Coating nozzle and program for the same

Abstract

To accurately and efficiently align each chalk bar with an initial position when reassembling is carried out through, for example, periodic cleaning.SOLUTION: A coating nozzle comprises: a die including a pair of block bodies facing each other with a gap therebetween, and discharging paint having flown into the gap by using an opening facing a prescribed direction of the gap as a discharge port; and a flow rate control mechanism for controlling a flow rate of paint flowing through the gap toward the discharge port. The flow rate control mechanism includes: a recess formed in an opposed surface of one block body; a chalk bar housed in the recess and movable in a direction closer to or farther from an opposed surface of the other block body; an actuator connected to the chalk bar; and a control unit for controlling the actuator. The control unit has an initial position aligning part for moving the chalk bar in the direction farther from the opposed surface of the other block body by a preset moving distance after the control unit controls the actuator and brings the chalk bar into contact with the opposed surface of the other block body.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a coating nozzle and a program for a coating nozzle.

Background Art

[0002] For example, in electronic devices such as displays, a film in which a functional paint is applied to a base material is used. As a coating device for applying the paint to this base material, Patent Document 1 discloses a die that includes a pair of block bodies facing each other with a gap therebetween and discharges the paint flowing into the gap, and a choke bar that can enter and exit a recess formed on the facing surface of one of the block bodies. A coating nozzle is disclosed that controls the thickness of the paint applied to the base material in units of μm by adjusting the distance between the choke bar and the other block body.

[0003] In this type of coating nozzle, when the paint enters the recess, it causes malfunction of the choke bar, so it needs to be regularly cleaned frequently. In this regular cleaning, it is overhauled, but when reassembling, it is necessary to align each choke bar to the initial position.

[0004] Specifically, the coating nozzle is designed so that the film thickness of the paint applied to the base material becomes the target value in a state where the choke bar is aligned to the initial position. Therefore, when reassembling, if the choke bar is not aligned to the initial position, it takes a long time to reach the target value during restart, and the yield deteriorates.

[0005] This initial position is usually set to a position where the choke bar is flush with the facing surface on which the recess of one of the block bodies is formed. Conventionally, an operator has performed this alignment work by feeling. Specifically, the operator operates a drive mechanism provided on the choke bar and determines whether or not the tip surface of the choke bar is flush with the facing surface of one of the block bodies by visual inspection and palpation. Therefore, it is very inefficient and lacks accuracy.

Prior Art Documents

Patent Document

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] Therefore, for example, when reassembling during regular cleaning or the like, the main problem is to be able to efficiently and accurately align the choke bar to the initial position.

Means for Solving the Problems

[0008] The coating nozzle according to the present invention includes a pair of block bodies facing each other with a gap therebetween, a die that discharges the paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism that controls the flow rate of the paint flowing toward the discharge port through the gap. The flow rate control mechanism includes a recess formed on the facing surface of one of the block bodies, a choke bar accommodated in the recess and movable in a direction approaching and a direction away from the facing surface of the other block body, an actuator connected to the choke bar, and a control unit that controls the actuator. The control unit has an initial alignment unit that controls the actuator, brings the choke bar into contact with the facing surface of the other block body, and then moves the choke bar in a direction away from the facing surface of the other block body by a preset moving distance.

[0009] According to the present invention, for example, if the moving distance is set to the same length as the interval between the gaps of the pair of block bodies, the choke bar can be easily aligned flush with the facing surface of one of the block bodies when reassembling. Also, since the choke bar is moved by the actuator, it can be accurately aligned. Further, even if the initial position is not flush with the facing surface of one of the block bodies, it can be aligned by measuring the distance to the facing surface of the other block body in advance.

[0010] For example, when the coating device stops due to a power outage or the like, in order to improve the yield at the time of resuming operation, it is preferable to align the choke bar to the initial position before resuming operation. However, in this case, since the gap between the pair of block bodies is filled with paint, the choke bar cannot be brought into contact with the opposing surface of the other block body.

