UV curing apparatus and UV curing method

Abstract

To improve environmental control of a part irradiated with ultraviolet rays in ultraviolet curing.SOLUTION: An ultraviolet curing device 1 includes: a roller 2 for guiding a film 100 to which a resin is coated; a first nitrogen gas introduction port 3 and a second nitrogen gas introduction port 4 for introducing nitrogen gas; an ultraviolet irradiation part 5 for irradiating the film 100 with ultraviolet rays from a space between the first nitrogen gas introduction port 3 and the second nitrogen gas introduction port 4; an oxygen concentration meter 6 for measuring oxygen concentration between the film 100 and the ultraviolet irradiation part 5; an air introduction port 7 for introducing air into a space between the film 100 and the ultraviolet irradiation part 5; and a controller 8 for controlling at least one of the amount of air introduced from the air introduction port 7, the amount of nitrogen gas introduced from the first nitrogen gas introduction port 3, and the amount of nitrogen gas introduced from the second nitrogen gas introduction port 4 so that the oxygen concentration is within a prescribed oxygen concentration set range.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an ultraviolet curing apparatus and an ultraviolet curing method.

Background Art

[0002] Generally, an ultraviolet curing technique is widely known in which monomers are irradiated with ultraviolet rays to cause a photopolymerization reaction, thereby changing them into polymers and curing them. In the ultraviolet curing technique, it is important to appropriately control the energy of the irradiated ultraviolet rays and the oxygen concentration and nitrogen concentration in the portion irradiated with the ultraviolet rays. If variations occur in the energy of the irradiated ultraviolet rays and the oxygen concentration and nitrogen concentration in the portion irradiated with the ultraviolet rays, the photopolymerization reaction will be excessively suppressed or will proceed excessively. As a result, variations will occur in the quality of the product, causing a decrease in yield. Conventionally, technical developments have been made to appropriately control the environment in the portion irradiated with ultraviolet rays.

[0003] Patent Document 1, which is an example of the prior art, discloses controlling the residual oxygen content in the mixed gas in a chamber for crosslinking a coating with ultraviolet rays or electron beams.

[0004] Patent Document 2, which is an example of the prior art, discloses a technique for variably adjusting the flow rate of nitrogen gas for preventing crosslinking defects supplied into a quartz tube in which UV crosslinking is performed according to the traveling speed of a striated body to be UV crosslinked.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] There is room for improvement in the environmental control of the portion irradiated with ultraviolet rays during ultraviolet curing.

[0007] The present invention has been made in view of the above, and an object thereof is to provide a technique for controlling the crosslinking reaction of a resin.

Means for Solving the Problems

[0008] One aspect of the present invention that solves the above problems and achieves the object is a roller that guides a film coated with a resin, a first nitrogen gas inlet and a second nitrogen gas inlet for introducing nitrogen gas, and an ultraviolet ray that irradiates the film with ultraviolet rays between the first nitrogen gas inlet and the second nitrogen gas inlet. An irradiation unit, an oxygen concentration meter that measures the oxygen concentration between the film and the ultraviolet irradiation unit, an air inlet that introduces air between the film and the ultraviolet irradiation unit, and the air introduced from the air inlet so that the oxygen concentration is within a preset oxygen concentration setting range. And a controller that controls at least one of the amount of nitrogen gas introduced from the first nitrogen gas inlet and the amount of nitrogen gas introduced from the second nitrogen gas inlet, which is an ultraviolet curing apparatus.

[0009] In one aspect of the present invention, in the ultraviolet curing apparatus having the above configuration, the controller includes an input unit to which an oxygen concentration value measured by the oxygen concentration meter is input, a storage unit that stores the preset oxygen concentration setting range, and the oxygen concentration value. A determination unit that determines whether or not it is within the oxygen concentration setting range, and a signal generation unit that generates and outputs a control signal for controlling the opening degree of the gas valve based on the determination of the determination unit.

[0010] In one aspect of the present invention, in the ultraviolet curing apparatus having the above configuration, the oxygen concentration setting range is 500 ppm or more and 1000 ppm or less.

[0011] Alternatively, in one aspect of the present invention, in the ultraviolet curing apparatus having the above configuration, the oxygen concentration setting range is 5000 ppm or more and 5% or less.

