Coating applicator and coating method

Abstract

To provide a coating applicator which can apply a coating liquid to a base material while removing air bubbles as much as possible, and to provide a coating method.SOLUTION: A coating applicator EA includes: coating liquid housing means 10 which houses a coating liquid CL; coating means 20 which feeds a base material BS along an outer peripheral surface of a roller 22 facing the coating liquid housing means 10 and applies the coating liquid CL in the coating liquid housing means 10 to a surface to be coated BS1 of the base material BS; and air bubble removing means 30 which provides energy for generating pressure fluctuation in the coating liquid CL in the coating liquid housing means 10 to remove air bubbles GB on the surface to be coated BS1 by the pressure fluctuation.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coating apparatus and a coating method. [Background technology]

[0002] BACKGROUND ART There is known a coating device that delivers a substrate along the outer peripheral surface of a roller facing a coating liquid storage means and applies the coating liquid in the coating liquid storage means to the surface of the substrate to be coated (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 5-49996 Summary of the Invention [Problem to be solved by the invention]

[0004] In the coating device (applicator) described in Patent Document 1, a bubble removal section is formed in the adhesive supply container (coating liquid storage means) to remove air bubbles on the surface to be coated. However, because the bubble removal section is simply positioned near the object to be coated (substrate), air bubbles may not be removed sufficiently depending on, for example, the viscosity of the adhesive (coating liquid) to be applied to the substrate or the size of the gap between the bubble removal section and the substrate.

[0005] An object of the present invention is to provide a coating apparatus and a coating method that can apply a coating liquid to a substrate while removing air bubbles as much as possible. [Means for solving the problem]

[0006] A coating device according to one aspect of the present invention comprises a coating liquid storage means for storing a coating liquid, a coating means for unwinding a substrate along the outer peripheral surface of a roller facing the coating liquid storage means and applying the coating liquid in the coating liquid storage means to a surface of the substrate to be coated, and a bubble removal means for applying energy that causes pressure fluctuations in the coating liquid in the coating liquid storage means and removing air bubbles on the surface to be coated by the pressure fluctuations.

[0007] In the coating apparatus according to one aspect of the present invention, the bubble removal means may include a vibrated member disposed within the coating liquid storage means, and a vibrating means for vibrating the vibrated member.

[0008] In the coating apparatus according to one aspect of the present invention, the bubble removing means may include a bubble removing roller disposed in the coating liquid containing means, and a driving device that drives the bubble removing roller.

[0009] In the coating device according to one aspect of the present invention, the bubble removing means may include a spraying means that sprays the coating liquid toward the surface to be coated of the substrate within the coating liquid storage means.

[0010] In the coating device according to one aspect of the present invention, the bubble removing means may include a suction means that sucks an area on the surface to be coated of the substrate within the coating liquid containing means.

[0011] A coating method according to one aspect of the present invention includes a coating liquid storage step of storing a coating liquid in a coating liquid storage means, a coating step of unwinding a substrate along the outer peripheral surface of a roller facing the coating liquid storage means and applying the coating liquid in the coating liquid storage means to a surface of the substrate to be coated, and a bubble removal step of applying energy to the coating liquid in the coating liquid storage means to generate pressure fluctuations and using the pressure fluctuations to remove air bubbles on the surface to be coated. [Effects of the Invention]

[0012] According to the present invention, energy is applied to the coating liquid in the coating liquid storage means to cause pressure fluctuations, and the pressure fluctuations remove air bubbles on the surface to be coated, making it possible to apply the coating liquid to the substrate with as few air bubbles as possible removed. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is an explanatory view of a coating device according to a first embodiment of the present invention. [Figure 2]FIG. 4 is an explanatory view of a coating device according to a second embodiment of the present invention. [Figure 3] FIG. 10 is an explanatory diagram of a coating device according to a third embodiment of the present invention. [Figure 4] FIG. 10 is an explanatory view of a coating device according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In this embodiment, the X-axis, Y-axis, and Z-axis are orthogonal to each other, and the X-axis and Y-axis are axes within a predetermined plane, and the Z-axis is an axis orthogonal to the predetermined plane. Furthermore, in this embodiment, when viewed from the front direction of Fig. 1 parallel to the Y-axis, "up" is the direction of the arrow on the Z-axis, "down" is the opposite direction, "left" is the direction of the arrow on the X-axis, "right" is the opposite direction, "front" is the direction toward the front in Fig. 1 parallel to the Y-axis, and "rear" is the opposite direction. Furthermore, in the second and subsequent embodiments, components having the same configuration and functions as those of the embodiments already described will be given the same numbers as those in those embodiments or will not be shown in the illustrations, and their descriptions will be simplified or omitted.

