Patent Grant
8522713
1. Field of the Invention
The present invention relates to a curtain coating method and a curtain coating apparatus, specifically a curtain coating method and a curtain coating apparatus in which at least one layer of a coating liquid is ejected from a slit, and the ejected coating liquid is made to fall freely by using a curtain edge guide, which guides the coating liquid in the form of a curtain liquid film, so as to apply the coating liquid onto a continuously running web.
2. Description of the Related Art
Curtain coating methods are coating methods frequently used in producing photosensitive materials and the like, for example photographic films. Among the curtain coating methods, for example, there is a method which includes ejecting a coating liquid from a nozzle slit of a curtain coating head 1, making the ejected coating liquid fall freely by using a curtain edge guide 2, which guides the coating liquid in the form of a curtain liquid film, so as to form a curtain liquid film 3, and bringing the curtain liquid film 3 into contact with a continuously running web 5 so as to form a coating film on the web, as shown in
Parenthetically, in such coating film forming methods, there is a phenomenon caused in which when a coating liquid flows along a curtain edge guide, the coating liquid flows slowly at both edges of the formed curtain liquid film supported by the curtain edge guide, and the coating liquid at the edges of the curtain liquid film flows in a manner that is shifted toward the central side owing to the difference in flow speed between the coating liquid at the edges of the curtain liquid film and the coating liquid on the central side of the curtain liquid film. Thus, when the coating liquid is made to fall freely and the formed curtain liquid film is brought into contact with a continuously running web so as to form a coating film on the web, there is such a drawback that the amount of the coating liquid attached becomes larger at the edges of the coating film with respect to the width direction. Consequently, there are undried portions easily existing when the coating film is dried, which causes blocking when a product is wound, and the edges swell, which causes cutting of the web when the product is wound, thereby lowering production efficiency.
As an attempt to prevent the foregoing, the drying temperature may be increased. However, there is such a problem that, regarding coating on thermosensitive paper, the thermosensitive paper develops color when the temperature of a coating film is high, thereby causing defects in products. Thus, increasing the drying temperature is not helpful in many cases.
To prevent the phenomenon in which the amount of the coating liquid attached becomes larger at the edges of the coating film, there is a well-known method which includes making the coating liquid fall freely while pouring an auxiliary liquid along edge portions at both ends of the curtain edge guide which support the formed curtain liquid film, thereby making the flow speed of the coating liquid at the edges closer to the flow speed of the coating liquid at the center (refer to Japanese Patent Application Laid-Open (JP-A) Nos. 2000-513, 2000-218209, 2001-104856, 2005-512768 and 2008-93656, for example). As shown in
However, when the auxiliary liquid is recovered, a small amount of the coating liquid is also recovered, thereby causing a residue (S) of the liquid to accumulate on a claw 10 and in a suction port 11, as shown in
To prevent swinging and inward deviation of a curtain liquid film in a curtain coating method, JP-A No. 11 -188299 (Troller Schweizer Engineering) discloses a curtain coating method which includes using a porous material for a curtain edge guide, and evenly pouring an auxiliary liquid onto a surface provided in contact with a curtain coating liquid in the curtain edge guide. Meanwhile, JP-A No. 2001-46939 (MITSUBISHI PAPER MILLS LIMITED.) discloses a curtain coating method which includes using a plate of glass for a surface provided in contact with a curtain coating liquid in a curtain edge guide. However, neither of these (JP-A No. 11-188299 and JP-A No. 2001-46939) discloses removal of a residue of the coating liquid and the auxiliary liquid at the bottom of the curtain edge guide.
The present invention is designed in light of the above-mentioned problems in related art, and an object of the present invention is to provide a curtain coating method and a curtain coating apparatus, in which accumulation of a residue of liquid in a suction port and on a claw provided at a bottom of a curtain edge guide can be effectively prevented, and thus inward deviation of a curtain liquid film at the curtain edge guide can be reduced.
To solve the above-mentioned problems, a curtain coating method and a curtain coating apparatus according to the present invention have the following specific technical features denoted by <1> to <60>.
<1> A curtain coating method including: ejecting at least one layer of a coating liquid from a slit; and making the ejected coating liquid fall freely by using a curtain edge guide which guides the coating liquid in the form of a curtain liquid film, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web, wherein when a residue of the liquid is left on a claw provided to support the curtain liquid film at a bottom of the curtain edge guide, the claw is configured to move.
<2> The curtain coating method according to <1>, wherein the claw is configured to move back and forth after the coating liquid is applied onto the web for at least a certain period of time.
<3> The curtain coating method according to <1>, wherein the coating liquid is applied onto the web while continuously moving the claw back and forth.
<4> The curtain coating method according to one of <2> and <3>, wherein the rate at which the claw moves back and forth is in the range of 0.00005 m/sec to 0.005 m/sec.
<5> The curtain coating method according to <1>, wherein the claw is a disc-shaped claw, and the disc-shaped claw is configured to rotate after the coating liquid is applied onto the web for at least a certain period of time.
<6> The curtain coating method according to <1>, wherein the claw is a disc-shaped claw, and the coating liquid is applied onto the web while continuously rotating the disc-shaped claw.
<7> The curtain coating method according to one of <5> and <6>, wherein the radius of the disc-shaped claw is in the range of 10 mm to 50 mm.
<8> The curtain coating method according to any one of <5> to <7>, wherein the rate at which the disc-shaped claw rotates is in the range of 0.0001 m/sec to 0.05 m/sec.
<9> The curtain coating method according to any one of <1> to <8>, wherein the coating liquid is applied onto the web, with the claw having an edge which slopes at an angle.
<10> The curtain coating method according to <9>, wherein the angle is in the range of 0° to 45°.
