Coating method, method for manufacturing multilayered material, coating apparatus, and multilayered material manufacturing apparatus

Abstract

To provide an application method for applying coating liquid to a web, which can reduce unevenness along a longitudinal direction of the web and can achieve high uniformity in coating thickness in a width direction, a manufacturing method for a multitiered object utilizing the application method, as well as an application device and a manufacturing device for the multitiered object for the same.SOLUTION: An application method, which applies coating liquid to a lengthy web having a first surface and a second surface, includes a conveying step in which the web is continuously conveyed along a conveyance passage, and an applying step (A) in which coating liquid (A) is guided onto the first surface and the coating liquid (A) is continuously applied to the first surface, using a bar (A) that rotates with a shaft (A) as a center, at an application position (A) on the conveyance passage. An extension direction of the shaft (A) in the applying step (A) has angles of 5°-30°with respect to a width direction of the web, and the applying step (A) includes a pressurizing step (Ap) of making the bar (A) press-contact the first surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for applying a coating liquid to a long web to be conveyed, a method for manufacturing a multi-layered product using such an application method, and an application device and a multi-layered product manufacturing device therefor.

Background Art

[0002] In many cases, a cylindrical bar used in a state of contacting the surface of a web is used for applying a coating liquid to the web. A typical example of such a bar is the bar in a so-called bar coater. The bar in a general bar coater rotates about its axis in a state where a part of it is immersed in the stored coating liquid and another part is pressed against the web, thereby guiding the coating liquid to the web surface and continuously applying the coating liquid over a wide range of the coating liquid. Further, not limited to the bar coater, the gravure roll in a gravure coater also guides the stored coating liquid to the web surface by a similar mechanism, so it can be said that this is also an aspect of the bar.

[0003] A long web such as a film is continuously conveyed from the upstream to the downstream of a conveyance path, a coating liquid is applied by a coating device provided in the conveyance path, a coating film is formed on the web, and further dried and cured, etc. to form a layer of a cured product, which is generally performed. Regarding such coating, for the purpose of improving quality, etc., a method for realizing a more uniform coating than the conventional coating is required, and for this reason, the existing manufacturing equipment may be modified.

[0004] On the other hand, when modifying such manufacturing equipment, it is also necessary to utilize existing manufacturing equipment as much as possible and reduce the cost of modifying the manufacturing process. For example, a coating device called the vertical kiss-reverse method is known as a coating device that achieves homogeneous coating, but this device can only coat webs that are conveyed in the vertical direction (i.e., the direction parallel to the direction of gravity). On the other hand, conventional coating devices using bar coaters generally coat webs that are conveyed in the horizontal direction (i.e., the direction perpendicular to the direction of gravity) or a direction close to it. Therefore, from the perspective of utilizing existing manufacturing equipment as much as possible, there is a need for a coating device that can coat webs that are conveyed in the horizontal direction or a direction close to it, similar to conventional bar coaters, and that also improves the homogeneity of the coating.

[0005] In the application of a coating solution to a web using a bar, the axis of the bar is usually positioned parallel to the width direction of the web. However, it has also been proposed that the axial direction of the bar be at an angle opposite to the width direction of the web. For example, Patent Document 1 discloses that a bar for scraping off the coating solution is positioned at an angle opposite to the width direction of the web, and that this angle is changed to adjust the coating thickness. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 6-170313 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] In coating using a bar, unevenness along the longitudinal direction of the web may occur due to the amount of coating liquid meniscus becoming partially larger at a certain position in the axial direction of the bar (roughly corresponding to the width direction of the web), forming droplets, or due to the trapping of foreign matter. To reduce such unevenness, it is necessary to quickly move large droplets or foreign matter in the axial direction of the bar and discharge them outward from the web width direction. This discharge can be promoted by setting the axial direction of the bar at an angle that is not parallel to the width direction of the web.

[0008] However, if the axial direction of the bar is set at an angle that is not parallel to the width direction of the web, it becomes necessary to use a bar that is even longer than the width dimension of the web, which can lead to even more unstable contact between the bar and the web in the central part, and as a result the coating thickness in the width direction may become even more uneven.

[0009] Accordingly, the object of the present invention is to provide a method for applying a coating liquid to a web that can reduce unevenness along the longitudinal direction of the web and has high uniformity of the coating thickness in the width direction, a method for manufacturing a multilayer material using such an application method, and an application apparatus and a multilayer material manufacturing apparatus therefor. [Means for solving the problem]

[0010] As a result of investigations aimed at solving the above-mentioned problems, the inventors of the present invention found that the above problems could be solved by employing a specific mechanism around the bar, and thus completed the present invention. In other words, the present invention provides the following:

[0011] [1] A method for applying a coating solution to a long web having a first surface and a second surface, A transport process for continuously transporting the web along a transport path, and The coating step (A) includes guiding the coating liquid (A) to the first surface using a bar (A) that rotates around an axis (A) at the coating position (A) of the transport path, and continuously applying the coating liquid (A) to the first surface. In the coating process (A), the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web. The coating step (A) is a coating method comprising pressing the bar (A) against the first surface and applying pressure to the web from the second surface side to the first surface side in a pressurized region (A) including the coating position (A) of the transport path. [2] The coating method according to [1], wherein the pressurization step (Ap) includes blowing a gas onto the second surface. [3] The coating method according to [2], wherein the pressurizing step (Ap) is performed by a floating conveying device that has a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface has a porous material surface. [4] The coating method according to [2] or [3], wherein the pressurizing step (Ap) is performed by pressurizing devices (Ap) provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying surface of the web upstream of the pressurizing area (A) and the conveying surface of the web downstream of the pressurizing area (A) are on the same plane. [5] The coating method according to any one of [1] to [4], wherein the coating step (A) further includes a separation step (As) in which pressure is applied to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A). [6] The coating method according to any one of [1] to [5], wherein the bar (A) is a gravure roll and the coating step (A) includes scraping off the coating liquid from the gravure roll with a blade. [7] A method for manufacturing a multilayer material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, Coating step (A), wherein the coating liquid (A) is continuously applied to the first surface of the web by the coating method described in any one of items (1) to (6) to form a coating film (A), and A curing step (A) to cure the aforementioned coating film (A) A method for manufacturing a multilayered material, including the method described above. [8] A coating step (B) in which, at a coating position (B) downstream of the coating position (A) in the transport path, the coating liquid (B) is guided to the second surface using a bar (B) that rotates around an axis (B), the coating liquid (B) is continuously applied to the second surface, and a coating film (B) is formed, and A curing step (B) to cure the aforementioned coating film (B) It further includes, In the coating step (B), the extension direction of the axis (B) at the coating position (B) is at an angle of 5° to 30° with respect to the width direction of the web. The method for manufacturing a multilayer material according to [7], wherein the coating step (B) includes pressing the bar (B) against the second surface and applying pressure to the web from the first surface side to the second surface side in the pressurized region (B) of the transport path, which includes the coating position (B). [9] The method for manufacturing a multilayer material according to [8], wherein the curing step (A) and the curing step (B) are carried out in a curing apparatus provided at a position downstream of the coating position (B) in the transport path.