[0015] [First embodiment] 1, the coating apparatus EA includes a coating liquid storage means 10 that stores a coating liquid CL, a coating means 20 that feeds a substrate BS along the outer peripheral surface of a roller 22 facing the coating liquid storage means 10 and applies the coating liquid CL from the coating liquid storage means 10 to a coating surface BS1 of the substrate BS, and a bubble removal means 30 that applies energy to the coating liquid CL in the coating liquid storage means 10 to generate pressure fluctuations and removes bubbles GB from the coating surface BS1 by the pressure fluctuations. The coating apparatus EA is a so-called knife coater. Furthermore, the coating surface BS1 of the substrate BS has irregularities BS2 formed thereon.

[0016] The coating liquid storage means 10 has a side portion 11, a bottom portion 12, and a substrate-facing edge portion 13 that faces the substrate BS entering along the outer peripheral surface of the roller 22, and is roughly box-shaped with an opening from the substrate-facing edge portion 13 to the top portion. The substrate-facing edge 13 is formed by the tip end portion of the bottom surface portion 12, and faces the portion of the substrate BS that is along the outer circumferential surface of the roller 22. The substrate BS that has been looped around the roller 22 enters a contact start position CP with the coating liquid CL in the coating liquid storage means 10 from the outside of the bottom surface portion 12 while facing the substrate-facing edge 13.

[0017] The coating means 20 includes a rotary motor 21 as a driving device, a roller 22 supported on the output shaft 21A of the rotary motor 21, and a knife section 23 having a knife edge 23A for measuring the coating liquid CL to be applied to the coating surface BS1. The roller 22 is disposed opposite the substrate-facing edge 13 of the coating liquid storage means 10, and pays out the wrapped substrate BS so that it contacts the coating liquid CL in the coating liquid storage means 10. The roller 22 may also be called a coating roller, a coating roll, a backup roller, a backup roll, or the like. The knife portion 23 has a shape in which the outer peripheral surface of a cylindrical member is cut out so as to have a knife edge 23A.

[0018] The bubble removing means 30 includes a vibrated member 31 disposed within the coating liquid containing means 10, and a linear motor 32 as a driving device and vibrating the vibrated member 31. In this embodiment, the vibrated member 31 is a plate-like member that extends in the extension direction of the roller 22 and in a direction toward the surface BS1 to be coated of the substrate BS, and its tip portion toward the surface BS1 to be coated is located near the surface BS1 to be coated of the substrate BS in the coating fluid storage means 10. The bubble removal means 30 supports the vibrated member 31 with the output shaft 32A of the linear motor 32, and vibrates the vibrated member 31 in its in-plane direction, thereby moving the vibrated member 31 toward and away from the surface BS1 to be coated of the substrate BS in the coating fluid storage means 10 near the surface BS1 to be coated.

[0019] The operation of the coating apparatus EA will now be described. First, an operator places a substrate BS in the coating apparatus EA as shown in FIG. 1 , and then the operator or a coating liquid injecting means such as a coating liquid storage tank or a coating liquid injecting pipe stores the coating liquid CL in the coating liquid storage means 10. Next, when the operator inputs a signal to start automatic operation via an operating means (not shown), such as an operation panel or a personal computer, the bubble removal means 30 drives the linear motor 32, which vibrates the vibrated member 31 to move it toward or away from the coating surface BS1 of the substrate BS. The coating means 20 then drives the rotary motor 21, which rotates the roller 22 and unwinds the substrate BS. The coating liquid CL is then measured by the knife unit 23 and applied to the coating surface BS1 of the substrate BS at a predetermined thickness.

[0020] As the substrate BS is fed, a wedge-shaped gap WG forms between the coating liquid CL and the incoming substrate BS near the substrate-facing edge 13 of the coating liquid container 10, as shown in FIG. 1. This gap WG can allow air bubbles GB to enter between the coating surface BS1 of the substrate BS and the coating liquid CL. However, while the substrate BS is being fed, the vibrated member 31 is vibrated and moves toward and away from the coating surface BS1 of the substrate BS. This imparts vibration energy to the coating liquid CL, causing pressure fluctuations in the coating liquid CL on the coating surface BS1. This pressure fluctuation causes the air bubbles GB to separate from the substrate BS, resulting in their removal. The removed air bubbles GB rise within the coating liquid container 10 and are expelled into the air.