[0011] Therefore, the coating nozzle according to the present invention includes a pair of block bodies facing each other with a gap therebetween, a die that discharges the paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism that controls the flow rate of the paint flowing toward the discharge port in the gap. The flow rate control mechanism includes a recess formed on the opposing surface of one of the block bodies, a choke bar housed in the recess and movable in a direction approaching and a direction away from the opposing surface of the other block body, an actuator connected to the choke bar, and a control unit that controls the actuator. The control unit has an initial alignment unit that controls the actuator, moves the choke bar in a direction approaching the opposing surface of the other block body by a preset moving distance after bringing the choke bar into contact with the bottom surface of the recess, and may be characterized in that.

[0012] According to the coating nozzle of the present invention, even when the gap between the pair of block bodies is filled with paint, the choke bar can be aligned to the initial position in addition to the effect of the coating nozzle.

[0013] As a specific embodiment of the flow rate control mechanism, the actuator uses a motor as a drive source, the flow rate control mechanism further includes a torque measuring device that measures the torque of the motor, and the initial alignment unit determines that the choke bar has come into contact when the measured torque measured by the torque measuring device is equal to or greater than a preset set torque.

[0014] According to such a configuration, it is possible to prevent the actuator from being damaged by applying more force than necessary.

[0015] Further, the die may further include a shim interposed between the pair of block bodies, and the moving distance may be the length of the thickness of the shim.

[0016] According to such a configuration, since the interval of the gap between the pair of block bodies is determined by the thickness of the shim, it is not necessary to measure the interval intentionally.

[0017] Further, the program for a coating nozzle according to the present invention includes a die that includes a pair of block bodies facing each other with a gap therebetween, and discharges paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism that controls the flow rate of the paint flowing toward the discharge port through the gap. The flow rate control mechanism includes a recess formed on a facing surface of one of the block bodies, a choke bar housed in the recess and movable in a direction approaching and a direction away from a facing surface of the other block body, an actuator connected to the choke bar, and a control unit that controls the actuator. In the program used for a coating nozzle including these components, the control unit functions as an initial alignment unit that controls the actuator to move the choke bar away from the facing surface of the other block body by a preset moving distance after bringing the choke bar into contact with the facing surface of the other block body.

[0018] Another program for a coating nozzle according to the present invention includes a pair of block bodies facing each other with a gap therebetween, a die that discharges the paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism that controls the flow rate of the paint flowing toward the discharge port through the gap. The flow rate control mechanism includes a recess formed on a facing surface of one of the block bodies, a choke bar housed in the recess and movable in directions approaching and separating from a facing surface of the other block body, an actuator connected to the choke bar, and a control unit that controls the actuator. In the program used for the coating nozzle, the control unit controls the actuator to bring the choke bar into contact with the bottom surface of the recess, and then functions as an initial alignment unit that moves the choke bar in a direction approaching the facing surface of the other block body by a preset moving distance.

Advantages of the Invention

[0019] With the coating nozzle according to the present invention as described above, for example, when reassembling during regular cleaning or the like, the choke bar can be efficiently and accurately aligned to the initial position.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Mode for Carrying Out the Invention

[0021] The coating nozzle according to an embodiment of the present invention will be described with reference to FIGS. 1 to 9.

[0022] The coating nozzle according to the present invention is used in a coating apparatus for manufacturing a film used in an electronic device such as a display. Note that the film is not limited to those for electronic devices.

[0023] <First Embodiment> As shown in FIG. 1, the coating nozzle N of the present embodiment is used in a coating apparatus 100 that applies a coating material to a base material X that travels by a traveling mechanism M. Therefore, before explaining the details of the coating nozzle N, the traveling mechanism M will be described.

[0024] The traveling mechanism M is for traveling the base material X. The traveling mechanism M of the present embodiment includes a holding portion M1 that holds a roll around which the base material X is wound, a drum M2 that U-turns the base material X drawn from the holding portion M1, and a winding device M3 that winds up the base material X U-turned by the drum M2.

