This application claims priority from Japanese Patent Application No. 2018-042863 filed on Mar. 9, 2018. The entire contents of the priority application are incorporated herein by reference.
The technology described herein relates to a method of producing a printed substrate.
A conventional method of producing a printed substrate is known and according to one example of such a printing method, a meshed synthetic resin sheet is subjected to printing continuously while being transferred in a longitudinal direction thereof. Specifically, this is a method of carrying out printing on a meshed synthetic resin sheet. According to the method, a long sized coarse fabric synthetic resin sheet is formed by uniting with combining warp and weft of one by drawing a synthetic resin film and tearing the same with very narrow width and printing is performed on the obtained mesh-like synthetic resin sheet continuously while being transported. The printing is performed by a flexographic printing and cell volume of an anilox roll supplying a printing ink to a plate cylinder is set so that the printing ink does not leak through a mesh of the mesh-like synthetic resin sheet that is between the plate cylinder and an impression cylinder and does not adhere to the impression cylinder. An example of such a printing method is disclosed in Japanese Unexamined Patent Application Publication No. 2017-61041.
According to the above printing method described in Japanese Unexamined Patent Application Publication No. 2017-61041, the cell volume of the anilox roll, which supplies print ink to the plate cylinder, is determined properly to suppress excessive supply of print ink. However, merely adjusting the cell volume of the anilox roll may result in a shortage or excess of the volume of print ink held by the plate cylinder. An excessive volume of print ink held raises a problem that the thickness of a print ink film formed on the synthetic resin sheet becomes large locally. An insufficient volume of print ink held, on the other hand, raises a problem that a print ink pattern formed on the synthetic resin sheet is faint.
The technology described herein was made in view of the above circumstances. An object is to achieve transfer of a coating liquid that ensures superior uniformity of film thickness.
A method of producing a printed substrate according to the technology described herein includes rotating an anilox roll having first recesses on an outer surface of the anilox roll, the outer surface being supplied with a coating liquid, rotating a plate cylinder fitted with a printing plate having second recesses on an outer surface of the printing plate, the outer surface being in contact with the outer surface of the anilox roll, transferring the coating liquid from the first recesses to the second recesses to hold the coating liquid in the second recesses, and rotating the plate cylinder while keeping the outer surface of the printing plate in contact with a substrate surface of a printed substrate to transfer the coating liquid held in the second recesses to the substrate surface of the printed substrate. A ratio of a maximum volume of the coating liquid held by the second recesses per unit area on the outer surface of the printing plate to a maximum volume of the coating liquid held by the first recesses per unit area on the outer surface of the anilox roll is determined to be a ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller).
According to this method, the coating liquid supplied to the outer surface of the anilox roll and held in the first recesses is transferred from the first recesses to the second recesses and is held in the second recesses as the anilox roll and the plate cylinder, the anilox roll having its outer surface kept in contact with the outer surface of the printing plate, are rotated. Afterward, as the plate cylinder with the printing plate having its outer surface kept in contact with the substrate surface of the printed substrate is rotated, the coating liquid in the second recesses is transferred to the substrate surface of the printed substrate. For the first recesses formed on the outer surface of the anilox roll as well as the second recesses formed on the outer surface of the printing plate, the maximum volume of the coating liquid that the recesses can hold is defined as “maximum volume of the coating liquid held in the recesses per unit area on the outer surface”. If the maximum volume of the coating liquid held by the first recesses per unit area on the outer surface of the anilox roll is compared with the maximum volume of the coating liquid held by the second recesses per unit area on the outer surface of the printing plate to find that the former maximum volume is excessively large or the latter maximum volume is excessively small, the second recesses of the printing plate fail to completely hold the coating liquid. This may lead to “film thickness irregularity”, which refers to a phenomenon that the thickness of a film of the coating liquid transferred to the printed substrate becomes large locally. If the maximum volume of the coating liquid held by the first recesses per unit area on the outer surface of the anilox roll is compared with the maximum volume of the coating liquid held by the second recesses per unit area on the outer surface of the printing plate to find that the former maximum volume is excessively small or the latter maximum volume is excessively large, on the other hand, the coating liquid held in the second recesses of the printing plate becomes insufficient in volume. This may lead to “faint”, which refers to formation of mottled patterns made up of spots where the coating liquid is transferred to the printed substrate and spots where the coating liquid is not transferred to the printed substrate.