[0012] Alternatively, one aspect of the present invention is an ultraviolet curing method in which ultraviolet rays are irradiated from between two nitrogen gas inlets to cure a film coated with a resin, comprising introducing nitrogen gas from each of the two nitrogen gas inlets, introducing air from an air inlet between the film and the portion irradiated with ultraviolet rays, measuring the oxygen concentration between the film and the portion irradiated with ultraviolet rays, controlling at least one of the amount of air introduced from the air inlet and the amount of nitrogen gas introduced from each of the two nitrogen gas inlets so that the oxygen concentration falls within a preset oxygen concentration range, guiding the film, and irradiating the film with ultraviolet rays from between the two nitrogen gas inlets.

[0013] In one aspect of the present invention, in the ultraviolet curing method having the above configuration, the control includes receiving the measured oxygen concentration value, determining whether the oxygen concentration value is within the oxygen concentration setting range, and generating and outputting a control signal for controlling the opening degree of a gas valve based on the determination.

[0014] In one aspect of the present invention, in the ultraviolet curing method having the above configuration, the oxygen concentration setting range is 500 ppm or more and 1000 ppm or less.

[0015] In one aspect of the present invention, in the ultraviolet curing method having the above configuration, the oxygen concentration setting range is 5000 ppm or more and 5% or less.

Advantages of the Invention

[0016] According to the present invention, the crosslinking reaction of the resin can be controlled.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0018] Hereinafter, embodiments for carrying out the present invention will be described with reference to the accompanying drawings. However, the present invention is not limited to the description of the following embodiments.

[0019] (Embodiment 1) Figure 1 is a cross-sectional view showing the configuration of an ultraviolet curing apparatus 1 according to an embodiment of the present invention. The ultraviolet curing apparatus 1 shown in Figure 1 includes a roller 2, a first nitrogen gas inlet 3, a second nitrogen gas inlet 4, an ultraviolet irradiation unit 5, an oxygen concentration meter 6, an air inlet 7, a controller 8, and a processing chamber 9.

[0020] The roller 2 guides the film 100 into the processing chamber 9. The film 100 advances at a constant speed in the advancing direction indicated by the arrow in Figure 1 and passes through the processing chamber 9. A resin, which is a monomer, is applied to the film 100, and the monomer changes into a polymer and cures by a photopolymerization reaction caused by the irradiated ultraviolet light.

[0021] The first nitrogen gas inlet 3 and the second nitrogen gas inlet 4 are gas inlets for introducing nitrogen gas into the processing chamber 9. In this way, by providing the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4, which are separated from each other, on both sides of the portion irradiated with ultraviolet light, the intrusion of outside air can be suppressed. A nitrogen gas source 30 is connected to the first nitrogen gas inlet 3, and a nitrogen gas source 40 is connected to the second nitrogen gas inlet 4. A gas valve 31 is provided between the first nitrogen gas inlet 3 and the nitrogen gas supply source 30, and a gas valve 41 is provided between the second nitrogen gas inlet 4 and the nitrogen gas supply source 40. Although the nitrogen gas supply source 30 and the nitrogen gas supply source 40 are shown in FIG. 1, the present invention is not limited thereto. For example, one nitrogen gas supply source may be connected to both the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4. Examples of the nitrogen gas supply source 30 and the nitrogen gas supply source 40 include nitrogen gas cylinders.

[0022] The ultraviolet irradiation unit 5 irradiates ultraviolet rays onto the film 100 between the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4. Here, the ultraviolet rays to be irradiated can have a constant energy throughout the process and can be uniformly irradiated onto the film 100.

[0023] The oxygen concentration meter 6 is a gas measuring device that measures the oxygen concentration in the space between the film 100 and the ultraviolet irradiation unit 5 in the processing chamber 9.

[0024] The air inlet 7 is a gas inlet that introduces air into the space between the film 100 and the ultraviolet irradiation unit 5 in the processing chamber 9. A nitrogen gas supply source 70 and an air supply source 72 are connected to the air inlet 7. A gas valve 71 is provided between the air inlet 7 and the nitrogen gas supply source 70. The air supply source 72 is connected between the air inlet 7 and the gas valve 71 via a gas valve 73. Examples of the nitrogen gas supply source 70 include nitrogen gas cylinders. Examples of the air supply source 72 include air cylinders.