[10] The curing step (A) is carried out in a curing device (A) located downstream of the coating position (A) and upstream of the coating position (B) in the transport path. The method for manufacturing a multilayer material according to [8], wherein the curing step (B) is performed in a curing device (B) located downstream of the coating position (B) in the transport path.

[11] A coating apparatus for applying a coating solution to a long web having a first surface and a second surface, A conveying device that continuously conveys the aforementioned web along a conveying path, A bar (A) provided at the coating position (A) of the transport path, which rotates around an axis (A), guides the coating liquid (A) to the first surface, and continuously coats the coating liquid (A) to the first surface, wherein the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web, and is provided so as to be in contact with the first surface, and A coating apparatus comprising a pressurizing device (Ap) that applies pressure to the web from the second surface side to the first surface side in a pressurized region (A) of the transport path that includes the coating position (A).

[12] The coating apparatus according to

[11] , wherein the pressurizing device (Ap) is a device for blowing gas onto the second surface.

[13] The coating apparatus according to

[12] , wherein the pressurizing device (Ap) is a levitation conveying device comprising a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface is the surface of a porous material.

[14] The coating apparatus according to

[12] or

[13] , wherein the pressurizing device (Ap) is provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying device is provided such that the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region (A) are on the same plane.

[15] The coating apparatus according to any one of

[11] to

[14] , further comprising a separation device (As) that applies pressure to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A).

[16] The coating apparatus according to any one of

[11] to

[15] , wherein the bar (A) is a gravure roll, and further comprises a blade capable of scraping the coating liquid off the gravure roll.

[17] A multilayer manufacturing apparatus for producing a multilayer material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, The coating device according to any one of

[11] to

[16] , which continuously applies the coating liquid (A) to the first surface of the web to form a coating film (A), a coating device (A), and A curing device (A) provided downstream of the coating device (A) for curing the coating film (A). A multi-layer article manufacturing apparatus including the above. 〔18〕 Provided downstream of the coating device (A) in the conveyance path, A coating device (B) that continuously applies a coating liquid (B) to the second surface of the web to form a coating film (B), and A curing device (B) provided downstream of the coating device (B) for curing the coating film (B). Further comprising the above. The coating device (B) is Provided at a coating position (B) downstream of the coating position (A) in the conveyance path, rotates about an axis (B), guides the coating liquid (B) to the second surface, and continuously applies the coating liquid (B) to the second surface. A bar (B) provided so as to be in pressure contact with the second surface, wherein the extension direction of the axis (B) has an angle of 5° to 30° with respect to the width direction of the web, and In a pressurizing region (B) including the coating position (B) in the conveyance path, a pressurizing device (Bp) is provided that applies pressure to the web from the first surface side toward the second surface side. The multi-layer article manufacturing apparatus according to

[17] . 〔19〕 As a device that also serves as the curing device (A) and the curing device (B), a curing device provided at a position downstream of the coating position (B) in the conveyance path is provided. The multi-layer article manufacturing apparatus according to

[18] . 〔20〕 As the curing device (A), a curing device (A) provided at a position downstream of the coating position (A) in the conveyance path and upstream of the coating position (B) is provided, [[ID=二十六]] As the curing device (B), a curing device (B) provided at a position downstream of the coating position (B) in the conveyance path is provided. The multi-layer article manufacturing apparatus according to

[18] . [[ID=二十八]]

Advantages of the Invention

[0012] The present invention provides a method for applying a coating liquid to a web that can reduce unevenness along the longitudinal direction of the web and has high uniformity of the coating thickness in the width direction, a method for manufacturing a multilayer material using such an application method, and an application apparatus and a multilayer material manufacturing apparatus therefor. [Brief explanation of the drawing]

[0013] [Figure 1] Figure 1 is a schematic side view showing an example of a coating method of the present invention, a coating apparatus and manufacturing apparatus for carrying out the coating method of the present invention including the coating method, and a coating method and manufacturing method for a multilayered material using the same. [Figure 2] Figure 2 is a top view showing a schematic, enlarged view of the coating apparatus 100A, which is a component of the manufacturing apparatus 10 shown in Figure 1. [Figure 3] Figure 3 is a side view showing a cross-section of the coating apparatus 100A, obtained by cutting it with a plane perpendicular to the direction of arrow R3 in Figure 2. [Figure 4] Figure 4 is a schematic top view showing the relationship between the pressurizing device (Ap), the bar (A), and the web when a free roll is used as the pressurizing device (Ap). [Figure 5] Figure 5 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 4, combined from three cross-sections perpendicular to the direction of arrow R5 in Figure 4. [Figure 6] Figure 6 is a schematic top view showing the relationship between the pressurizing device (Ap), the bar (A), and the web when a levitation conveying device is used as the pressurizing device (Ap). [Figure 7] Figure 7 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 6, combined from three cross-sections perpendicular to the direction of arrow R6 in Figure 6. [Figure 8] Figure 8 is a side view showing the bar 110A, the levitation conveying devices 151OA and 151DA, and the web 11 as observed from the direction of arrow R9U, as shown in Figure 2. [Modes for carrying out the invention]

[0014] The present invention will be described in detail below with reference to embodiments and examples, but the present invention is not limited to the embodiments and examples shown below, and may be implemented with modifications as appropriate without departing from the scope of the claims and equivalents of the present invention.

[0015] In this application, the orientation of the components of a member for carrying out the method of the present invention is "parallel" and may include an error within a range that does not significantly impair the effects of the present invention. For example, such an error may be such that the angle between one direction and another direction is preferably within ±5°, more preferably within ±3°, with respect to one direction.

[0016] In this application, a "long" web refers to a web having a length of five times or more its width, preferably ten times or more, and specifically, a web of a length that can be rolled up for storage or transport. There is no particular upper limit to the ratio of length to width of the web, but it may be, for example, 100,000 times or less.

[0017] In this application, for the sake of explanation, one end of the web in the width direction is defined as "end DS" and the other end as "end OS". In actual implementation, there is no specific requirement to designate one end as the other, and these can be determined arbitrarily. In the following explanation, the end on the far side of the drawing in Figure 1 will be referred to as end DS, and the end on the near side of the drawing will be referred to as end OS.

[0018] In this application, the term "web" may be used to refer collectively to a material such as a film used as a substrate before the formation of a coating film, a coated web obtained after the formation of a coating film (i.e., a multilayer material including the coating film and the substrate), and the web after it has been subjected to further processes such as curing.

[0019] [Overview of coating method and coating apparatus] The coating method of the present invention is a method for applying a coating liquid to a long web, and the coating apparatus of the present invention is an apparatus for such coating. The long web has a first surface and a second surface, which are the main surfaces on its front and back sides. In the following description, the web will mainly describe an example in which a film is used that does not have a specific distinction between the front and back surfaces. However, the web used in the present invention is not limited to this, and a web may be used in which the front and back surfaces have different characteristics such as material and properties. In that case, either surface may be designated as the first surface. In the following description, the example of coating the first surface and the example of coating both the first surface and the second surface will be described. Furthermore, in this application, in order to distinguish between the operation and apparatus components for coating the first surface and the operation and apparatus components for coating the second surface, the former may be denoted by the symbol "(A)" and the latter by the symbol "(B)".