<11> The curtain coating method according to any one of<1> to <10>, wherein the curtain edge guide is provided with a magnetic material, and part or all of the claw is made of a magnetic material or a material attracted to the magnetic material of the curtain edge guide.
<12> The curtain coating method according to <1>, wherein the claw is in the form of a belt and is configured to move after the coating liquid is applied onto the web for at least a certain period of time.
<13> The curtain coating method according to <1>, wherein the claw is in the form of a belt, and the coating liquid is applied onto the web while continuously moving the claw.
<14> The curtain coating method according to one of <12> and <13>, wherein the rate at which the claw moves is in the range of 0.00005 m/sec to 0.005 m/sec.
<15> The curtain coating method according to anyone of <1> to <14>, wherein the claw has a coating liquid contacting surface formed of a hydrophobic member.
<16> The curtain coating method according to any one of <1> to <15>, wherein a residue of the liquid accumulating on the claw is cleaned off.
<17> The curtain coating method according to <16>, wherein a brush is used to clean off the residue of the liquid.
<18> The curtain coating method according to <16>, wherein a scraper blade is used to clean off the residue of the liquid.
<19> A curtain coating apparatus including: a slit from which at least one layer of a coating liquid is ejected; a curtain edge guide configured to guide the ejected coating liquid in the form of a curtain liquid film and make the coating liquid fall freely, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web; and a claw which supports the curtain liquid film at a bottom of the curtain edge guide, wherein when a residue of the liquid is left on the claw, the claw is configured to move.
<20> The curtain coating apparatus according to <19>, wherein the claw is configured to move back and forth.
<21> The curtain coating apparatus according to <19>, wherein the claw is configured to move back and forth continuously.
<22> The curtain coating apparatus according to one of <20> and <21>, wherein the rate at which the claw moves back and forth is in the range of 0.00005 m/sec to 0.005 m/sec.
<23> The curtain coating apparatus according to <19>, wherein the claw is a disc-shaped claw, and the disc-shaped claw is configured to rotate.
<24> The curtain coating apparatus according to <19>, wherein the claw is a disc-shaped claw, and the disc-shaped claw is configured to rotate continuously.
<25> The curtain coating apparatus according to one of <23> and <24>, wherein the radius of the disc-shaped claw is in the range of 10 mm to 50 mm.
<26> The curtain coating apparatus according to any one of <23> to <25>, wherein the rate at which the disc-shaped claw rotates is in the range of 0.0001 m/sec to 0.05 m/sec.
<27> The curtain coating apparatus according to any one of <19> to <26>, wherein the claw has an edge which slopes at an angle.
<28> The curtain coating apparatus according to <27>, wherein the angle is in the range of 0° to 45°.
<29> The curtain coating apparatus according to any one of <19> to <28>, wherein the curtain edge guide is provided with a magnetic material, and part or all of the claw is made of a magnetic material or a material attracted to the magnetic material of the curtain edge guide.
<30> The curtain coating apparatus according to <19>, wherein the claw is in the form of a belt and is configured to move.
<31> The curtain coating apparatus according to <19>, wherein the claw is in the form of a belt and is configured to move continuously.
<32> The curtain coating apparatus according to one of <30> and <31>, wherein the rate at which the claw moves is in the range of 0.00005 m/sec to 0.005 m/sec.
<33> The curtain coating apparatus according to any one of <19> to <32>, wherein the claw has a coating liquid contacting surface formed of a hydrophobic member.
<34> The curtain coating apparatus according to any one of <19> to <33>, further including a unit configured to clean off a residue of the liquid accumulating on the claw.
<35> The curtain coating apparatus according to <34>, wherein the unit is a brush.
<36> The curtain coating apparatus according to <34>, wherein the unit is a scraper blade.
<37> A curtain coating method including: ejecting at least one layer of a coating liquid from a slit; and making the ejected coating liquid fall freely by using a curtain edge guide which guides the coating liquid in the form of a curtain liquid film, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web, wherein an additional auxiliary liquid is poured onto a curtain liquid film contacting surface of a claw provided to support the curtain liquid film at a bottom of the curtain edge guide.
<38> The curtain coating method according to <37>, wherein the coating liquid is applied onto the web, with the claw having an edge which slopes at an angle.
<39> The curtain coating method according to <38>, wherein the angle is in the range of 0° to 45°.
<40> The curtain coating method according to any one of <37> to <39>, wherein the edge of the claw has a thickness of 0.4 mm or less.
<41> The curtain coating method according to any one of <37> to <40>, wherein the additional auxiliary liquid is supplied to the curtain liquid film contacting surface of the claw, using a pouring pipe, and the additional auxiliary liquid is brought into contact with the curtain liquid film contacting surface so as to flow on the curtain liquid film contacting surface.
<42> The curtain coating method according to any one of <37> to <41>, wherein the additional auxiliary liquid is supplied to the claw, using a/the pouring pipe, and the additional auxiliary liquid is poured from an edge of the claw.
<43> The curtain coating method according to any one of <37> to <42>, wherein the additional auxiliary liquid is supplied to the claw, using a/the pouring pipe, and the additional auxiliary liquid is made to stream out of the curtain liquid film contacting surface of the claw so as to flow on the curtain liquid film contacting surface.
<44> The curtain coating method according to any one of <37> to <43>, wherein the curtain liquid film contacting surface of the claw is formed of a superhydrophilic film which contains a superhydrophilic material.
<45> The curtain coating method according to <44>, wherein the superhydrophilic film contains a photocatalyst.
<46> The curtain coating method according to <45>, wherein the claw is irradiated with light so as to sustain an excited state of the photocatalyst contained in the superhydrophilic film.