[0025] Based on the oxygen concentration in the space between the film 100 and the ultraviolet irradiation unit 5 in the processing chamber 9 measured by the oxygen concentration meter 6, the controller 8 controls at least one of the amount of air introduced from the air inlet 7, the amount of nitrogen gas introduced from the first nitrogen gas inlet 3, and the amount of nitrogen gas introduced from the second nitrogen gas inlet 4.

[0026] Figure 2 is a functional block diagram showing the configuration of the controller 8 shown in Figure 1. The controller 8 shown in Figure 2 includes an input unit 81, a storage unit 82, a determination unit 83, and a signal generation unit 84.

[0027] The input unit 81 is an input interface connected to the oxygen concentration meter 6 and into which the oxygen concentration value, which is the result measured by the oxygen concentration meter 6, is input. The oxygen concentration value, which is the measurement result of the oxygen concentration meter 6, is input to the input unit 81.

[0028] The storage unit 82 stores a preset oxygen concentration setting range. The storage unit 82 can be realized by a recording medium such as a semiconductor memory and a magnetic disk. Here, the oxygen concentration setting range is preferably 500 ppm or more and 1000 ppm or less, or 5000 ppm or more and 5% or less. With such an oxygen concentration setting range, cracking or warping of the film 100 can be prevented.

[0029] The determination unit 83 determines whether the oxygen concentration value input from the oxygen concentration meter 6 to the input unit 81 is within the oxygen concentration setting range stored in the storage unit 82. The determination unit 83 can be realized by a processor such as an MPU (Micro-Processing Unit) and a CPU (Central Processing Unit).

[0030] Based on the determination of the determination unit 83, the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve. This gas valve is provided between the gas inlet to be controlled by the controller 8 and the gas supply source. Specifically, at least one of the gas valve 71 between the air inlet 7 and the nitrogen gas supply source 70 connected to the air inlet 7, the gas valve 73 connected between the air inlet 7 and the gas valve 71, the gas valve 31 between the first nitrogen gas inlet 3 and the nitrogen gas supply source 30 connected to the first nitrogen gas inlet 3, and the gas valve 41 between the second nitrogen gas inlet 4 and the nitrogen gas supply source 40 connected to the second nitrogen gas inlet 4 is the object to be controlled by the controller 8.

[0031] When the amount of nitrogen gas introduced from the first nitrogen gas inlet 3 and the amount of nitrogen gas introduced from the second nitrogen gas inlet 4 are constant, if the amount of air introduced from the air inlet 7 increases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 decreases and the oxygen concentration increases, or if the amount of air introduced from the air inlet 7 decreases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 increases and the oxygen concentration decreases. When the amount of nitrogen gas introduced from the second nitrogen gas inlet 4 and the amount of air introduced from the air inlet 7 are constant, if the amount of nitrogen gas introduced from the first nitrogen gas inlet 3 increases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 increases and the oxygen concentration decreases, or if the amount of nitrogen gas introduced from the first nitrogen gas inlet 3 decreases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 decreases and the oxygen concentration increases. When the amount of nitrogen gas introduced from the first nitrogen gas inlet 3 and the amount of air introduced from the air inlet 7 are constant, if the amount of nitrogen gas introduced from the second nitrogen gas inlet 4 increases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 increases and the oxygen concentration decreases, or if the amount of nitrogen gas introduced from the second nitrogen gas inlet 4 decreases, the nitrogen concentration in the measurement space of the oxygen concentration meter 6 decreases and the oxygen concentration increases.

[0032] Figure 3 is a flowchart showing the operation of the controller 8 shown in Figure 2. First, when the controller 8 shown in FIG. 2 starts processing and the oxygen concentration value, which is the result measured by the oxygen concentration meter 6, is input to the input unit 81 (S1), the determination unit 83 determines whether this oxygen concentration value is within the oxygen concentration setting range stored in the storage unit 82 (S2). Then, based on the determination result of the determination unit 83, the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve (S3), and ends the processing. For example, when the oxygen concentration value, which is the result measured by the oxygen concentration meter 6, is lower than the oxygen concentration setting range, the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve between the gas inlet of the control target of the controller 8 and the gas supply source so that the oxygen concentration increases. Or, when the oxygen concentration value, which is the result measured by the oxygen concentration meter 6, is higher than the oxygen concentration setting range, the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve between the gas inlet of the control target of the controller 8 and the gas supply source so that the oxygen concentration decreases. The opening degree of the gas valve may be proportionally controlled by the control signal.