[0020] Figure 1 is a schematic side view showing an example of a coating method of the present invention, a coating apparatus and manufacturing apparatus for carrying out the coating method of the present invention including the coating method, and a coating method and manufacturing method for a multilayered material using the same.

[0021] In Figure 1, the multilayer manufacturing apparatus 10 includes a conveying device consisting of free rolls 191, 192, and 193, a suction roll 194, and other conveying devices (not shown), which guide the web 11 so that its longitudinal direction moves in the direction of arrow R1, thereby forming a conveying path for continuous conveyance of the web 11.

[0022] The manufacturing apparatus 10 includes two coating apparatuses: a coating apparatus 100A for coating the first surface of the web 11 (coating process (A)) to form a single-sided coated web 12, and a coating apparatus 100B for coating the second surface of the web (coating process (B)) to form a double-sided coated web 13. For the sake of illustrating the overall structure in Figure 1, the coating apparatuses 100A and 100B are shown only in a very schematic manner in Figure 1.

[0023] The suction roll 194 rotates in the direction of arrow R2 at a controlled speed while sucking the wrapped, single-sided coated web 12 to its circumferential surface. By adjusting the transport speed upstream of the suction roll 194, the rotation speed of the suction roll 194, and the transport speed downstream of the suction roll 194, the tension applied to the web when it passes through the coating device 100A and the tension applied to the web when it passes through the coating device 100B can be independently adjusted. The manufacturing apparatus 10 further includes a curing device 195 located downstream of the coating device 100B for curing the coating film of the applied coating liquid.

[0024] [Coating process (A) using bar (A)] The coating apparatus of the present invention includes a bar (A) provided at a coating position (A) in the transport path, which rotates around an axis (A) to guide the coating liquid (A) to the first surface and continuously coats the coating liquid (A) to the first surface. In the coating apparatus of the present invention, the extension direction of the axis of the bar has an angle of 5° to 30° with respect to the width direction of the web and is provided to be in contact with the first surface. The coating apparatus of the present invention further includes a pressurizing device (Ap) that applies pressure to the web from the second surface side to the first surface side in a pressurizing region (A) of the transport path, including the coating position (A).

[0025] The coating method of the present invention includes a coating step (A) in which a coating liquid (A) is guided to a first surface using the bar (A) and the coating liquid (A) is continuously applied to the first surface. The coating step (A) further includes a pressurizing step (Ap) in which the bar (A) is pressed against the first surface and pressure is applied to the web from the second surface side to the first surface side in a pressurized region (A) including the coating position (A) of the transport path.

[0026] An example of the coating process (A) and the apparatus used therefor will be explained with reference to Figures 2 and 3. Figure 2 is an enlarged top view showing a schematic representation of the coating apparatus 100A, which is a component of the manufacturing apparatus 10 shown in Figure 1, and Figure 3 is a side view showing a cross-section of the coating apparatus 100A cut by a plane perpendicular to the direction of arrow R3 in Figure 2.

[0027] The coating apparatus 100A includes a tank 120A for storing the coating liquid 21A, a bar 110A for applying the coating liquid 21A from the tank 120A to the first surface of the web 11, and flotation conveying devices 131A and 132A, which serve as pressurizing devices (Ap), provided downstream and upstream of the bar, respectively.

[0028] The bar 110A is provided with a suitable spindle (not shown) so as to rotate around its axis 110AX, and is rotatably supported via the spindle. The bar 110A has a circumferential surface 111A and is configured to transmit driving force via the spindle so as to rotate in the forward direction (i.e., the rotation direction in which the circumferential surface 111A moves in the same direction as the direction of travel of the web 11 in the portion where the web 11 wraps around the circumferential surface 111A) or in the reverse direction (i.e., the rotation direction in which the circumferential surface 111A moves in the opposite direction to the direction of travel of the web 11 in the portion where the web 11 wraps around the circumferential surface 111A). Figure 3 shows an example of rotating the bar 110A in the reverse direction, i.e., in the direction of arrow R4.

[0029] The cylindrical bar 110A extends across the entire width of the web from end DS to end OS in the width direction on the transport path, and is positioned so that a portion of it is immersed in the coating liquid 21A in the tank 120A. The bar 110A is positioned such that the direction in which its axis 110AX extends is at an angle of θ110AX with respect to the width direction of the web 11 (the direction indicated by the arrow Rw), with its DS side tilted downstream and its OS side tilted upstream. The levitation transport devices 131A and 132A also extend across the entire width of the web, and are positioned so as to be tilted with respect to the width direction of the web, with their longitudinal direction parallel to the axis 110AX of the bar 110A.

[0030] Bar 110A is provided on the first surface 11-1 side of the web 11 on the transport path and is positioned to press against the first surface 11-1. On the other hand, the levitation transport devices 131A and 132A of the coating device 100A are provided on the second surface (surface 11-2 or surface 12-2) side of the web.

[0031] As the bar 110A, any shape used in various known coating devices can be used. Examples include wire bars and non-wire bars used as bars in bar coaters. Another example is a gravure roll used in a gravure coater. When using a gravure roll, a blade can be used in conjunction with it to scrape off excess coating liquid from the circumferential surface of the gravure roll between the time the coating liquid is scooped up and when it reaches the web surface.

[0032] By pressing the bar 110A against the first surface of the web, the bar 110A is wrapped by the web at an overlap angle θ110WA. Because the bar 110A is pressed against the web in this manner and partially contained in the coating liquid 21A, the bar 110A can be operated to guide the coating liquid to the first surface of the web. Specifically, by rotating the bar 110A in the direction of arrow R4, the coating liquid 21A in the tank 120A can be scooped up and transported upward along with the circumferential surface 111A, and guided to the first surface 11-1 of the web 11.

[0033] Thus, in embodiments in which pressure welding is performed upstream and downstream of bar (A), it is preferable that the lap angle θ110WA be within a specific range of angles, from the viewpoint of achieving effective pressure welding and preventing problems such as web wear due to excessive pressure welding. Specifically, the lap angle θ110WA is preferably 0.5° or more, and preferably 10° or less.

[0034] The coating liquid 21A that reaches the first surface 11-1 of the web 11 forms a meniscus 22A at the end of the wrap angle (i.e., the position where the wrap begins or ends; in this example, a position on the transport path where the web 11 moves away from the area where it wraps the bar 110A). A portion of the coating liquid 21A in the meniscus 22A moves downstream while adhering to the first surface 11-1 of the web 11, thereby forming a single-sided coated web 12 consisting of the web 11 and a layer 23A of the coating liquid 21A. In this way, when a new layer is formed on the original web, the surface of the new layer becomes the surface of the web. That is, in the single-sided coated web 12, the surface 12-1 on the layer 23A side becomes the first surface of the web 12, while the surface on the web 11 side becomes the second surface of the web 12.