<47> The curtain coating method according to <46>, wherein the claw is made of an ultraviolet-transmitting member, light is applied from the surface of the claw where the superhydrophilic film is not formed, and the excited state of the photocatalyst is thus sustained.
<48> The curtain coating method according to any one of <44> to <47>, wherein when a residue of the liquid is left on the claw, the claw is configured to move.
<49> A curtain coating apparatus including: a slit from which at least one layer of a coating liquid is ejected; a curtain edge guide configured to guide the ejected coating liquid in the form of a curtain liquid film and make the coating liquid fall freely, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web; a claw configured to support the curtain liquid film at a bottom of the curtain edge guide; and a unit configured to pour an additional auxiliary liquid onto a curtain liquid film contacting surface of the claw.
<50> The curtain coating apparatus according to <49>, wherein the claw has an edge which slopes at an angle.
<51> The curtain coating apparatus according to <50>, wherein the angle is in the range of 0° to 45°.
<52> The curtain coating apparatus according to any one of <49> to <51>, wherein the edge of the claw has a thickness of 0.4 mm or less.
<53> The curtain coating apparatus according to any one of <49> to <52>, further including a pouring pipe for supplying the additional auxiliary liquid to the curtain liquid film contacting surface of the claw, and a unit configured to bring the additional auxiliary liquid into contact with the curtain liquid film contacting surface of the claw such that the additional auxiliary liquid flows on the curtain liquid film contacting surface.
<54> The curtain coating apparatus according to any one of <49> to <53>, (further) including a/the pouring pipe for supplying the additional auxiliary liquid to the claw, and a unit configured to pour the additional auxiliary liquid from an edge of the claw.
<55> The curtain coating apparatus according to any one of <49> to <54>, (further) including a/the pouring pipe for supplying the additional auxiliary liquid to the claw, and a unit configured to get the additional auxiliary liquid to stream out of the curtain liquid film contacting surface of the claw so as to flow on the curtain liquid film contacting surface.
<56> The curtain coating apparatus according to any one of <49> to <55>, wherein the curtain liquid film contacting surface of the claw is formed of a superhydrophilic film which contains a superhydrophilic material.
<57> The curtain coating apparatus according to <56>, wherein the superhydrophilic film contains a photocatalyst.
<58> The curtain coating apparatus according to <57>, further including a light irradiation device configured to irradiate the superhydrophilic film of the claw with light.
<59> The curtain coating apparatus according to <58>, wherein the claw is made of an ultraviolet-transmitting member, and the light is applied by the light irradiation device from the surface of the claw where the superhydrophilic film is not formed.
<60> The curtain coating apparatus according to any one of <55> to <59>, wherein when a residue of the liquid is left on the claw, the claw is configured to move.
According to the present invention, it is possible to provide a curtain coating method and a curtain coating apparatus, in which accumulation of a residue of liquid on a claw provided at a bottom of a curtain edge guide can be effectively prevented, and thus inward deviation of a curtain liquid film at the curtain edge guide can be is reduced.
The present invention provides a curtain coating apparatus and a curtain coating method, in which when a residue of liquid is left on a claw provided to support a curtain liquid film at a bottom of a curtain edge guide, the residue is removed.
Broadly, as units (methods) for removing the residue, the following will be explained: a unit (and a method) for moving the claw when a residue of liquid is left on the claw; and a unit (and a method) for pouring an auxiliary liquid onto a curtain liquid film contacting surface of the claw. It should be noted that the curtain coating apparatus (and the curtain coating method) of the present invention may employ both of these units (methods).
The present invention includes (A) and (B) below.
(A) A curtain coating method including: ejecting at least one layer of a coating liquid from a slit; and making the ejected coating liquid fall freely by using a curtain edge guide which guides the coating liquid in the form of a curtain liquid film, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web, wherein when a residue of the liquid is left on a claw provided to support the curtain liquid film at a bottom of the curtain edge guide, the claw is configured to move.
(B) A curtain coating apparatus including: a slit from which at least one layer of a coating liquid is ejected; a curtain edge guide configured to guide the ejected coating liquid in the form of a curtain liquid film and make the coating liquid fall freely, while pouring an auxiliary liquid from the whole of a surface provided in contact with the coating liquid in the curtain edge guide, so as to apply the coating liquid onto a continuously running web; and a claw which supports the curtain liquid film at a bottom of the curtain edge guide, wherein when a residue of the liquid is left on the claw, the claw is configured to move.
Specifically, the present invention provides a curtain coating method and a curtain coating apparatus, wherein when a residue of liquid is left on a claw provided to support a curtain liquid film at a bottom of a curtain edge guide, the claw is moved so as to remove the residue from a curtain liquid film contacting surface of the claw and the vicinity thereof, and thus inward deviation of the curtain liquid film at the curtain edge guide, caused by accumulation of the residue on the curtain liquid film contacting surface and in a suction port, can be reduced; and wherein by cleaning off the residue remaining on the claw, which has been removed from the curtain liquid film contacting surface, it is always possible to prevent inward deviation of the curtain liquid film.
As described above, regarding the curtain coating method and the curtain coating apparatus of the present invention, in order to stabilize a curtain liquid film, a coating liquid is applied onto a continuously running web while pouring an auxiliary liquid from the surface provided in contact with the curtain liquid film in the curtain edge guide. The auxiliary liquid is not particularly limited as long as it is in liquid form and has fluidity. In the case where the coating liquid is an aqueous liquid, preferred examples of the auxiliary liquid include water, and solutions prepared by mixing water with resins or by mixing water with surfactants, etc. In the case where the coating liquid is a solvent-like liquid, preferred examples of the auxiliary liquid include the solvent contained in the coating liquid, and solutions prepared by mixing the solvent with resins or by mixing the solvent with surfactants, etc.