[0021] According to the above-described embodiment, energy is applied to the coating liquid CL in the coating liquid storage means 10 to cause pressure fluctuations, and the pressure fluctuations remove the bubbles GB on the surface BS1 to be coated, thereby making it possible to apply the coating liquid CL to the substrate BS while removing as many bubbles GB as possible.

[0022] Furthermore, even if the air bubbles GB are not in contact with the surface BS1 to be coated and are contained in the portion of the coating liquid CL within a predetermined thickness range where the coating liquid CL layer is formed from the surface BS1 to be coated, the air bubbles GB can be removed by generating pressure fluctuations in the portion of the coating liquid CL, thereby preventing the air bubbles GB from being contained in the coating liquid CL layer formed on the surface BS1 to be coated.

[0023] [Second embodiment] In this embodiment, as shown in FIG. 2, the configuration of the bubble removing means 30A is different from that of the first embodiment.

[0024] The air bubble removing means 30A includes an air bubble removing roller 33 arranged in the coating liquid containing means 10, and a rotary motor 34 that supports the air bubble removing roller 33 on an output shaft 34A and serves as a drive device for driving the air bubble removing roller 33. The bubble removing roller 33 extends parallel to the roller 22 and is disposed in the coating liquid containing means 10 so as to face the roller 22 with the substrate BS therebetween. The bubble removing roller 33 is disposed between the roller 22 and the coating surface BS1 of the substrate BS that is wrapped around the roller 22, with a gap approximately equal to the thickness of the coating liquid CL to be applied to the coating surface BS1.

[0025] In this embodiment, when an operator inputs a signal to start automatic operation via the operating means, the bubble removal means 30A drives the rotary motor 34 to rotate the bubble removal roller 33 in the same direction as the rotational direction of the roller 22. This imparts the rotational energy of the bubble removal roller 33 to the coating liquid CL, causing a pressure fluctuation in the coating liquid CL on the coating surface BS1 of the substrate BS. This pressure fluctuation causes the bubble GB to separate from the substrate BS, and the bubble GB is removed.

[0026] According to the embodiment described above, it is possible to obtain the same effects as in the first embodiment. Furthermore, since the air bubble removal roller 33 is rotated in the same direction as the rotation direction of the roller 22, a flow of the coating liquid CL can be caused to occur in the opposite direction to the movement direction of the substrate BS, thereby facilitating the removal of the air bubbles GB.

[0027] [Third embodiment] In this embodiment, as shown in FIG. 3, the configuration of the bubble removing means 30B is different from that of the first embodiment.

[0028] The bubble removing means 30B is provided with a spraying means 35 that sprays the coating liquid CL toward the coating surface BS1 of the substrate BS in the coating liquid containing means 10. The spraying means 35 includes a coating liquid supplying means 35B such as a pressure pump or turbine that supplies the coating liquid CL in the coating liquid tank 35A, and a spraying member 35C such as a spray pipe or nozzle that sprays the coating liquid CL supplied by the coating liquid supplying means 35B onto the coating surface BS1 of the substrate BS within the coating liquid storage means 10. The spraying member 35C has an outlet at its tip end that extends parallel to the roller 22, and sprays the coating liquid CL from the outlet toward the coating surface BS1 of the substrate BS.

[0029] In this embodiment, when an operator inputs a signal to start automatic operation via the operating means, the bubble removal means 30B drives the coating liquid supply means 35B, which sprays the coating liquid CL from the spraying member 35C. As a result, the energy of the sprayed coating liquid CL is imparted to the coating liquid CL on the coating surface BS1 of the substrate BS, causing a pressure fluctuation in the coating liquid CL on the coating surface BS1. This pressure fluctuation causes the bubbles GB to separate from the substrate BS, and the bubbles GB are removed.

[0030] According to the embodiment described above, it is possible to obtain the same effects as in the first embodiment.

[0031] [Fourth embodiment] In this embodiment, as shown in FIG. 4, the configuration of the bubble removing means 30C differs from that of the first embodiment.