[0035] Another portion of the coating liquid 21A in the meniscus 22A may fall back into the tank 120A. Yet another portion of the coating liquid 21A in the meniscus 22A may rotate further along the circumferential surface 111A, thereby interposing between the web 11 and the bar 110A in the region where the web 11 wraps around the bar 110A. In this way, the interposition of the liquid coating liquid means that the pressure contact between the bar 110A and the web 11 is not direct pressure contact, but rather pressure contact with the coating liquid interposed. In this state of pressure contact between the bar 110A and the web 11, scratching between them is less likely, and therefore damage to the web 11 is minimal.

[0036] The size of the meniscus 22A can be adjusted by the rotation speed of the bar 110A and other conditions. From the viewpoint of preventing areas with insufficient coating, the size of the meniscus 22A is required to be larger than a certain size. On the other hand, if the meniscus 22A becomes excessively large, large droplets 22AL may be generated at certain positions in the width direction of the bar 110A. When such droplets 22AL are generated, they may remain at that position during the coating process and continue to exist for a certain period of time. As a result, the thickness of the coating layer 23A applied at that position becomes partially thicker, which can lead to the undesirable phenomenon of unevenness along the longitudinal direction of the web.

[0037] In the coating method of the present invention, the extension direction of the axis 110AX of the bar 110A has an angle of θ110AX with respect to the width direction of the web. Therefore, the droplet 22AL is rapidly moved in the direction in which the bar 110A is tilted downstream (i.e., the DS side in the example of Figure 2) by the combined force of being pulled downstream by the web and the force trying to move along the bar 110A, and quickly falls from the DS side end of the web. As a result, the occurrence of unevenness along the longitudinal direction of the web can be suppressed.

[0038] During the coating process, in addition to droplets 22AL caused by variations in the size of the meniscus 22A, variations in the longitudinal direction of the bar 110A may occur due to various factors. For example, foreign matter present in the coating liquid 21A or on the circumferential surface 111A of the bar 110A may reach the position of the meniscus 22A and remain there, causing variations along the longitudinal direction of the web. These various factors causing variations that tend to remain at a certain position on the meniscus 22A can be quickly removed from the side edges of the web by a mechanism similar to that of the droplets 22AL described above, because the extension direction of the axis 110AX of the bar 110A has an angle of θ110AX with respect to the width direction of the web.

[0039] In the present invention, the angle between the extension direction of the axis (A) of the bar (A) and the width direction of the web (corresponding to the angle θ110AX in the example in Figure 2) is 5° or more, preferably 8° or more, and on the other hand, 30° or less, preferably 15° or less. By having this angle above the lower limit, it becomes possible to quickly remove substances that cause unevenness, such as droplets and foreign matter. On the other hand, by having this angle below the upper limit, it is possible to suppress undesirable phenomena such as scratches on the web by the bar, the occurrence of wrinkles in the web, and uneven thickness where the coating thickness in the center of the web width direction is relatively thicker than the coating thickness at the edges.

[0040] The bar (A) may be tilted either upstream at its DS end or downstream at its OS end. However, if the coating apparatus has a mechanism to eliminate elements that cause uneven thickness, such as droplets, in addition to the tilt of the bar (A), it is preferable to tilt the bar (A) in a direction that allows it to quickly eliminate such elements in cooperation with the mechanism. For example, if the bar (A) is a wire bar with a wire wound in a spiral shape, and has a spiral circumferential structure, and has a mechanism that sends elements that cause uneven thickness to one end as the bar rotates, it is preferable to have the downstream end facing downstream.

[0041] Since the coating device 100A has a flotation conveying device 131A upstream of the coating device 100A and a flotation conveying device 132A downstream of the coating device 100A as pressurizing devices (Ap), the region 100AZ of the conveying path, which is downstream of the flotation conveying device 131A and upstream of the flotation conveying device 132A and includes the coating position, is defined as the pressurizing region (A).

[0042] Each of the levitation conveying devices 131A and 132A has a conveying surface 133A and 134A that supports the web non-contact. The levitation conveying devices are configured such that their conveying surfaces overlap with the conveying path. In the examples of Figures 2 and 3, each of the levitation conveying devices 131A and 132A extends from the end DS to the end OS of the web, and their conveying surfaces 133A and 134A overlap at overlap angles θ133WA and θ134WA. The conveying surfaces 133A and 134A have surfaces of a porous material having numerous holes (not shown). The levitation conveying devices 131A and 132A are configured to eject gas from these holes, thereby allowing the conveying surfaces 131A and 132A to apply pressure from the second surface side to the first surface side of the web while maintaining a non-contact state.

[0043] As an example of a levitation conveying device, one in which the conveying curved surface is formed of a porous material is preferably used. Examples of porous materials include porous carbon, porous alumina, porous ceramics, and porous metal sintered materials. When a levitation conveying device has a conveying surface formed of a porous material, if a pressurized air device is connected to the levitation conveying device and gas is pressurized into the levitation conveying device, the gas is ejected from the pores on the surface of the porous material on the conveying surface to the outside of the conveying surface, and the conveying surface pressurizes the web without contact.

[0044] When the transport surface is formed from a porous material, numerous minute holes can be easily created on the transport surface. Therefore, compared to materials where it is relatively difficult to create minute holes such as slit nozzles or punched holes, it becomes possible to pressurize the film by pumping gas at low flow rates and with low pulsation. Consequently, it becomes easy to maintain a stable pressurized state.

[0045] The average pore diameter on the conveying curved surface is preferably 0.1 μm or more, more preferably 0.5 μm or more, preferably 30 μm or less, and more preferably 3.0 μm or less. If the pore diameter is too large, some pores may become blocked, causing gas leakage from other pores. However, if the pore diameter is below the upper limit, the pressure loss within the porous material is large, so even if some pores become blocked, gas leakage can be prevented.

[0046] A levitation conveying device can levitate a web by applying an upward force with gas to a web that is biased downward by gravity and / or tension, thereby supporting the web without contact. However, the levitation conveying device is not limited to this, and as shown in the examples in Figures 2 and 3, for example, it can also apply a downward force with gas from the levitation conveying device to a web that is extended in a nearly horizontal direction under tension, thereby pressurizing the web downward in a non-contact manner below the levitation conveying device.

[0047] The conveying surfaces 133A and 134A of the levitation conveying devices 131A and 132A are partially cylindrical curved surfaces. By having a conveying surface that is a columnar surface such as a curved surface having the shape of a cylindrical or elliptical portion of a cylinder, the conveying surface can be made to be wrapped by the conveying path at a certain wrap angle. The linear direction on the columnar surface can be parallel to the web surface on the web conveying path that wraps the conveying surface. In this application, this axis direction is called the wrap axis direction. In the example of levitation conveying devices 131A and 132A, they have wrap axes 133AX and 134AX, respectively, and this direction is the wrap axis direction of each levitation conveying device.