The shape of the claw may be arbitrarily decided as long as the claw can support the curtain liquid film at the bottom of the curtain edge guide and receive the auxiliary liquid which has flowed down. Generally though, the claw is in the form of a flat surface. The material for the claw may be arbitrarily selected unless it is corroded by the coating liquid and the auxiliary liquid. Generally though, the material is selected from stainless steel, brass, aluminum, iron, glass, PET and so forth.
The following explains the present invention (a curtain coating method and a curtain coating apparatus) in further detail, referring to the drawings.
Since the embodiments described below are embodiments suitable for the present invention, they are subject to various limitations which are technically preferred. It should be noted that the scope of the present invention is not confined to these embodiments unless otherwise stated.
(First Embodiment)
A first embodiment of the present invention is an embodiment in which curtain coating is performed using a claw in the form of a flat plate.
In this curtain coating method, as shown in
The rate at which the claw 101 moves back and forth is in the range of 0.00005 m/sec to 0.005 m/sec. If the rate is less than 0.00005 m/sec, a residue of the liquid accumulates on the curtain liquid film contacting surface of the claw, and thus the curtain liquid film deviates inward. If the rate is greater than 0.005 m/sec, the curtain liquid film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
(Second Embodiment)
A second embodiment of the present invention is an embodiment in which curtain coating is performed using a claw in the shape of a disc.
It is desirable that the claw 102 at the bottom of the curtain edge guide 2 be rotated a certain period of time after application of the coating liquid, or that the claw 102 be continuously rotated from the beginning of the application of the coating liquid or a certain period of time after the application of the coating liquid, thereby preventing a residue of the liquid from accumulating on a curtain liquid film contacting surface of the claw. Especially when the coating liquid is applied while continuously rotating the claw 102, it is possible to further reduce inward deviation of a curtain liquid film at the curtain edge guide 2. Accordingly, the curtain coating apparatus is provided with a function of rotating the claw (which includes continuously rotating the claw). Also, the residue is removed by suction using a residue-sucking vacuum unit (not shown) or the like.
It is appropriate that the radius of the disc-shaped claw 102 be in the range of 10 mm to 50 mm. If the radius is less than 10 mm, the curvature of a portion of the claw to support the curtain liquid film is so great that the curtain liquid film swings when applied, and thus the coating width becomes unstable. If the radius is greater than 50 mm, the apparatus cannot be made compact.
Also, the rotational rate of the claw 102 as a circumferential speed is in the range of 0.0001 m/sec to 0.05 m/sec. If the rotational rate as a circumferential speed is less than 0.0001 m/sec, a residue of the liquid accumulates on the curtain liquid film contacting surface of the claw, and thus the curtain liquid film deviates inward. If the rotational rate as a circumferential speed is greater than 0.05 m/sec, the curtain liquid film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
(Third Embodiment)
A third embodiment of the present invention is an embodiment in which curtain coating is performed using a claw in the form of a belt.
In this embodiment, the belt-like claw 103 is moved at least a certain period of time after application of a coating liquid so as to remove a residue of the liquid from a curtain liquid film contacting surface of the claw, and thus inward deviation of a curtain liquid film at the curtain edge guide 2, caused by accumulation of the residue on the curtain liquid film contacting surface, can be reduced. Also, it is possible to further reduce inward deviation of the curtain liquid film at the curtain edge guide 2 by applying the coating liquid while continuously moving the belt-like claw 103 at the bottom of the curtain edge guide 2, and thus always preventing a residue of the liquid from accumulating on the curtain liquid film contacting surface. Also, the residue is removed by suction using a residue-sucking vacuum unit (not shown) or the like. Accordingly, the curtain coating apparatus is provided with a function of moving the claw in the form of a belt (which includes continuously moving the claw).
The rate at which the belt-like claw 103 moves is in the range of 0.00005 m/sec to 0.005 m/sec. If the rate is less than 0.00005 m/sec, a residue of the liquid accumulates on the curtain liquid film contacting surface of the claw, and thus the curtain liquid film deviates inward. If the rate is greater than 0.005 m/sec, the curtain liquid film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
(Fourth Embodiment)
A fourth embodiment of the present invention is an embodiment in which curtain coating is performed using the claw (claw configured to move back and forth) 101 having an edge that slopes at an angle θ, and the disc-shaped claw 102 having an edge (peripheral portion) that slopes at an angle θ.
When the claws 101 and 102 have edges sloping at an angle θ as described above, it becomes easier for curtain liquid films to be in contact with the respective claws when applied onto webs, which enables the claws to support edges of the curtain liquid films to a greater extent (there is an increase in contact area between the claws and the curtain liquid films), and thus it becomes possible to further reduce inward deviation of the curtain liquid films, caused by residues of liquid left on the curtain liquid film contacting surfaces of the claws.
The angle θ is preferably in the range of 0° to 45°, more preferably in the range of 10° to 35°. When the angle θ is less than 0°, the edges of the curtain liquid films cannot be sufficiently supported by the respective claws, and thus the curtain liquid films deviate inward upon deposition of even small amounts of residues on the curtain liquid film contacting surfaces of the claws. When the angle θ is greater than 45°, coating liquids easily move to the backs of the respective claws 101 and 102 and the amounts of the coating liquids attached become larger at edges of coating films with respect to the coating width direction; thus, there are undried portions easily existing due to insufficient drying at the time of production, the coating liquids are possibly attached to conveyance rolls of the webs during the production, later smearing the coating film surfaces of the webs, blocking possibly arises when products are wound, and the webs are possibly cut because of the swollen edges when the products are wound.