[0033] In this way, by controlling at least one of the amount of air introduced from the air inlet 7, the amount of nitrogen gas introduced from the first nitrogen gas inlet 3, and the amount of nitrogen gas introduced from the second nitrogen gas inlet 4 by the controller 8, the cross-linking reaction of the resin in the film 100 can be controlled.

[0034] Note that the controller 8 may continue the control until the oxygen concentration value is within the oxygen concentration setting range. FIG. 4 is another flowchart showing the operation of the controller 8 shown in FIG. 2. First, when the controller 8 shown in FIG. 2 starts processing and the oxygen concentration value, which is the result measured by the oxygen concentration meter 6, is input to the input unit 81 (S11), the determination unit 83 determines whether this oxygen concentration value is within the oxygen concentration setting range stored in the storage unit 82 (S12). When the oxygen concentration value is within the oxygen concentration setting range stored in the storage unit 82 (S12: Y), the processing ends. When the oxygen concentration value is not within the oxygen concentration setting range stored in the storage unit 82 (S12: N), the determination unit 83 further determines whether the oxygen concentration value is greater than the oxygen concentration setting range stored in the storage unit 82 (S13). When the oxygen concentration value is greater than the oxygen concentration setting range stored in the storage unit 82 (S13: Y), the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve, thereby reducing the introduced air amount or increasing the introduced nitrogen gas amount (S14), and returning to S11. When the oxygen concentration value is not greater than the oxygen concentration setting range stored in the storage unit 82 (S13: N), the signal generation unit 84 generates and outputs a control signal for controlling the opening degree of the gas valve, thereby increasing the introduced air amount or reducing the introduced nitrogen gas amount (S15), and returning to S11. According to the flowchart shown in FIG. 4, automatic control can be performed until the oxygen concentration value is within the oxygen concentration setting range.

[0035] Further, the present invention is not limited to the ultraviolet curing device 1 shown in FIG. 1. FIG. 5 is a cross-sectional view showing the configuration of an ultraviolet curing device 1a according to a modified example of an embodiment of the present invention. The ultraviolet curing device 1a shown in FIG. 5 includes rollers 2a and 2b, a first nitrogen gas inlet 3 and a second nitrogen gas inlet 4, an ultraviolet irradiation unit 5, an oxygen concentration meter 6, an air inlet 7, a controller 8, and a processing chamber 9a.

[0036] The ultraviolet curing device 1a shown in FIG. 5 is different from the ultraviolet curing device 1 shown in FIG. 1 in that two rollers for guiding the film 100 are provided, that is, rollers 2a and 2b are provided instead of the roller 2, and a processing chamber 9a having a different shape is provided instead of the processing chamber 9, and other configurations are the same. The roller 2a and the roller 2b are arranged so that the irradiation surface of the ultraviolet rays from the ultraviolet irradiation unit 5, that is, the film 100 is flat and substantially at the same height with reference to the ultraviolet irradiation unit 5. According to the ultraviolet curing device 1a shown in FIG. 5, it is possible to flatten the area irradiated with ultraviolet rays from the ultraviolet irradiation unit 5, and the film 100 can be irradiated with ultraviolet rays uniformly.

[0037] As described above, according to this embodiment, the crosslinking reaction of the resin can be controlled. In addition, the crosslinking reaction of the resin can be appropriately controlled according to the material properties of the resin. Furthermore, such control of the crosslinking reaction of the resin can also be performed automatically.

[0038] Note that the present invention is not limited to the ultraviolet curing devices 1 and 1a. The present invention also includes an ultraviolet curing method in which ultraviolet rays are irradiated and cured from between two nitrogen gas inlets onto a film coated with a resin. That is, an ultraviolet curing method in which ultraviolet rays are irradiated and cured from between the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4 onto the film 100 coated with a resin, including introducing nitrogen gas from each of the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4, introducing air from the air inlet 7 between the film 100 and the portion irradiated with ultraviolet rays, measuring the oxygen concentration between the film 100 and the portion irradiated with ultraviolet rays, controlling at least one of the amount of air introduced from the air inlet 7 and the amount of nitrogen gas introduced from each of the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4 so that the oxygen concentration is within a preset oxygen concentration setting range, guiding the film 100, and irradiating the film 100 with ultraviolet rays from between the first nitrogen gas inlet 3 and the second nitrogen gas inlet 4, is also included in the present invention.