[0048] The web is transported along a transport path that wraps around the levitation transport devices 131A and 132A, and the tension required for transport is applied in the longitudinal direction of the web. As a result, pressure is applied to the web in the pressurized region (A) on the transport path by the levitation transport devices 131A and 132A from the second surface side to the first surface side, and the pressurizing process (Ap) is achieved. By performing the pressurizing process (Ap) in the pressurized region (A) in this way, the web is pressed against the bar (A), and as a result, the bar (A) comes into close contact with the web, resulting in a uniform coating thickness. Consequently, unevenness along the longitudinal direction of the web can be reduced, and the application of the coating liquid to the web with high uniformity of coating thickness in the width direction is achieved.

[0049] In the above example, a levitation conveying device is used as the pressurizing device (Ap), and the pressurizing process (Ap) is performed by blowing gas onto the second surface while the web is wrapped. However, the pressurizing device (Ap) in the present invention is not limited to this, and for example, a device such as a free roll may be used. However, by using a levitation conveying device as the pressurizing device (Ap) and performing the pressurizing process (Ap) by blowing gas onto the second surface, many advantages can be obtained, as will be explained below.

[0050] When a free roll, typically used for web transport, is employed as the pressurizing device (Ap), if the roll's axial direction is not parallel to the web's width direction, the web will move diagonally along the roll's surface. However, since the movement of the roll's surface due to the roll's rotation is only perpendicular to the axis, the web is transported with a scratching motion in the width direction relative to the roll's surface. This can result in scratches and wrinkles due to the web's meandering. Therefore, to avoid such scratches and wrinkles, the roll's axial direction must be parallel to the web's width direction. On the other hand, when a levitation transport device is employed as the pressurizing device (Ap), there is no such restriction, and the lap axis of the levitation transport device can be positioned parallel to or close to the axis of the bar (A). Such an arrangement makes it possible to make the length of the web's pass line from the upstream pressurizing device (Ap) through the bar (A) to the downstream pressurizing device uniform in the web's width direction. As a result, it is possible to reduce the possibility of scratches and wrinkles while achieving more uniform coating.

[0051] Figure 4 is a schematic top view showing the relationship between the pressurizing device (Ap), bar (A), and web when a free roll is used as the pressurizing device (Ap), and Figure 5 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 4, combined with three cross-sections perpendicular to the direction of arrow R5 in Figure 4. These three cross-sections are the cross-sections at positions PDS and POS near the widthwise ends shown in Figure 4, and the cross-section at position PC in the widthwise center. In the examples of Figures 4 and 5, the axial direction of bar (A) 410 is inclined with respect to the widthwise direction of the web 41, while the axial directions of the free rolls 431 and 432 are parallel to the widthwise direction of the web 41. In this case, the pass lines LDS and LOS of the web 41 at positions PDS and POS are longer than the pass line LC at position PC. Therefore, the tension applied to the web 41 at position PC is relatively weaker. Such differences in tension can lead to an undesirable phenomenon where the coating thickness in the center becomes relatively thicker than the coating thickness at the edges, depending on various conditions such as the physical properties of the web and the coating solution, as well as the operating conditions.

[0052] Figure 6 is a schematic top view showing the relationship between the pressurizing device (Ap), the bar (A), and the web when a levitation conveying device is used as the pressurizing device (Ap), and Figure 7 is a side view showing the pressurizing device (Ap), bar (A), and web shown in Figure 6, combined from three cross-sections perpendicular to the direction of arrow R6 in Figure 6. In the examples of Figures 6 and 7, the axial direction of the bar (A) 410 is inclined with respect to the width direction of the web 61, while the axial directions of the levitation conveying devices 631 and 632 are also inclined with respect to the width direction of the web 61, and these are parallel to the axial direction of the bar (A) 410. In this case, the pass lines LDS and LOS of the web 61 at positions PDS and POS are the same as the pass line LC at position PC. Therefore, the tension applied to the web 61 at position PC is equal to that at other positions. Consequently, the difference between the coating thickness at the center and the coating thickness at the edges can be easily reduced compared to the examples shown in Figures 4 and 5.

[0053] Since the levitation conveying devices 631 and 632 apply pressure to the web 61 without contact, even if the lap axis direction is not parallel to the width direction of the web and the web moves diagonally on the conveying curved surface, the conveying curved surface does not scratch the web surface, thus avoiding scratches and wrinkles. Because scratches on the web surface can be avoided, it is easy to apply strong pressure to the web with the levitation conveying device and increase the lap angle. Therefore, when it is required to apply high pressure to the bar (A), such high pressure can be easily achieved.

[0054] Furthermore, by performing the pressurization process (Ap) non-contact, the coating process (A) can be carried out even when it is desirable to avoid direct contact between the second surface of the web and the material, such as when an additional layer of uncured coating liquid is formed on the second surface. In addition, the gas used for pressurization can also have the effect of dampening the vibration of the web, thus reducing unevenness in coating caused by vibration.

[0055] It is preferable that the axial direction of bar (A) and the direction of the lap axis of the levitation conveying device are parallel or nearly parallel. Specifically, the preferred range of angles between the axial direction of bar (A) and the respective lap axis directions of the levitation conveying device varies depending on the elasticity of the web, the tension applied to the web, etc., but for example, it is preferably within 10°, more preferably within 5°.

[0056] In the examples shown in Figures 1 to 3, two levitation conveying devices 131A and 132A, located upstream and downstream of bar (A) (bar 110A), are used as pressurizing devices (Ap) for the pressurizing process (Ap), and the area from the upstream levitation conveying device 131A to the downstream levitation conveying device 132A is set as the pressurizing area (A). However, the present invention is not limited to this. For example, three or more pressurizing devices (Ap) may be provided for the pressurizing process (Ap). Pressurizing devices (Ap) may be provided at a position upstream of bar (A), a position downstream of bar (A), a position opposite bar (A), or a combination of two or more of these positions. When multiple pressurizing devices are provided, among the pressurizing devices that extend across the entire width of the web, the pressurizing device closest to bar (A) on the upstream side of bar (A) and the pressurizing device closest to bar (A) on the downstream side of bar (A) may be designated as pressurizing devices (Ap), and the area between them may be designated as the pressurizing area (A).

[0057] [Particularly preferred embodiment: upstream and downstream conveying directions] In the coating method of the present invention, the pressurizing step (Ap) includes blowing gas onto the second surface using a pressurizing device (Ap) such as a levitation conveying device, and it is preferable that the pressurizing step (Ap) is performed by pressurizing devices (Ap) provided at two or more locations, including the upstream position and the downstream position of the bar (A). Furthermore, in this embodiment, it is preferable that the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region (A) are on the same plane. Furthermore, in this embodiment, it is preferable that the conveying direction of the web upstream and the conveying direction of the web downstream are parallel.