(Fifth Embodiment)
A fifth embodiment of the present invention is an embodiment in which curtain coating is performed using the curtain edge guide 2 provided with a magnetic material 15; the claw (claw configured to move back and forth) 101, part or all of which is made of a magnetic material or a material attracted to the magnetic material 15 of the curtain edge guide 2; and the disc-shaped claw 102, part or all of which is made of a magnetic material or a material attracted to the magnetic material 15 of the curtain edge guide 2.
Thus, as shown in
Preferred examples of the magnetic material include magnetite, KS steel, MK steel, ferrite magnets, samarium-cobalt magnets, alnico magnets, neodymium magnets, samarium-iron-nitrogen magnets, platinum magnets, praseodymium magnets, plastic magnets, manganese-aluminum magnets, iron-chromium-cobalt magnets, bond magnets and molecular magnets. Preferred examples of the material attracted to the magnetic material 15 include iron and stainless steel.
(Sixth Embodiment)
A sixth embodiment of the present invention is an embodiment in which curtain coating is performed using a hydrophobic member to form a coating liquid (curtain liquid film) contacting surface of a claw.
The use of the hydrophobic member to form the coating liquid (curtain liquid film) contacting surface of the claw makes it possible for the claw to repel water contained in a coating liquid and in an auxiliary liquid, and thus it is possible to reduce accumulation of a residue of the liquid on the curtain liquid film contacting surface of the claw and prevent inward deviation of a curtain liquid film. Examples of the hydrophobic member include resins such as Teflon (registered trademark), and silicon resins.
(Seventh Embodiment)
A seventh embodiment of the present invention is an embodiment in which curtain coating is performed after or while cleaning off a residue of liquid accumulating on a claw.
A brush, a scraper blade or the like is used to clean off the residue. Also, a residue-sucking vacuum unit configured to suck in the residue is provided in the vicinity of the brush, the scraper blade or the like.
Meanwhile,
(Eighth Embodiment)
A curtain coating method and a curtain coating apparatus of an eighth embodiment of the present invention are exemplarily represented by
The auxiliary liquid poured onto the surface provided in contact with the coating liquid in the curtain edge guide (hereinafter referred to as “curtain edge guide auxiliary liquid”) and the additional auxiliary liquid poured onto the claw's surface which is in contact with the coating liquid (hereinafter referred to as “claw liquid-contacting surface auxiliary liquid”) may be the same or different.
The additional auxiliary liquid is not particularly limited as long as it is in liquid form and has fluidity. In the case where the coating liquid is an aqueous liquid, examples of the additional auxiliary liquid include water, and solutions prepared by mixing water with resins or by mixing water with surfactants, etc. In the case where the coating liquid is a solvent-like liquid, examples of the auxiliary liquid include the solvent contained in the coating liquid, and solutions prepared by mixing the solvent with resins or by mixing the solvent with surfactants, etc. It should be noted that in the case where a solution containing a resin is used, the resin itself contained in the claw liquid-contacting surface auxiliary liquid may possibly be left as a residue, so that the claw liquid-contacting surface auxiliary liquid is preferably different from the curtain edge guide auxiliary liquid. Accordingly, in the case where the coating liquid is an aqueous liquid, the claw liquid-contacting surface auxiliary liquid is preferably water, or a solution prepared by mixing water with a surfactant, etc. In the case the coating liquid is a solvent-like liquid, the claw liquid-contacting surface auxiliary liquid is preferably the solvent contained in the coating liquid, or a solution prepared by mixing the solvent with a surfactant, etc.
Specific examples of the auxiliary liquid include water; alcohols such as methanol, ethanol, isopropanol, n-butanol and methylisocarbinol; ketones such as acetone, 2-butanone, ethyl amyl ketone, diacetone alcohol, isophorone and cyclohexanone; amides such as N,N-dimethylformamide and N,N-dimethylacetoamide; ethers such as diethyl ether, isopropyl ether, tetrahydrofuran, 1,4-dioxane and 3,4-dihydro-2H-pyran; glycol ethers such as 2-methoxyethanol, 2-ethoxyethanol, 2-butoxyethanol and ethyleneglycol dimethylether; glycol ether acetates such as 2-methoxyethyl acetate, 2-ethoxyethyl acetate and 2-butoxyethyl acetate; esters such as methyl acetate, ethyl acetate, isobutyl acetate, amyl acetate, ethyl lactate and ethylene carbonate; aromatic hydrocarbons such as benzene, toluene and xylene; aliphatic hydrocarbons such as hexane, heptane, iso-octane and cyclohexane; halogenated hydrocarbons such as methylene chloride, 1,2-dichlorethane, dichloropropane and chlorbenzene; sulfoxides such as dimethylsulfoxide; and pyrrolidones such as N-methyl-2-pyrrolidone and N-octyl-2-pyrrolidone.
The material for the claw 21 is not particularly limited unless it is corroded by the coating liquid and the auxiliary liquid, and the material may be arbitrarily selected. Examples thereof include stainless steel, brass, aluminum, iron, glass and PET.
Regarding the shape of the claw 21, as shown in
The angle 25 at which the edge of the claw 21 slopes is preferably in the range of 0° to 45°. When the angle 25 is smaller than 0°, it is impossible to form a film of the auxiliary liquid between a member of the claw and the coating liquid to be sucked, and the edge of the curtain liquid film cannot be sufficiently supported by the claw, thus causing the curtain liquid film to deviate inward upon deposition of even a small amount of a residue of the liquid. When the angle 25 is larger than 45°, the coating liquid easily moves to the back of the claw, so that the amount of the coating liquid attached becomes larger at edges of a coating film with respect to the coating width direction, and the coating film may not be sufficiently dried at the time of production. Owing to the existence of undried portions, the coating liquid is possibly attached to a conveyance roll of a web, later smearing the coating film surface of the web, blocking possibly arises when a product is wound, and the web is possibly cut because of the swollen edges when the product is wound.