[0032] The bubble removing means 30C is provided with suction means 36 that sucks the area on the surface BS1 to be coated of the substrate BS within the coating liquid containing means 10. The suction means 36 includes a pressure reducing means 36A such as a vacuum pump or a vacuum ejector, a suction pipe 36B connected to the pressure reducing means 36A, and a recovery means 36C such as a liquid receiving pan or a recovery liquid tank for recovering the coating liquid CL sucked in together with the air bubbles GB. The suction pipe 36B is disposed within the coating liquid storage means 10, with its tip located near the surface BS1 to be coated of the substrate BS. A suction port extending parallel to the roller 22 is provided at the tip of the suction pipe 36B, and the suction port sucks the area on the surface BS1 to be coated of the substrate BS.

[0033] In this embodiment, when an operator inputs a signal to start automatic operation via the operating means, the bubble removal means 30C drives the pressure reduction means 36A and sucks the area on the coating surface BS1 of the substrate BS. As a result, a suction force is applied as energy from the suction pipe 36B to the coating liquid CL on the coating surface BS1, causing a pressure fluctuation in the coating liquid CL on the coating surface BS1. This pressure fluctuation causes the bubbles GB to separate from the substrate BS and be sucked into the suction pipe 36B, thereby removing the bubbles GB. Of the removed bubbles GB, those not sucked into the suction pipe 36B rise up within the coating liquid storage means 10 and are discharged into the air.

[0034] According to the embodiment described above, it is possible to obtain the same effects as in the first embodiment. Furthermore, since the air bubbles GB can be sucked by the suction means 36, the removal of the air bubbles GB can be facilitated.

[0035] As described above, the best configurations, methods, and the like for implementing the present invention have been disclosed in the above description, but the present invention is not limited thereto. That is, although the present invention has been particularly illustrated and described mainly with reference to specific embodiments, those skilled in the art can make various modifications to the above-described embodiments in terms of shape, material, quantity, and other detailed configurations without departing from the scope of the technical idea and purpose of the present invention. Furthermore, the above-disclosed descriptions limiting the shape, material, and the like are provided as examples to facilitate understanding of the present invention and are not intended to limit the present invention. Therefore, descriptions using names of components that are free from some or all of the limitations on shape, material, and the like are included in the present invention. Furthermore, the means and steps in the present invention are not limited in any way as long as they can perform the operations, functions, or steps described for those means and steps, and are in no way limited to the components and steps of just one embodiment shown in the above embodiment.

[0036] The coating liquid storage means 10 may be any means capable of storing the coating liquid CL and configured so that the coating liquid CL is applied to the coating surface BS1 of the substrate BS that is unrolled along the outer peripheral surface of the roller 22 facing the coating liquid storage means 10; for example, the bottom surface portion 12 may be horizontal, or the bottom surface portion 12 may be inclined.

[0037] The application means 20 may have, for example, a knife portion 23 shaped like a blade, the tip of which is a knife edge 23A, or the knife portion 23 may have only one knife edge 23A, or the knife portion 23 may have multiple knife edges 23A.

[0038] The bubble removal means 30 may, for example, vibrate the vibrated member 31 in the vertical direction, or vibrate the vibrated member 31 in the tangential direction of the coated surface BS1 of the substrate BS wrapped around the roller 22, and the vibrated member 31 does not have to be formed in a plate shape. The bubble removal means 30A may rotate the bubble removal roller 33 in the opposite direction to the rotation direction of the roller 22, or the bubble removal roller 33 may be positioned between the surface BS1 to be coated and the roller 33 with a distance equal to or less than the thickness of the coating liquid CL to be applied to the surface BS1 to be coated. The bubble removal means 30B may comprise a spraying means 35 having a plurality of spraying members 35C arranged side by side in the extension direction of the roller 22, and the coating liquid CL may be sprayed onto the surface BS1 to be coated of the substrate BS using these plurality of spraying members 35C, or may comprise a spraying member 35C having a plurality of outlets arranged side by side in the extension direction of the roller 22, and the coating liquid CL may be sprayed onto the surface BS1 to be coated of the substrate BS from the plurality of outlets. The bubble removal means 30C may include a suction means 36 having a plurality of suction pipes 36B arranged in parallel in the extension direction of the roller 22, and these plurality of suction pipes 36B may be used to suck an area on the coated surface BS1 of the substrate BS, or may include a suction pipe 36B having a plurality of suction ports arranged in parallel in the extension direction of the roller 22, and the plurality of suction ports may be used to suck an area on the coated surface BS1 of the substrate BS. The bubbles GB removed by the bubble removal means 30, 30A, 30B, and 30C may not be in contact with the coated surface BS1, but may be contained in the coating liquid CL portion within a predetermined thickness region where the coating liquid CL layer is formed from the coated surface BS1. The energy applied by the bubble removal means 30, 30A, 30B, 30C may be any energy that causes pressure fluctuations in the coating liquid CL in the coating liquid storage means 10, such as kinetic energy due to vibration, spraying, suction, pressing, etc., electromagnetic wave or light energy, thermal energy, sound energy, electrical energy, or a combination of these, and can be determined as desired taking into consideration the characteristics, properties, properties, material, composition, etc. of the coating liquid CL.