[0058] In the examples shown in Figures 1 to 3, the region 100AZ defined by the levitation conveying devices 131A and 132A, which are pressurizing devices (Ap), is defined as the pressurizing region (A). Upstream of this region, the upstream region 100AU is defined, and downstream of it, the downstream region 100AD is defined. Both the upstream region 100AU and the downstream region 100AD lie on the plane indicated by line Lv1 in Figure 3. Furthermore, the conveying directions R9U and R9D in the upstream region 100AU and the downstream region 100AD are parallel. By arranging the conveying path in this way, even if the bar (A) is pressed in forcefully, problems such as twisting and meandering of the web can be suppressed from the upstream region to the downstream region, uniform pressure can be applied to the web, and the length of the web pass line from the upstream region to the downstream region can be made uniform in the web width direction. As a result, the possibility of scratches and wrinkles is reduced, and more uniform coating can be achieved. In addition, since such a transport path can be configured using relatively simple methods, such as aligning the planes of the upstream and downstream regions and aligning the transport direction, it also has the advantage of making it easy to adjust the equipment.

[0059] From the viewpoint of aligning the web conveying surface upstream of the pressurized area (A) and the web conveying surface downstream of the pressurized area (A) on the same plane, it is preferable that the sum of the wrap angles of the levitation conveying device (in the example in Figure 3, wrap angles θ133WA and θ134WA) is equal to or close to the wrap angle of the bar (A) (in the example in Figure 3, wrap angle θ110WA). Specifically, it is preferable that the absolute value of the difference between these angles is 3° or less.

[0060] [Separation process (As)] In a preferred example, the coating step (A) includes a separation step (As). In the separation step (As), pressure is applied to the web from a first surface side to a second surface side at a position in the transport path corresponding to the end of the web in the width direction, thereby separating the end of the web in the width direction from the bar (A). The coating apparatus of the present invention may include a separation device (As) for performing such a separation operation.

[0061] Specifically, the separation device (As) for performing the separation process (As) may be a roller that is in contact only with the widthwise end of the first surface side of the web on the transport path, or a levitation transport device or nozzle that blows gas only onto the widthwise end of the first surface side.

[0062] In the example shown in Figure 2, the separation devices (As) are small levitation conveying devices 151OA, 151DA, 152OA, and 152DA located upstream and downstream of the bar 110A, which blow gas only onto the widthwise ends of the web. These will be described in more detail with reference to Figure 8. Figure 8 is a side view showing the bar 110A, the levitation conveying devices 151OA and 151DA, and the web 11 as seen from the direction of arrow R9U. In Figure 8, for illustrative purposes, only the web 11 is shown as a longitudinal section cut by a vertical plane passing through the axis 110AX of the bar 110A. In this example, gas is ejected upward from the upstream levitation conveying devices 151OA and 151DA, and the downstream levitation conveying devices 152OA and 152DA (not shown in Figure 8), thereby levitating the widthwise ends 11DS and 11OS of the web 11 and separating them from the surface of the bar 110A. By performing such a separation process (As), it becomes possible to form regions where the coating liquid (A) is not applied only at the widthwise ends 11DS and 11OS.

[0063] Creating areas where coating is not applied to the widthwise ends can be useful in subsequent processes after the coating process. For example, when manufacturing a multilayer product by forming a cured coating layer on a long web, the web may be subjected to a further stretching process after the coating application. From the viewpoint of achieving optical properties and improving work efficiency, it is often preferable to perform such a stretching process simultaneously with the curing process after the coating process, or after forming the cured coating layer to create a multilayer product. In such a stretching process, the widthwise ends of the multilayer product may be gripped by a gripping mechanism, such as a gripper of a tenter stretcher. When gripping in this way, if a layer of coating or a layer of cured coating is formed at the widthwise ends, the coating may easily adhere to the gripper, contaminating it and potentially causing problems in the stretching process. On the other hand, the areas gripped by the gripper are prone to significant web distortion, and are generally trimmed and removed in subsequent processes; therefore, there is no benefit to applying the coating to the areas gripped by the gripper. Therefore, by performing the separation process (As), contamination of the gripper can be suppressed, and subsequent processes can be carried out smoothly.

[0064] The formation of areas where coating is not performed at the widthwise edges can also be achieved, for example, by making the length of bar (A) shorter than the widthwise dimension of the web. However, if the length of bar (A) is shorter than the widthwise dimension of the web, the pressure of the web pressing at the widthwise edges becomes relatively large, which can lead to the problem that the coating thickness at the widthwise edges is smaller than that at the center. Furthermore, as the bar end rotates while in contact with the web, vibrations occur in the pressure of the web at the widthwise end, making the web support unstable. As a result, uneven coating can occur even in the widthwise center where precise quality control is required. This instability in support is particularly pronounced in the coating method of the present invention, due to the angled placement of the bar (A). By employing a bar (A) that extends over a region longer than the widthwise dimension of the web, and by performing a separation step (As), it becomes possible to create a region where coating is not performed at the widthwise end while making the web support more stable. In addition, it is possible to suppress problems such as breakage due to stress concentration of the web at the bar (A) end, and since coating can be performed on webs of any width narrower than the extended length of the bar (A) in the widthwise direction of the apparatus, it is also possible to perform the coating method on webs of various widths using a common apparatus.

[0065] [Method and apparatus for manufacturing multilayered materials] The present invention relates to a method for manufacturing a multilayered material comprising a long web having a first surface and a second surface, and a cured coating layer provided on the first surface, or on both the first and second surfaces, and the present invention relates to a multilayered material manufacturing apparatus for manufacturing such a multilayered material.

[0066] The multilayer manufacturing apparatus of the present invention includes the coating apparatus (A) of the present invention described above, and a curing apparatus (A) provided downstream thereof for curing the coating film (A). The method for manufacturing a multilayer product of the present invention includes a coating step (A) in which a coating liquid (A) is continuously applied to the first surface of a web by the coating method of the present invention described above to form a coating film (A), and a curing step (A) in which the coating film (A) is cured.

[0067] The multilayer manufacturing apparatus of the present invention may further include, as optional components, a coating device (B) provided downstream of a coating device (A) for continuously applying a coating liquid (B) to the second surface of a web to form a coating film (B), and a curing device (B) provided downstream of the coating device (B) for causing the coating film (B) to form. The method for manufacturing a multilayer material of the present invention may, as optional components, include a coating step (B) and a curing step (B) using such a coating device (B) and curing device (B).

[0068] The coating device (B) may be the same as the coating device (A) described above, except that the first and second surfaces of the web to be processed are reversed (i.e., the coating surface is the second surface, not the first surface, and therefore the pressurization by the pressurizing device is applied from the first surface side to the second surface side). Specifically, the coating device (B) may be a bar (B) that rotates around an axis (B) to guide the coating liquid (B) to the second surface and continuously coat the coating liquid (B) to the second surface, wherein the extension direction of the axis (B) is at an angle of 5° to 30° with respect to the width direction of the web and is provided to be in contact with the second surface, and a pressurizing device (Bp) that applies pressure to the web from the first surface side to the second surface side in a pressurizing region (B) of the transport path that includes the coating position (B).