The thickness 26 of the edge of the claw 21 is preferably 0.4 mm or less. When the thickness 26 is greater than 0.4 mm, it is impossible to form a film of the auxiliary liquid between the member of the claw and the coating liquid, and thus a residue of the liquid is attached to the liquid contacting surface at the edge of the claw, causing inward deviation of the curtain liquid film.
Examples of units and methods for supplying the auxiliary liquid to the claw and pouring it onto the surface of the claw are as follows.
(1) A unit and a method for pouring the auxiliary liquid from the edge onto the surface of the claw 21 by the use of pouring pipes 27, as shown in
Use of any of these units and methods makes it possible for the auxiliary liquid (claw liquid-contacting surface auxiliary liquid 202) to is flow on the claw's surface which is in contact with the coating liquid, and thus makes it possible to reduce formation of a residue of the liquid.
(Ninth Embodiment)
A ninth embodiment of the present invention is an embodiment in which the claw 21, placed at the bottom of the curtain edge guide 2, has as its surface a superhydrophilic film 28 that exhibits superhydrophilicity, as shown in
By providing the superhydrophilic film on the surface of the claw, i.e. the claw's surface which is in contact with a coating liquid, a liquid film is formed over the surface of the coating liquid to be sucked together with an auxiliary liquid, and this liquid film makes it possible to reduce formation of a residue of the liquid.
Examples of methods for forming the superhydrophilic film include a method of coating the claw surface with a composition which contains a superhydrophilic material, and a method of affixing to the claw surface a film or sheet which contains a superhydrophilic material.
Examples of the superhydrophilic material include photocatalysts. A photocatalyst is a material wherein when the material absorbs light having energy that exceeds the band gap energy, which is the energy difference between energy bands of a crystal of the material, i.e. between the upper limit of its valence band and the lower limit of its conduction band, photoexcitation occurs in which electrons in the valence band are excited into the conduction band, and these electrons and electron holes left due to the lack of electrons in the valence band induce photocatalytic reaction. Examples of the photocatalysts include titanium oxide, zinc oxide, tin oxide, ferric oxide and dibismuth trioxide. Among these, preference is given to titanium oxide because it improves in hydrophilicity with light absorption and is therefore superior in wettability.
(Tenth Embodiment)
A tenth embodiment of the present invention is an embodiment in which a light irradiation device 29 is provided so as to irradiate the surface of the claw 21 with excitation light, as shown in
By continuously irradiating the surface of the claw 21 with excitation light from the light irradiation device 29, it is possible to sustain an excited state of a photocatalyst provided for the surface of the claw 21 and thus to reduce formation of a residue of liquid.
The excitation light is not particularly limited as long as it can excite the photocatalyst. For example, it is preferable to use an ultraviolet ray therefor. Examples of the light irradiation device configured to apply an ultraviolet ray include light irradiation units incorporating light sources such as germicidal lamps, black lights, xenon lamps, metal halide lamps and mercury vapor lamps. Irradiation with the excitation light makes it easily possible to sustain the excited state of the photocatalyst.
(Eleventh Embodiment)
An eleventh embodiment of the present invention is an embodiment in which an ultraviolet-transmitting member 31 is used to constitute the claw 21 placed at the bottom of the curtain edge guide 2, and the claw has the superhydrophilic film 28 as its surface, as shown in
The use of the ultraviolet-transmitting member to constitute the claw makes it possible to continuously irradiate the superhydrophilic film, which contains a photocatalyst, with an ultraviolet ray from the back of the coating liquid contacting surface of the claw, and thus to sustain an excited state of the photocatalyst and thereby reduce formation of a residue of liquid even in long-time continuous coating.
Examples of the ultraviolet-transmitting member include glass, acrylic resins and polyethylene films.
(Twelfth Embodiment)
A twelfth embodiment of the present invention is an embodiment in which the claw 21 placed at the bottom of the curtain edge guide 2 is in the shape of a disc and can rotate, the claw 21 has a photocatalyst-containing superhydrophilic film as its surface, and the light irradiation device 29 is provided, as shown in
By applying an ultraviolet ray to the photocatalyst-containing surface of the disc-shaped claw 21 other than the coating liquid contacting surface thereof while the claw 21 is being continuously rotated, it is possible to sustain an excited state of the photocatalyst-containing surface and thereby reduce formation of a residue of liquid even in long-time continuous coating.
The radius of the disc-shaped claw 21 is preferably in the range of 10 mm to 50 mm. If the radius is less than 10 mm, the curvature of a portion of the claw to support a curtain liquid film is great, causing the curtain liquid film to swing when applied, and thus the coating width becomes unstable. If the radius is greater than 50 mm, the apparatus cannot be made compact.
The rotational rate of the claw 21 as a circumferential speed is preferably greater than 0 m/sec and less than or equal to 0.05 m/sec. If the rotational rate as a circumferential speed is 0 m/sec, the coating liquid contacting surface of the claw cannot be sufficiently irradiated with the ultraviolet ray, thereby shortening the length of time for which continuous coating is possible. If the rotational rate as a circumferential speed is greater than 0.05 m/sec, the curtain liquid is film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
(Thirteenth Embodiment)
A thirteenth embodiment of the present invention is an embodiment in which the claw 21 placed at the bottom of the curtain edge guide 2 can move back and forth, the claw 21 has a photocatalyst-containing superhydrophilic film as its surface, and the light irradiation device 29 is provided, as shown in
By applying an ultraviolet ray to the photocatalyst-containing surface of the claw 21 other than the coating liquid contacting surface thereof while the claw 21 is being continuously moved back and forth, it is possible to sustain an excited state of the photocatalyst-containing surface and thereby reduce formation of a residue of liquid even in long-time continuous coating.