[0025] The coating nozzle N is installed with a discharge port D facing the drum M2, and discharges a coating material onto the base material X that travels along the drum M2. As shown in FIG. 2, it includes a die 10 and a flow rate control mechanism 20.

[0026] The die 10 applies paint to the base material X and includes a pair of block bodies 11 and 12 and a shim 13. The pair of block bodies 11 and 12 are substantially rectangular parallelepiped-shaped and are installed so as to face each other with a gap therebetween. The shim 13 is interposed between the pair of block bodies 11 and 12 and is formed with a certain thickness. This shim 13 has a substantially concave shape along three sides of the opposing surfaces 11s and 12s of the block bodies 11 and 12. Therefore, a gap G surrounded by their opposing surfaces 11s and 12s and the shim 13 is formed between the pair of block bodies 11 and 12. This gap G opens toward one side where the shim 13 is not interposed, and this opening forms the discharge port D. Note that the pair of block bodies 11 and 12 are installed so that the width direction of the discharge port D coincides with the width direction of the base material X that travels in the width direction.

[0027] In this embodiment, among the pair of block bodies 11 and 12, a member constituting the flow rate control mechanism 20 is provided on one block body 11, and a supply path 12L for supplying paint to the gap G is formed on the other block body 12. As shown in FIG. 3, this supply path 12L is formed in the center when viewed from the opening direction side of the discharge port D, and opens to the opposing surface 12s of the other block body 12 and is connected to the gap G. That is, the supply path 12L is formed at the center in the width direction of the other block body 12. Note that this supply path 12L may be formed, for example, on the one block body 11 provided with the member constituting the flow rate control mechanism 20. Further, the supply path 12L of this embodiment extends linearly from the opposing surface 12s toward the opposite surface, but may, for example, extend by bending from the opposing surface 12s toward the surface facing the direction opposite to the opening direction of the discharge port D.

[0028] The flow rate control mechanism 20 controls the flow rate of the paint that flows from the supply path 12L into the gap G and flows toward the discharge port D so that the film thickness of the paint applied to the base material X becomes the target film thickness at any location in the width direction of the base material X.

[0029] The flow control mechanism 20 of this embodiment includes a film thickness measuring device 21 for measuring the film thickness of the paint applied to the base material X, a recess 22 formed on the opposing surface 11s of one block body 11, a plurality of choke bars 23 that are accommodated in the recess 22 so as to be able to enter and exit, an actuator 24 connected to the choke bar 23, and a control unit C for controlling the actuator 24.

[0030] As shown in FIG. 1, the film thickness measuring device 21 is installed on the downstream side of the discharge port D with respect to the traveling direction of the base material X, and measures the thickness of the paint applied to the base material X at a plurality of locations in the width direction thereof.

[0031] The recess 22 opens to the opposing surface 11s of one block body 11. In this embodiment, it is a rectangular long hole extending along the width direction of the discharge port D. The length in the longitudinal direction of this recess 22 coincides with the length in the width direction of the discharge port D. That is, it extends over the entire width of the gap G. Further, on the bottom surface 22s of the recess 22, through holes 22h penetrating to the outside of one block body 11 are formed in the same number as the choke bars 23. The recess 22 is provided between the discharge port D and the supply path 12L when viewed from the side.

[0032] The plurality of choke bars 23 are substantially rectangular parallelepiped-shaped and are arranged in a row in the longitudinal direction of the recess 22 and accommodated. This choke bar 23 is movable so as to enter and exit the recess 22. That is, it is movable in the direction approaching or moving away from the other block body 12. Note that the length of the choke bar 23 in its moving direction (axial direction) is shorter than the depth of the recess 22, and the whole can be accommodated in the recess 22.

[0033] As shown in FIG. 4, each of these choke bars 23 has an annular seal member 23s extending over the entire circumference of the side peripheral surface 23b, and the adjacent choke bars 23 are in contact with each other at the seal members 23s.