However, by determining the ratio of the maximum volume of the coating liquid held by the second recesses per unit area on the outer surface of the printing plate to the maximum volume of the coating liquid held by the first recesses per unit area on the outer surface of the anilox roll to be a ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller), a proper volume of the coating liquid transferred to the printed substrate is ensured. Specifically, determining the above ratio to be equal to or larger than 0.50 hardly allows the coating liquid transferred from the first recesses of the anilox roll to the second recesses of the printing plate to become excessive in volume, and therefore allows the second recesses of the printing plate to hold the coating liquid properly. This is preferable for achieving the uniform thickness of a film of the coating liquid transferred to the printed substrate. Determining the above ratio to be equal to or smaller than 2.00, on the other hand, hardly allows the coating liquid transferred from the first recesses of the anilox roll to the second recesses of the printing plate to become insufficient in volume, and therefore allows the second recesses of the printing plate to hold a sufficient volume of the coating liquid. This prevents formation of a spot where the coating liquid is not transferred to the printed substrate. As a result, it becomes easier to transfer the coating liquid to the printed substrate, as a film with a uniform thickness. Note that, even if the ratio is determined to be within the above value ranges, for example, adjusting the printing pressure of the printing plate to the printed substrate may be preferable in some cases.
According to the technology described herein, transfer of a coating liquid that ensures superior uniformity of a film thickness can be achieved.
A first embodiment will be described with reference to
The flexographic printing apparatus 10 is used to, for example, print (coat) an oriented film forming resin containing a polyimide resin or the like when an oriented film is formed on the liquid crystal panel substrate S making up a liquid crystal panel (display panel). In the first embodiment, the liquid crystal panel substrate S on which the oriented film is formed by the flexographic printing apparatus 10 is a so-called mother substrate carrying array substrates and counter substrates arranged on its substrate surface, the substrates making up the liquid crystal panel.
As shown in
As shown in
As shown in
As shown in
As shown in
The flexographic plate 15 is made of a resin, such as polybutadiene. As shown in
As shown in
The flexographic printing apparatus 10 according to the first embodiment has the above structure. A method of flexographic printing of an oriented film using the flexographic printing apparatus 10, that is, an example of a method of producing the liquid crystal panel substrate S will then be described.
First, the positional relation of the doctor roll 13 with the anilox roll 12 is adjusted, as shown in
When the anilox roll 12 and the plate cylinder 14 rotate in their respective directions reverse to each other, as shown in
Now, for comparison with the first embodiment, first and second comparative examples will be described with reference to
However, according to the first embodiment, a ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12, that is, “MVA2/MVA1” is determined to be a ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller). This ratio ensures a proper volume of the coating liquid CL transferred to the liquid crystal panel substrate S. Specifically, determining the above ratio “MVA2/MVA1” to be equal to or larger than 0.50 hardly allows the coating liquid CL transferred from the first recesses 17 of the anilox roll 12 to the second recesses 18 of the flexographic plate 15 to become excessive in volume, and therefore allows the second recesses 18 of the flexographic plate 15 to hold the coating liquid CL properly. This is preferable for achieving the uniform thickness of a film of the coating liquid CL transferred to the liquid crystal panel substrate S. Determining the above ratio “MVA2/MVA1” to be equal to or smaller than 2.00, on the other hand, hardly allows the coating liquid CL transferred from the first recesses 17 of the anilox roll 12 to the second recesses 18 of the flexographic plate 15 to become insufficient in volume, and therefore allows the second recesses 18 of the flexographic plate 15 to hold a sufficient volume of the coating liquid CL. This prevents formation of a spot where the coating liquid CL is not transferred to the liquid crystal panel substrate S. As a result, it becomes easier to transfer the coating liquid CL to the liquid crystal panel substrate S, as a film with a uniform thickness.
In particular, according to the first embodiment, an excess portion of the coating liquid CL supplied to the outer surface of the anilox roll 12 is drawn by the doctor roll 13. By adjusting the contact pressure of the doctor roll 13 to the anilox roll 12, therefore, a given amount of the coating liquid CL can be held at the outside of the first recesses 17 on the outer surface of the anilox roll 12. Using the doctor roll 13 offers the following advantage. Even when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is larger than 1.70 and equal to or smaller than 2.00, by adjusting the contact pressure of the doctor roll 13 to the anilox roll 12, in addition to the coating liquid CL held in the first recesses 17 on the outer surface of the anilox roll 12, the coating liquid CL held outside the first recesses 17 is transferred to the second recesses 18 of the flexographic plate 15. A case where the coating liquid CL transferred to the second recesses 18 is insufficient in volume, therefore, hardly occurs. As a result, development of “faint” is suppressed.