The rate at which the claw 21 moves back and forth is preferably greater than 0 m/sec and less than or equal to 0.005 m/sec. If the rate is 0 m/sec, the coating liquid contacting surface of the claw cannot be sufficiently irradiated with the ultraviolet ray, thereby shortening the length of time for which continuous coating is possible. If the rate is greater than 0.005 m/sec, a curtain liquid film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
(Fourteenth Embodiment)
A fourteenth embodiment of the present invention is an embodiment in which the claw 21 placed at the bottom of a curtain edge guide 2 is in the form of a belt and can continuously move, the claw 21 has a photocatalyst-containing superhydrophilic film as its surface, and the light irradiation device 29 is provided, as shown in
By applying an ultraviolet ray to the photocatalyst-containing surface of the belt-like claw 21 other than the coating liquid contacting surface thereof while the claw 21 is being continuously moved, it is possible to sustain an excited state of the photocatalyst-containing surface and thereby reduce formation of a residue of liquid even in long-time continuous coating.
The rate at which the claw 21 moves is preferably greater than 0 m/sec and less than or equal to 0.005 m/sec. If the rate is 0 m/sec, the coating liquid contacting surface of the claw cannot be sufficiently irradiated with the ultraviolet ray, thereby shortening the length of time for which continuous coating is possible. If the rate is greater than 0.005 m/sec, a curtain liquid film cannot be supported by an edge of the claw, and thus the curtain liquid film deviates inward.
The following explains the present invention in further detail, referring to Examples and Comparative Examples. It should, however, be noted that the present invention is not confined to these Examples and Comparative Examples. The term “part(s)” used below means part(s) by mass.
Regarding these Examples, Examples 1, 2 and 19 pertain to the above-mentioned second embodiment of the present invention, Example 3 pertains to the above-mentioned third embodiment of the present invention, Example 4 pertains to the above-mentioned third embodiment of the present invention, Examples 5 to 12 pertain to the above-mentioned fourth embodiment of the present invention, Examples 13 and 14 pertain to the above-mentioned fifth embodiment of the present invention, Examples 15 to 17 pertain to the above-mentioned sixth embodiment of the present invention, Examples 18 and 20 to 26 pertain to the above-mentioned seventh embodiment of the present invention, Examples 27 to 33 pertain to the above-mentioned eighth embodiment of the present invention, Example 34 pertains to the above-mentioned ninth embodiment of the present invention, Examples 35 pertains to the above-mentioned tenth embodiment of the present invention, Examples 36 and 37 pertain to is the above-mentioned eleventh embodiment of the present invention, Examples 38 and 39 pertain to the above-mentioned twelfth embodiment of the present invention, Examples 40 and 41 pertain to the above-mentioned thirteenth embodiment of the present invention, and Examples 42 and 43 pertain to the above-mentioned fourteenth embodiment of the present invention.
At a bottom of a curtain edge guide of the slide curtain coating apparatus shown in
(Thermosensitive recording layer coating liquid: 150 mPa·s in viscosity, 38 mN/m in static surface tension)
The static surface tension was measured using the Automatic Surface Tensiometer CBVP-A3 (manufactured by Kyowa Interface Science Co., Ltd.).
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the radius of the disc-shaped claw 102 was changed from 20 mm to 5 mm. The results are shown in Table 1-A.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that a peripheral portion of the disc-shaped claw 102 sloped at an angle of 30° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the peripheral portion of the disc-shaped claw 102 sloped at an angle of 45° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the peripheral portion of the disc-shaped claw 102 sloped at an angle of 50° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the peripheral portion of the disc-shaped claw 102 sloped at an angle of 5° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 3, except that one edge of the claw 101 in the form of a flat plate sloped at an angle of 30° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 3, except that the one edge of the claw 101 in the form of a flat plate sloped at an angle of 45° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 3, except that the one edge of the claw 101 in the form of a flat plate sloped at an angle of 50° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 3, except that the one edge of the claw 101 in the form of a flat plate sloped at an angle of 5° as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that a sheet of Teflon (registered trademark) having a thickness of 100 μm was affixed onto the coating liquid (curtain liquid film) contacting surface of the disc-shaped claw 102. The results are shown in Table 1-A.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 3, except that a sheet of Teflon (registered trademark) having a thickness of 100 μm was affixed onto the coating liquid (curtain liquid film) contacting surface of the claw 101 which was in the form of a flat plate. The results are shown in Table 1-B.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 4, except that a sheet of Teflon (registered trademark) having a thickness of 100 μm was affixed onto the coating liquid (curtain liquid film) contacting surface of the belt-like claw 103. The results are shown in Table 1-B.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 1, except that the slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 18, except that the circumferential speed of the disc-shaped claw 102 was changed to 0.1 m/sec. The results are shown in Table 1-B.
The slide curtain coating apparatus shown in
The slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 21, except that the claw 101 was configured to move back and forth in a controlled manner at a rate of 0.01 m/sec. The results are shown in Table 1-B.
The slide curtain coating apparatus shown in
The slide curtain coating apparatus shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 24, except that the rate at which the claw 103 moved was changed to 0.01 m/sec. The results are shown in Table 1-B.
The slide curtain coating apparatus shown in
As shown in
Coating was carried out in the same manner as in Example 1, except that the claw was not configured to rotate. The results are shown in Table 1-B.
Coating was carried out in the same manner as in Example 3, except that the claw was not configured to move back and forth. The results are shown in Table 1-B.