[0069] Specific examples of coating apparatus (B) and its components include the same ones as those of coating apparatus (A) above. In a specific multilayer manufacturing apparatus, coating apparatus (B) may be an apparatus with exactly the same specifications as coating apparatus (A) which is provided together, or it may be an apparatus with different specifications from coating apparatus (A). Similarly, coating process (B) may be an apparatus with exactly the same specifications as coating process (A), except that the first and second surfaces of the web to be processed are reversed, or it may be a process with other differences in specifications. If the specifications of coating apparatus (A) and coating process (A) are different from the specifications of coating apparatus (B) and coating process (B), either of these specifications may be used as the upstream side (coating apparatus (A); coating process (A)).

[0070] In particular, if the coating apparatus (A) is equipped with a separation device (As) and performs a separation process (As) thereafter, it is preferable that the coating apparatus (B) is also equipped with a separation device (Bs) having similar components and performs a similar separation process (Bs). This allows for the formation of areas on both the front and back surfaces of the web where coating is not performed at the widthwise edges, and as a result, even when a cured layer of the coating liquid is formed on both surfaces, the effect of separation can be obtained well.

[0071] The curing apparatus (A) and curing apparatus (B) may be different and separate devices, or they may be a common device that serves both purposes. Similarly, the curing process (A) and curing process (B) may be different and separate processes, or they may be a common process that serves both purposes. For example, a multilayer manufacturing apparatus may include a curing apparatus that serves both as curing apparatus (A) and curing apparatus (B), and is located downstream of the coating position (B) in the transport path.

[0072] In the example of the multilayer manufacturing apparatus 10 and manufacturing method using the same shown in Figure 1, the coating apparatus 100A coats the first surface of the web 11 (coating process (A)) to form a single-sided coated web 12, and then the coating apparatus 100B coats the second surface of the single-sided coated web 12 (coating process (B)) to form a double-sided coated web 13. Subsequently, the curing process, which combines curing process (A) and curing process (B), is performed using a curing apparatus 195, which is a device that serves as both curing apparatus (A) and curing apparatus (B). In this example, the curing apparatus 195 is an oven that dries the coating liquid layers on both sides of the web, and by performing this drying, the coating liquid layers are cured, and a multilayer material is obtained in which a cured coating liquid layer is provided on both sides of the web.

[0073] In such a process, the single-sided coated web 12 is subjected to the coating process (B) while the coating film (A) layer formed in the coating process (A) is not yet hardened. However, by using the same floating conveying devices 131A and 132A used in the pressing process (Ap) as the pressurizing device (Bp) for the pressurizing process (Bp) in the coating process (B), the coating film (A) can be processed without directly contacting the device in the conveying path from downstream of the coating process (A) to the hardening process by the hardening device 195. As a result, the hardening process (A) and the hardening process (B) can be carried out by a common process that combines both, thereby simplifying the equipment required for the hardening process, shortening the conveying path required for the hardening process, and reducing the costs required for the hardening process.

[0074] However, the present invention is not limited thereto, and the curing process (A) and curing process (B) may be separate processes, and the curing apparatus (A) and curing apparatus (B) may be separate apparatuses. Specifically, the manufacturing apparatus may include a curing apparatus (A) located downstream of the coating position (A) and upstream of the coating position (B) in the transport path, and a curing apparatus (B) located downstream of the coating position (B) in the transport path, and the curing process (A) and curing process (B) may be performed using these curing apparatuses (A) and curing apparatus (B), respectively. In yet another example, the manufacturing apparatus may include a coating apparatus (A) and a curing apparatus (A), and a device for winding up the cured web, and the web after the curing process may be wound up to form a roll, then the web may be unwound from the roll, and the coating process (B) and curing process (B) may be performed using the same apparatus that performed the coating process (A) and curing process (A).

[0075] [Variation] The coating method and multilayer manufacturing method of the present invention may include any additional steps in addition to those described above. Similarly, the coating apparatus and multilayer manufacturing apparatus of the present invention may include any additional components in addition to those described above. For example, a step of stretching the web and an apparatus for doing so may be included after the curing step. In particular, if a separation step (As) using a separation device (As) (and, if performed, a separation step (Bs) using a separation device (Bs)) is carried out, stretching using a stretching machine such as a tenter stretcher can be easily performed thereafter, so the steps of stretching the web in the width direction and in the diagonal direction can be carried out particularly well.

[0076] In the example of the multilayer manufacturing apparatus described above, an oven for drying the coating liquid was provided as the curing device, but the present invention is not limited to this, and the curing device may be other devices. For example, if the solvent contained in the coating liquid is highly volatile and the coating liquid can be easily cured simply under the conditions of transport in the transport path, the transport path for transporting the web can be used as the curing device. Alternatively, if the coating liquid has the property of curing by undergoing a reaction such as crosslinking when irradiated with energy rays such as ultraviolet rays and electron beams, a device that irradiates such energy rays may be used as the curing device.

[0077] [Description of materials] In the coating method and multilayer manufacturing method of the present invention, various films can be used as the web to which the coating liquid is to be applied. As the film, a resin film containing various polymers can be used. Examples of such polymers include olefin polymers such as polyethylene and polypropylene; polyesters such as polyethylene terephthalate and polybutylene terephthalate; polyarylene sulfides such as polyphenylene sulfide; polyvinyl alcohol; polycarbonate; polyarylate; cellulose ester; polyethersulfone; polysulfone; polyallylsulfone; polyvinyl chloride; alicyclic structure-containing polymers; acrylic polymers; styrene-based polymers such as polystyrene; and so on. These may be used individually or in combination of two or more in any ratio.

[0078] Preferably, the resin constituting the film is a resin containing an alicyclic structure-containing polymer (hereinafter referred to as "alicyclic structure-containing polymer resin" as appropriate), a resin containing an acrylic polymer, or a resin containing polycarbonate. Alicyclic structure-containing polymer resins are particularly preferred because they offer excellent transparency, low moisture absorption, dimensional stability, and lightweight properties, making them suitable for use as optical films. Specific examples of resins constituting the film are those described in Japanese Patent Publication No. 5845895.

[0079] Examples of coating liquids used in the coating method and multilayer manufacturing method of the present invention include polyurethane aqueous dispersions for forming a urethane resin layer, and mixtures of the polyurethane aqueous dispersion with particles such as silica particles. A specific example of a polyurethane aqueous dispersion is described in Japanese Patent Publication No. 5845895.

