between the thickness of the coating layer and the specified thickness by a designated adjustment ratio. When the coating traction ratio in the first coating process is set as the initial coating traction ratio, in the Nth change process where N is an integer greater than or equal to 2, a new coating traction ratio is set in the form of the sum of the (N-1) traction ratio adjustment values ​​calculated in the change processes up to the (N-1)th, the traction ratio adjustment value calculated in the Nth change process, and the initial coating traction ratio.

2. A method for manufacturing a laminate having a coating layer, the method comprising: In the coating process, a coating agent is applied to a transported substrate using a coating roller to form a coating layer on the substrate. The coating agent is applied to the substrate based on the ratio of the rotational speed of the coating roller to the transport speed of the substrate, i.e., the coating traction ratio. The thickness acquisition process is used to obtain the thickness of the coating layer. Calculate the process and the difference between the thickness of the coating layer and the specified thickness; as well as The process is modified by changing the coating pull ratio in the coating process based on the difference between the thickness of the coating layer and the specified thickness. While automatically performing the coating process, the thickness acquisition process, the calculation process, and the modification process, the coating process, the thickness acquisition process, the calculation process, and the modification process are repeatedly performed. The thickness acquisition process is performed at specified intervals. The calculation process is performed each time the thickness acquisition process is performed. The coating process, the thickness acquisition process, the calculation process, and the modification process are repeated at intervals longer than the specified interval. The change process in each cycle is based on the difference between the coating thickness calculated in the last calculation process among the multiple calculation processes performed within the cycle and the specified thickness, thereby changing the coating pull ratio in the coating process. When the coating traction ratio before the change of the change process is set as the first coating traction ratio, and the coating traction ratio after the change process is set as the second coating traction ratio, the second coating traction ratio is set in the form of the sum of the traction ratio adjustment value obtained by multiplying the difference between the thickness of the coating layer and the specified thickness by a specified adjustment ratio and the first coating traction ratio.

3. The manufacturing method according to claim 1 or 2, wherein, The thickness of the coating layer is the average thickness of the coating layer within a specified range along the transport direction of the substrate.

4. A management method for managing the ratio of the rotational speed of a coating roller to the conveying speed of a substrate, i.e., the coating traction ratio, used in a coating process, wherein the coating process involves applying a coating agent onto a conveyed substrate using a coating roller to form a coating layer on the substrate, the management method comprising: The thickness acquisition process obtains the thickness of the coating layer formed by the coating process. Calculate the process and the difference between the thickness of the coating layer and the specified thickness; as well as The process is modified by changing the coating pull ratio in the coating process based on the difference between the thickness of the coating layer and the specified thickness. In the management method, the thickness acquisition process, the calculation process, and the change process are executed automatically, while the coating process, the thickness acquisition process, the calculation process, and the change process are repeated continuously. The thickness acquisition process is performed at specified intervals. The calculation process is performed each time the thickness acquisition process is performed. The coating process, the thickness acquisition process, the calculation process, and the modification process are repeated at intervals longer than the specified interval. The change process in each cycle is based on the difference between the coating thickness calculated in the last calculation process among the multiple calculation processes performed within the cycle and the specified thickness, thereby changing the coating pull ratio in the coating process. In the modification process, the traction ratio adjustment value is calculated by multiplying the difference between the thickness of the coating layer and the specified thickness by a designated adjustment ratio. When repeatedly performing the coating process, the thickness acquisition process, the calculation process, and the modification process, when the coating traction ratio of the first coating process is set as the initial coating traction ratio, in the Nth modification process where N is an integer greater than or equal to 2, a new coating traction ratio is set in the form of the sum of the (N-1) traction ratio adjustment values ​​calculated in the modification processes up to the (N-1)th modification process, the traction ratio adjustment value calculated in the Nth modification process, and the initial coating traction ratio.

5. A management method for managing the ratio of the rotational speed of a coating roller to the conveying speed of a substrate, i.e., the coating traction ratio, used in a coating process, wherein the coating process involves applying a coating agent onto a conveyed substrate using a coating roller to form a coating layer on the substrate, the management method comprising: The thickness acquisition process obtains the thickness of the coating layer formed by the coating process. Calculate the process and the difference between the thickness of the coating layer and the specified thickness; as well as The process is modified by changing the coating pull ratio in the coating process based on the difference between the thickness of the coating layer and the specified thickness. In the management method, the thickness acquisition process, the calculation process, and the change process are executed automatically, while the coating process, the thickness acquisition process, the calculation process, and the change process are repeated continuously. The thickness acquisition process is performed at specified intervals. The calculation process is performed each time the thickness acquisition process is performed. The coating process, the thickness acquisition process, the calculation process, and the modification process are repeated at intervals longer than the specified interval. The change process in each cycle is based on the difference between the coating thickness calculated in the last calculation process among the multiple calculation processes performed within the cycle and the specified thickness, thereby changing the coating pull ratio in the coating process. When the coating traction ratio before the change of the change process is set as the first coating traction ratio, and the coating traction ratio after the change process is set as the second coating traction ratio, in the change process, the second coating traction ratio is set in the form of the sum of the traction ratio adjustment value obtained by multiplying the difference between the thickness of the coating layer and the specified thickness by a specified adjustment ratio and the first coating traction ratio.

6. The management method according to claim 4 or 5, wherein, The thickness of the coating layer is the average thickness of the coating layer within a specified range along the transport direction of the substrate.

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