[0039] The coating apparatus EA may be configured to use a combination of any two or more of the air bubble removal means 30, 30A, 30B, and 30C. For example, the coating apparatus EA may be configured to include air bubble removal means 30B and 30C, and to spray the coating liquid CL onto the coating surface BS1 of the substrate BS using the air bubble removal means 30B, while sucking the coating liquid CL from the coating surface BS1 using the air bubble removal means 30C.

[0040] The material, type, variety, shape, etc. of the substrate BS and the material, type, variety, composition, etc. of the coating liquid CL are not particularly limited. For example, the substrate BS may be made of paper, laminated paper, plastic, cellulose, rubber, etc., and the coating surface BS1 may not have the irregularities BS2 formed thereon, and may be a single layer or multiple layers. The coating liquid CL may be, for example, an adhesive, a pressure-sensitive adhesive, or a release agent.

[0041] The driving equipment in the above embodiments may be electric equipment such as rotary motors, linear motors, single-axis robots, so-called articulated robots with joints on two or three or more axes, actuators such as air cylinders, hydraulic cylinders, rodless cylinders and rotary cylinders, which may be used alone, or may be a direct or indirect combination of such electric equipment and actuators, or may be electric equipment, actuators, etc. that are capable of torque control, speed control, etc. for the output parts of such electric equipment, actuators, etc., or may not be capable of torque control, speed control, etc.

[0042] In the above-described embodiment, when a rotating member such as a roller is used, the surface of the rotating member or the rotating member itself may be made of a deformable material such as rubber or resin, or the surface of the rotating member or the rotating member itself may be made of a non-deformable material. [Explanation of symbols]

[0043] EA... Coating equipment 10... Coating liquid containing means 20...Application means 22...Laura 30, 30A, 30B, 30C...Air bubble removal means 31... Vibration receiving member 32... Linear motion motor (excitation means) 33...Air bubble removal roller 34...Rotation motor (drive device) 35...Spraying means 36...Suction means BS…Base material BS1...Surface to be coated CL…Coating liquid GB...Air bubbles

Claims

1. a coating liquid containing means for containing a coating liquid; a coating means for feeding a substrate along an outer peripheral surface of a roller facing the coating liquid storage means and applying the coating liquid in the coating liquid storage means to a surface to be coated of the substrate; a bubble removal means for applying energy to the coating liquid in the coating liquid storage means to cause a pressure fluctuation, and for removing bubbles on the surface to be coated by the pressure fluctuation.

2. 2. The coating apparatus according to claim 1, wherein the bubble removing means comprises a vibrated member disposed in the coating liquid containing means, and a vibrating means for vibrating the vibrated member.

3. 2. The coating apparatus according to claim 1, wherein the bubble removing means comprises an air bubble removing roller disposed in the coating liquid containing means, and a driving device for driving the air bubble removing roller.

4. 2. The coating apparatus according to claim 1, wherein the bubble removing means comprises a spraying means for spraying the coating liquid toward the surface of the substrate to be coated within the coating liquid storage means.

5. 2. The coating apparatus according to claim 1, wherein the bubble removing means comprises suction means for sucking the area on the surface to be coated of the substrate within the coating liquid containing means.

6. a coating liquid containing step of containing the coating liquid in a coating liquid containing means; a coating step of feeding a substrate along an outer peripheral surface of a roller facing the coating liquid storage means and coating the coating liquid in the coating liquid storage means onto a surface to be coated of the substrate; a bubble removal step of applying energy to the coating liquid in the coating liquid storage means to cause a pressure fluctuation, and removing bubbles on the surface to be coated by the pressure fluctuation.

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