[0034] The seal member 23s has a rectangular annular shape. This seal member 23s is fitted and fixed in a groove 23c formed over the entire circumferential surface 23b of the choke bar 23, and protrudes slightly outward from the circumferential surface 23b. Note that the method of fixing the seal member 23s to the choke bar 23 is not limited to this, and for example, the seal member 23s may be fixed by sticking it to the circumferential surface 23b of the choke bar 23. The material of this seal member 23s may be, for example, insoluble in paint, and examples include rubber and plastic resin. Specific examples of plastic resin include Teflon resin and fluororesin.

[0035] The outer circumferential surfaces of the seal members 23s are all flat. Therefore, the seal members 23s of the choke bars 23 adjacent to each other are in surface contact with each other. Also, the seal members 23s of each choke bar 23 are in surface contact with the inner circumferential surface of the recess 22.

[0036] Also, the thickness of the seal member 23s in the moving direction (axial direction) of the choke bar 23 is set to be equal to or greater than the target film thickness of the coating film applied to the base material X, and more preferably, it is set to be equal to or greater than the thickness of the shim 13. In the present embodiment, the thicknesses of all the seal members 23s are the same.

[0037] The actuator 24 includes a drive source 24a and a transmission mechanism 24b that transmits the operation of the drive source 24a to the choke bar 23. In the present embodiment, the drive source 24a is a motor and is fixed to one of the block bodies 11. Also, the transmission mechanism 24b is a conversion mechanism that converts the rotational motion of the drive source 24a into a linear motion and transmits it to the choke bar 23. Examples of this transmission mechanism 24b include a mechanism using the engagement of a male screw and a female screw, a rack and pinion mechanism, and a slider crank mechanism. In the present embodiment, the rotational motion of the motor is converted into a linear motion via the transmission mechanism 24b, and this linear motion is transmitted to the choke bar 23 via a shaft that has passed through the through hole 22h.

[0038] Further, the flow rate control mechanism 20 of the present embodiment further includes a torque measuring device (not shown) that measures the torque of the motor which is the drive source 24a.

[0039] The control unit C is composed of a dedicated or general-purpose computer having input means such as a CPU, a memory, an input / output interface, a display, and a keyboard. Specifically, as shown in FIG. 6, the control unit C functions as a target value storage unit C1, an interval control unit C2, etc. by the CPU and peripheral devices cooperating according to a control program stored in the memory.

[0040] Hereinafter, the control unit C will be described together with its operation.

[0041] The target film thickness storage unit C1 stores the target value of the film thickness of the paint to be applied to the base material X.

[0042] The interval control unit C2 adjusts the interval between the tip surface 23a of the choke bar 23 and the opposing surface 12s of the other block body 12 based on the deviation between the actually measured value measured by the film thickness measuring device 21 and the target value, and controls the flow rate of the paint flowing in the gap G toward the discharge port D, thereby performing feedback control so that the actually measured value approaches the target value. Specifically, the actually measured value acquired from the film thickness measuring device 21 is compared with the target value stored in the target film thickness storage unit C1. When the actually measured value is larger, the choke bar 23 corresponding to the location where the actually measured value in the width direction of the base material X is measured is moved in a direction approaching the other block body 12, thereby narrowing the interval between the tip surface 23a of the choke bar 23 and the other block body 12 and reducing the flow rate of the paint flowing between them. On the other hand, when the actually measured value is smaller, the choke bar 23 corresponding to the location where the actually measured value in the width direction of the base material X is measured is moved in a direction away from the other block body 12, thereby widening the interval between the tip surface 23a of the choke bar 23 and the other block body 12 and increasing the flow rate of the paint flowing between them.

[0043] Thus, the control unit C according to the present invention further functions as an initial alignment unit C3. This initial alignment unit C3 moves all the plurality of choke bars 23 to their initial positions, for example, during reassembly such as regular cleaning.

[0044] Here, the initial position is a position preset at the time of designing the coating nozzle N. In the present embodiment, as shown in FIG. 7, the position is such that the tip surface 23a of the choke bar 23 facing the other block body 12 is flush with the facing surface 11s of the one block body 11. Therefore, when all the choke bars 23 are moved to the initial positions, the facing surface 11s of the one block body 11 becomes a flat surface including the tip surfaces 23a of these choke bars 23. Note that the initial position is not limited to this. For example, it may be a position protruding from the concave portion 22 even though the tip surfaces 23a of the respective choke bars 23 are flush, or it may be a position where the tip surfaces 23a of the respective choke bars 23 are not flush.