[0039] Also, in this embodiment, the ultraviolet curing device has been described, but the present invention is not limited thereto. The present invention can be applied when curing a resin by irradiation with electron beams, and can also be applied to prevent the generation of ozone. Alternatively, according to the present invention, it is possible to prevent coloring due to oxidation in the heating part during resin molding or to prevent the generation of odor.

[0040] Note that the present invention is not limited to the above-described embodiments, and also includes various modified examples in which components are added, deleted, or converted with respect to the above-described configuration.

Explanation of Reference Numerals

[0041] 1, 1a Ultraviolet curing device 2, 2a, 2b Roller 3 First nitrogen gas inlet 30 Nitrogen gas supply source 31 Gas valve 4 Second nitrogen gas inlet 40 Nitrogen gas supply source 41 Gas valve 5 Ultraviolet irradiation part 6 Oxygen concentration meter 7 Air inlet 70 Nitrogen gas supply source 71 Gas valve 72 Air supply source 73 Gas valve 8 Controller 81 Input part 82 Storage part 83 Judgment part 84 Signal generation part 9, 9a Processing chamber 100 Film

Claims

1. A roller for guiding a film coated with resin into a processing chamber, a first nitrogen gas inlet and a second nitrogen gas inlet for introducing nitrogen gas, an ultraviolet irradiation unit for irradiating the film with ultraviolet rays between the first nitrogen gas inlet and the second nitrogen gas inlet, an oxygen concentration meter for measuring the oxygen concentration between the film and the ultraviolet irradiation unit, an air inlet for introducing air between the film and the ultraviolet irradiation unit, The oxygen concentration meter is a gas measuring device that measures the oxygen concentration in the space between the film and the ultraviolet irradiation unit in the processing chamber, a controller that controls at least one of the amount of air introduced from the air inlet, the amount of nitrogen gas introduced from the first nitrogen gas inlet, and the amount of nitrogen gas introduced from the second nitrogen gas inlet so that the oxygen concentration is within a preset oxygen concentration setting range based on the measured oxygen concentration. An ultraviolet curing device comprising:

2. The controller includes: an input unit to which an oxygen concentration value measured by the oxygen concentration meter is input, a storage unit that stores a preset oxygen concentration setting range, a determination unit that determines whether the oxygen concentration value is within the oxygen concentration setting range, a signal generation unit that generates and outputs a control signal for controlling the opening degree of a gas valve based on the determination of the determination unit. The ultraviolet curing device according to claim 1.

3. The ultraviolet curing device according to claim 1 or claim 2, wherein the oxygen concentration setting range is 500 ppm or more and 1000 ppm or less.

4. The ultraviolet curing device according to claim 1 or claim 2, wherein the oxygen concentration setting range is 5000 ppm or more and 5% or less.

5. An ultraviolet curing method for curing a film coated with resin by irradiating ultraviolet rays between two nitrogen gas inlets, comprising: introducing nitrogen gas from each of the two nitrogen gas inlets, introducing air from an air inlet between the film and the portion irradiated with ultraviolet rays, measuring the oxygen concentration between the film and the portion irradiated with ultraviolet rays, By measuring the oxygen concentration, based on the oxygen concentration in the space between the film and the ultraviolet irradiation unit in the processing chamber, controlling at least one of the amount of air introduced from the air inlet and the amount of nitrogen gas introduced from each of the two nitrogen gas inlets so that the oxygen concentration is within a preset oxygen concentration setting range. Guiding the film into the processing chamber, Irradiating the film with ultraviolet rays from between the two nitrogen gas inlets, An ultraviolet curing method including the above steps.

6. The control includes: Inputting the measured oxygen concentration value, Determining whether the oxygen concentration value is within the oxygen concentration setting range, Generating and outputting a control signal for controlling the opening degree of the gas valve based on the determination. The ultraviolet curing method according to claim 5.

7. The ultraviolet curing method according to claim 5 or claim 6, wherein the oxygen concentration setting range is 500 ppm or more and 1000 ppm or less.

8. The ultraviolet curing method according to claim 5 or claim 6, wherein the oxygen concentration setting range is 5000 ppm or more and 5% or less.

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