[0080] [Uses of multi-layered structures] The multilayer material obtained by the manufacturing method or apparatus of the present invention can be used as a component of a display device such as a liquid crystal display device or an organic electroluminescent display device. In particular, the obliquely stretched multilayer material can be used as a component having a phase difference in the oblique direction, and when used as a phase difference film, it can be usefully used as a phase difference film having a slow phase axis in the desired direction with a high yield. [Explanation of Symbols]

[0081] 10: Multilayer manufacturing equipment 11: Web 11-1: First surface 11-2: Second surface 12: Web with one-sided coating 12-1: First surface 12-2: Second surface 13: Double-sided coated web 21A: Coating solution 22A: Meniscus 22AL:Droplet 23A: Layer of coating solution 41: Web 61: Web 100A: Coating device 100AD: Downstream area 100AU:Upstream area 100AZ: Pressurized area (A) 100B: Coating device 110A: Bar 110AX: Axis 111A: Peripheral surface 11DS: Width direction edge 11OS: Width direction edge 120A: Tank 131A: Levitation conveying device 132A: Levitation conveying device 151DA: Levitation conveying device 151OA: Levitation conveying device 152DA: Levitation conveying device 152OA: Levitation conveying device 191: Free Roll 192: Free Roll 193: Free Roll 194: Suction Roll 195:Curing equipment 410: Bar (A) 431: Free Roll 432: Free Roll 631: Levitation transport device 632: Levitation conveying device LC: Pass Line LDS: Passline LOS: Passline PC: Position in the center in the width direction PDS: Position near the end in the width direction POS: Position near the end in the width direction R9D: Conveying direction R9U: Conveying direction

Claims

1. A method for applying a coating solution to a long web having a first surface and a second surface, A transport process for continuously transporting the web along a transport path, and The coating step (A) includes a coating position (A) in the transport path, in which a bar (A) that rotates around an axis (A) is used to guide the coating liquid (A) to the first surface, and the coating liquid (A) is continuously applied to the first surface. In the coating process (A), the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web. The coating step (A) includes pressing the bar (A) against the first surface and applying pressure to the web from the second surface side to the first surface side in a pressurized region (A) including the coating position (A) of the transport path, The pressurization step (Ap) is a coating method comprising blowing a gas onto the second surface.

2. The coating method according to claim 1, wherein the pressurization step (Ap) is performed by a floating conveying device that has a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface has a porous material surface.

3. The coating method according to claim 1, wherein the pressurizing step (Ap) is performed by pressurizing devices (Ap) provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region (A) are on the same plane.

4. The coating method according to claim 1, wherein the coating step (A) further includes a separation step (As) in which pressure is applied to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A).

5. The coating method according to claim 1, wherein the bar (A) is a gravure roll, and the coating step (A) includes scraping off the coating liquid from the gravure roll with a blade.

6. A method for manufacturing a multilayered material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, A coating step (A) is performed by continuously applying the coating liquid (A) to the first surface of the web using the coating method described in any one of claims 1 to 5, thereby forming a coating film (A), and A curing step (A) to cure the coating film (A) A method for manufacturing a multilayered material, including the method described above.

7. Coating step (B), wherein, at a coating position (B) downstream of the coating position (A) in the transport path, a bar (B) rotating around an axis (B) is used to guide the coating liquid (B) to the second surface, and the coating liquid (B) is continuously applied to the second surface to form a coating film (B), and A curing step (B) to cure the aforementioned coating film (B) It further includes, In the coating process (B), the extension direction of the axis (B) at the coating position (B) is at an angle of 5° to 30° with respect to the width direction of the web. The method for manufacturing a multilayer material according to claim 6, wherein the coating step (B) includes pressing the bar (B) against the second surface and applying pressure to the web from the first surface side to the second surface side in a pressurized region (B) of the transport path that includes the coating position (B).

8. The method for manufacturing a multilayer material according to claim 7, wherein the curing step (A) and the curing step (B) are performed in a curing apparatus provided at a position downstream of the coating position (B) in the transport path.

9. The curing step (A) is performed in a curing device (A) located downstream of the coating position (A) and upstream of the coating position (B) in the transport path. The method for manufacturing a multilayer material according to claim 7, wherein the curing step (B) is performed in a curing device (B) located downstream of the coating position (B) in the transport path.

10. A coating apparatus for applying a coating liquid to a long web having a first surface and a second surface, A conveying device that continuously conveys the aforementioned web along a conveying path, A bar (A) provided at the coating position (A) of the transport path, which rotates about an axis (A), guides the coating liquid (A) to the first surface, and continuously coats the coating liquid (A) to the first surface, wherein the extension direction of the axis (A) is at an angle of 5° to 30° with respect to the width direction of the web, and is provided so as to be in contact with the first surface, and In the pressurized region (A) of the transport path, which includes the coating position (A), a pressurizing device (Ap) is provided that applies pressure to the web from the second surface side toward the first surface side. The pressurizing device (Ap) is a coating device that blows gas onto the second surface.

11. The coating apparatus according to claim 10, wherein the pressurizing device (Ap) is a floating conveying device comprising a conveying curved surface that supports the web in a non-contact manner, and the conveying curved surface is the surface of a porous material.

12. The coating apparatus according to claim 10, wherein the pressurizing device (Ap) is provided at two or more locations including the upstream position of the bar (A) and the downstream position of the bar (A), and the conveying device is provided such that the conveying surface of the web upstream of the pressurizing region (A) and the conveying surface of the web downstream of the pressurizing region (A) are on the same plane.

13. The coating apparatus according to claim 10, further comprising a separation device (As) that applies pressure to the web from the first surface side to the second surface side at a position corresponding to the end of the web in the width direction of the transport path, thereby separating the end of the web in the width direction from the bar (A).

14. The coating apparatus according to claim 10, wherein the bar (A) is a gravure roll, and further comprises a blade capable of scraping the coating liquid off the gravure roll.

15. A multilayer manufacturing apparatus for producing a multilayer material comprising a long web having a first surface and a second surface, and a coated liquid cured layer provided on the first surface, or on both the first surface and the second surface, A coating apparatus according to any one of claims 10 to 14, wherein the coating apparatus (A) continuously applies the coating liquid (A) to the first surface of the web to form a coating film (A), and A curing device (A) is provided downstream of the coating device (A) for curing the coating film (A). A multilayer manufacturing apparatus, including a multilayer material manufacturing apparatus.

16. Located downstream of the coating device (A) in the aforementioned transport path, A coating apparatus (B) that continuously applies a coating liquid (B) to the second surface of the web to form a coating film (B), and A curing device (B) is provided downstream of the coating device (B) for curing the coating film (B). Furthermore, The coating apparatus (B) is A bar (B) provided at a coating position (B) downstream of coating position (A) in the transport path, which rotates around an axis (B) to guide the coating liquid (B) to the second surface and continuously coats the coating liquid (B) to the second surface, wherein the extension direction of the axis (B) is at an angle of 5° to 30° with respect to the width direction of the web, and the bar (B) is provided so as to be in contact with the second surface, and In the pressurized region (B) of the transport path, which includes the coating position (B), a pressurizing device (Bp) is provided that applies pressure to the web from the first surface side to the second surface side. The apparatus for manufacturing multilayer materials according to claim 15.

17. The multilayer manufacturing apparatus according to claim 16, further comprising a curing device that serves as both the curing device (A) and the curing device (B), and is provided at a position downstream of the coating position (B) in the transport path.

18. The curing device (A) is provided as a curing device (A) located downstream of the coating position (A) in the transport path and upstream of the coating position (B), The multilayer manufacturing apparatus according to claim 16, further comprising a curing device (B) provided at a position downstream of the coating position (B) in the transport path.

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