[0045] As shown in FIG. 5, the initial alignment unit C3 of the present embodiment includes a set torque storage unit C3a, a first moving unit C3b, a moving distance storage unit C3c, and a second moving unit C3d.

[0046] The set torque storage unit C3a stores a set torque, which is a torque value generated in the motor that is the drive source 24a of the actuator 24 and is larger than the torque value generated when the choke bar 23 is actually moving. That is, the set torque is the torque value when an excessive load is generated on the motor.

[0047] As shown in FIG. 6, the first moving part C3b moves so that all the choke bars 23 contact the other block body 12. Specifically, when the first moving part C3b receives an initial alignment instruction from the input / output interface, it first moves all the choke bars 23 in a direction approaching the other block body 12. At this time, the measured torque is obtained from the torque measuring device, the measured torque is compared with the set torque, and when the measured torque reaches the set torque, it is determined that the choke bar 23 has contacted the opposing surface 12s of the other block body 12, and the choke bar 23 is stopped.

[0048] The movement distance storage part C3c stores the movement distance necessary to move the choke bar 23 that has been brought into contact with the other block body 12 by the first moving part C3b back to the initial position. In the present embodiment, the thickness of the shim 13 is stored as the movement distance.

[0049] As shown in FIG. 7, after receiving a stop signal from the first moving part C3b, the second moving part C3d moves all the choke bars 23 to the initial position. Specifically, when the second moving part C3d first receives a stop signal from the first moving part C3b, it moves all the choke bars 23 in a direction away from the other block body 12. At this time, it moves with reference to the movement distance stored in the movement distance storage part. In the present embodiment, each choke bar 23 is moved to the initial position where its front end surface 23a is flush with the opposing surface 11s of the one block body 11.

[0050] According to the coating apparatus 100 according to the present embodiment, since the actuator 24 is controlled by the initial alignment part C3 and the choke bar 23 connected to the actuator 24 is moved to the initial position, for example, when reassembling during regular cleaning, the choke bar 23 can be moved to the initial position easily and accurately. As a result, the cleaning time can be shortened and the yield can also be improved.

[0051] In addition, since all the choke bars 23 are once brought into contact with the other block body 12, after resetting the error due to the dead zone of the actuator 24, it can be moved to the initial position. As a result, the movement to the initial position becomes more accurate. That is, even if the dead zone widths of the respective actuators 24 are made to coincide, immediately after reassembly, it is not known how much dead zone exists when the choke bar 24 is moved in a predetermined direction. Therefore, by once bringing it into contact with the other block body 12, the dead zone widths when the choke bar 23 is moved in a direction away from the predetermined direction (the other block body 12) coincide, and it can be accurately moved to the initial position.

[0052] FIG. 8 shows a modification of the first embodiment. This modification is a modification of the initial alignment portion C3 of the first embodiment, and the first moving portion C3b is configured to move to the initial position after bringing all the choke bars 23 into contact with the bottom surface 22s of the recess 22. In this case, the moving distance storage unit C3c may store, as the moving distance, the length obtained by subtracting the depth of the recess 22 from the axial length of the choke bar 23.

[0053] With such a configuration, for example, even if the gap of the die 10 is filled with paint, the choke bar 23 can be moved to the initial position.

[0054] <Other Embodiments> Note that the present invention is not limited to the above-described embodiment. In the above-described embodiment, the seal members are configured to contact each other with the choke bar moved to the initial position. However, for example, as shown in FIG. 9, the seal members 23s of the choke bars 23 adjacent to each other may be configured to contact the side peripheral surface 23b of the other choke bar 23. Further, the choke bar 23 may not have the seal member 23s and may be adjacent with the side peripheral surfaces 23b contacting each other.