Coating was carried out in the same manner as in Example 4, except that the claw was not configured to move. The results are shown in Table 1-B.
An apparatus was used that included the slide curtain coating apparatus shown in
A thermosensitive recording layer coating liquid prepared according to the following formulation was applied onto a web (paper) at a coating speed of 400 m/min, with a coating width of 250 mm and at a flow rate of coating liquid (ejected from a nozzle slit) of 3,000 g/min.
At that time, the volume of the auxiliary liquid (water) on the liquid contacting surface of the claw (the volume of the claw liquid-contacting surface auxiliary liquid 202) was 120 cc/min (60 cc/min each), the volume of an auxiliary liquid (water) flowing along the curtain edge guide (the volume of a curtain edge guide auxiliary liquid 201) was 30 cc/min, and the suction pressure of a vacuum unit for recovering the auxiliary liquid was −20 kpa. Also, the claw was made to protrude from a curtain liquid film contacting surface of a porous member by 2 mm. Further, the thickness of the edge of the claw, denoted by the numeral 26 in
(Thermosensitive recording layer coating liquid: 150 mPa·s in viscosity, 38 mN/m in static surface tension)
The static surface tension was measured using the Automatic Surface Tensiometer CBVP-A3 (manufactured by Kyowa Interface Science Co., Ltd.).
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the angle at which the edge of the claw 21 sloped was changed to 0°. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the angle at which the edge of the claw 21 sloped was changed to 45°. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the angle at which the edge of the claw 21 sloped was changed to 50°. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the angle at which the edge of the claw 21 sloped was changed to −5°. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the thickness of the edge of the claw 21 was changed to 0.4 mm. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the thickness of the edge of the claw 21 was changed to 0.5 mm. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the auxiliary liquid (water) was poured such that the volume of the auxiliary liquid (water) on the liquid contacting surface of the claw 21 (the volume of the claw liquid-contacting surface auxiliary liquid 202) was 100 cc/min, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that a claw surface 24 was formed of stainless steel mesh, and the auxiliary liquid (water) was poured such that the volume of the auxiliary liquid (water) streaming onto the liquid contacting surface of the claw 21 (the volume of the claw liquid-contacting surface auxiliary liquid 202) was 100 cc/min, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the claw surface 24 was formed of a porous member, and the auxiliary liquid (water) was poured such that the volume of the auxiliary liquid (water) streaming onto the liquid contacting surface of the claw 21 (the volume of the claw liquid-contacting surface auxiliary liquid 202) was 100 cc/min, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that a photocatalyst sheet (HYDROTECTFILM, produced by TOTO LTD.) was affixed as a superhydrophilic film 28 to the surface (coating liquid contacting surface) of the claw 21, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 34, except that the surface (coating liquid contacting surface) of the claw 21 was irradiated with an ultraviolet ray using a black light as a light irradiation device 29, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the claw 21, formed by affixing a photocatalyst sheet (HYDROTECTFILM, produced by TOTO LTD.) as a superhydrophilic film 28 to a surface of a PET film (0.2 mm in thickness) as an ultraviolet-transmitting member 31, was irradiated with an ultraviolet ray from the surface opposite to the coating liquid contacting surface, using an ultraviolet lamp (TBB-30, manufactured by HYBEC CORPORARION) having a tube diameter of 3 mm and a length of 30 mm and serving as a light irradiation device 29, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 36, except that the claw was not irradiated with an ultraviolet ray. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the claw 21 was a disc-shaped claw (which was made of stainless steel and was 20 mm in radius and 0.18 mm in thickness), a photocatalyst sheet (HYDROTECTFILM, produced by TOTO LTD.) was affixed as a superhydrophilic film 28 to the coating liquid contacting surface of the claw 21, the claw 21 was rotated at a circumferential speed of 0.0001 m/sec by a drive motor, and the surface of the claw 21 was irradiated with an ultraviolet ray using a black light as a light irradiation device 29, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 38, except that the disc-shaped claw 21 was not rotated. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 38, except that the circumferential speed of the claw 21 was changed to 0.1 m/sec. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the length of the claw 21 with respect to its moving direction was changed to 1,000 mm, the width of the claw 21 was changed to 30 mm, a photocatalyst sheet (HYDROTECTFILM, produced by TOTO LTD.) was affixed as a superhydrophilic film 28 to the coating liquid contacting surface of the claw, the claw with the superhydrophilic film was sandwiched between driving rubber rolls 32 and configured to move back and forth in a controlled manner at a rate of 0.00005 m/sec by a motor, and the superhydrophilic film 28 was irradiated with an ultraviolet ray using a black light as a light irradiation device 29, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 40, except that the claw 21 was not configured to move back and forth. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 40, except that the rate at which the claw 21 moved back and forth was changed to 0.01 m/sec. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that the claw 21 was made of stainless steel and was in the form of a belt (which was 800 mm in length with respect to its moving direction, 30 mm in width and 0.01 mm in thickness), a photocatalyst sheet (HYDROTECTFILM, produced by TOTO LTD.) was affixed as a superhydrophilic film 28 to the coating liquid contacting surface of the claw, the claw with the superhydrophilic film was supported by driving rubber rolls 32 and configured to move at a rate of 0.00005 m/sec by the use of a drive motor, and the superhydrophilic film 28 was irradiated with an ultraviolet ray using a black light as a light irradiation device 29, as shown in
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 42, except that the claw 21 was not moved. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 42, except that the rate at which the claw 21 moved was changed to 0.01 m/sec. The results are shown in Table 2.
The thermosensitive recording layer coating liquid was applied onto a web in the same manner as in Example 27, except that an auxiliary liquid was not poured onto the coating liquid contacting is surface of the claw 21. The results are shown in Table 2.
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