[0055] In the above-described embodiment, a plurality of choke bars are provided, but a single choke bar may be used. Further, in the above-described embodiment, a plurality of choke bars are accommodated in one recess, but they may be accommodated in separate recesses.

[0056] Further, the initial alignment unit may exhibit any function of the embodiment and its modifications.

[0057] In addition, combinations of parts of various embodiments, modifications, etc. may be made as long as they do not contravene the gist of the present invention.

Explanation of Reference Numerals

[0058] 100: Coating device M: Travel mechanism N: Coating nozzle 10: Die 11: One block body 12: The other block body 20: Flow rate control mechanism 22: Concave portion 23: Choke bar 24: Actuator 24a: Drive source (motor) C: Control unit C3: Initial alignment unit

Claims

1. A die comprising a pair of block bodies facing each other with a gap therebetween, the die discharging paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism for controlling the flow rate of the paint flowing through the gap toward the discharge port, wherein the flow rate control mechanism includes a recess formed on a facing surface of one of the block bodies, a choke bar accommodated in the recess and movable in directions approaching and moving away from a facing surface of the other block body, an actuator connected to the choke bar, and a control unit for controlling the actuator, and the control unit has an initial alignment unit that controls the actuator, contacts the choke bar with the facing surface of the other block body, and then moves the choke bar in a direction away from the facing surface of the other block body by a preset moving distance. A coating nozzle characterized by this.

2. A die comprising a pair of block bodies facing each other with a gap therebetween, the die discharging paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism for controlling the flow rate of the paint flowing through the gap toward the discharge port, wherein the flow rate control mechanism includes a recess formed on a facing surface of one of the block bodies, a choke bar accommodated in the recess and movable in directions approaching and moving away from a facing surface of the other block body, an actuator connected to the choke bar, and a control unit for controlling the actuator, and the control unit has an initial alignment unit that controls the actuator, contacts the choke bar with the bottom surface of the recess, and then moves the choke bar in a direction approaching the facing surface of the other block body by a preset moving distance. A coating nozzle characterized by this.

3. The actuator uses a motor as a drive source, and the flow rate control mechanism further includes a torque measuring device for measuring the torque of the motor. The coating nozzle according to any one of Claims 1 or 2, wherein the initial alignment unit determines that the choke bar has contacted when the measured torque measured by the torque measuring device is equal to or greater than a preset set torque.

4. The die further includes a shim interposed between the pair of block bodies, and the coating nozzle according to any one of Claims 1 or 2, wherein the moving distance is the length of the thickness of the shim.

5. A die having a pair of block bodies facing each other with a gap therebetween, and discharging paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism for controlling the flow rate of the paint flowing through the gap toward the discharge port, wherein the flow rate control mechanism includes a recess formed on the facing surface of one of the block bodies, a choke bar accommodated in the recess and movable in a direction approaching and a direction away from the facing surface of the other block body, an actuator connected to the choke bar, and a control unit for controlling the actuator. In a program used for a coating nozzle, The control unit functions as an initial alignment unit that controls the actuator to bring the choke bar into contact with the facing surface of the other block body, and then moves the choke bar in a direction away from the facing surface of the other block body by a preset moving distance. A program for a coating nozzle characterized by this.

6. A die having a pair of block bodies facing each other with a gap therebetween, and discharging paint flowing into the gap through an opening facing a predetermined direction of the gap as a discharge port, and a flow rate control mechanism for controlling the flow rate of the paint flowing through the gap toward the discharge port, wherein the flow rate control mechanism includes a recess formed on the facing surface of one of the block bodies, a choke bar accommodated in the recess and movable in a direction approaching and a direction away from the facing surface of the other block body, an actuator connected to the choke bar, and a control unit for controlling the actuator. In a program used for a coating nozzle, The control unit functions as an initial alignment unit that controls the actuator to bring the choke bar into contact with the bottom surface of the recess, and then moves the choke bar in a direction approaching the facing surface of the other block body by a preset moving distance. A program for a coating nozzle characterized by this.

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