It is more preferable that the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 be a ratio ranging from 0.90 to 1.70 (0.90 or larger and 1.70 or smaller). When the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is equal to or larger than 0.50 and smaller than 0.90, or is larger than 1.70 and equal to or smaller than 2.00, not adjusting the printing pressure of the flexographic plate 15 to the liquid crystal panel substrate S may lead to development of “film thickness irregularity” or “faint”. However, when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is determined to be the ratio ranging from 0.90 to 1.70 (0.90 or larger and 1.70 or smaller), a proper volume of the coating liquid CL transferred to the liquid crystal panel substrate S is ensured without adjusting the printing pressure of the flexographic plate 15 to the liquid crystal panel substrate S, and therefore development of “film thickness irregularity” or “faint” is suppressed. This offers high productivity.
It is more preferable that the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 be a ratio ranging from 0.90 to 1.40 (0.90 or larger and 1.40 or smaller). When the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is larger than 1.40 and equal to or smaller than 1.70, not adjusting the contact pressure of the doctor roll 13 to the anilox roll 12 may lead to development of “faint”. However, when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is determined to be the ratio ranging from 0.90 to 1.40 (0.90 or larger and 1.40 or smaller), a proper volume of the coating liquid CL transferred to the liquid crystal panel substrate S is ensured without adjusting the contact pressure of the doctor roll 13 to the anilox roll 12, and therefore development of “faint” is suppressed. This offers high productivity.
A first comparative test described below has been conducted to obtain knowledge about a way in which the state of the coating liquid CL transferred to the outer surface of the produced liquid crystal panel substrate S changes when the above ratio “MVA2/MVA1” is changed. In the first comparative test, the liquid crystal panel substrate S is produced using the flexographic printing apparatus 10 according to the first embodiment under conditions in which the above ratio “MVA2/MVA1” varies, and the finished state of a coating film CL (oriented film) formed on the outer surface of the produced liquid crystal panel substrate S is evaluated by a worker who visually checks the coating film CL. Whether the coating film CL is uniform in thickness is checked as evaluation criteria. When the coating film CL sufficiently uniform in thickness is formed without making specific adjustment, an evaluation result “fine” is given. When the uniformity of the thickness of the coating film CL is ensured by making prescribed adjustment, an evaluation result “acceptable” is given. When the coating film CL remains non-uniform in thickness after making adjustment, an evaluation result “unacceptable” is given. The results of the first comparative test are indicated in a table shown in
The results of the first comparative test will be described.
However, determining the above ratio “MVA2/MVA1” to be the ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller) gives the evaluation result “fine” or “acceptable”. Specifically, determining the above ratio “MVA2/MVA1” to be a ratio ranging from 0.90 to 1.50 (0.90 or larger and 1.50 or smaller) gives the evaluation result “fine”, and determining the ratio “MVA2/MVA1” to be equal to or larger than 0.50 and smaller than 0.90 or to be larger than 1.50 and equal to or smaller than 2.00 gives the evaluation result “acceptable”. When the ratio “MVA2/MVA1” is equal to or larger than 0.50 and smaller than 0.90 or is larger than 1.50 and equal to or smaller than 2.00, the state of the coating liquid CL applied to the liquid crystal panel substrate S is generally fine. Still, slight faint or film thickness irregularity may result. In this case, making adjustment of the printing pressure of the flexographic plate 15 to the liquid crystal panel substrate S or of the contact pressure of the doctor roll 13 to the anilox roll 12 improves the state of the coating liquid CL applied to the liquid crystal panel substrate S. This offers film quality equivalent to “fine”. When the “MVA2/MVA1” is the ratio ranging from 0.90 to 1.50 (0.90 or larger and 1.50 or smaller), the fine state of the coating liquid CL applied to the liquid crystal panel substrate S is achieved without making the above adjustment. This allows an improvement in a non-defective ratio and productivity. According to the first comparative test, the maximum volumes MVA2 and MVA1 that determine the same ratio “MVA2/MVA1” vary in their respective values. When the values of the maximum volumes MVA2 and MVA1 are both large, the thickness of a film of the coating liquid CL transferred to the outer surface of the liquid crystal panel substrate S tends to be large. When the values of the maximum volumes MVA2 and MVA1 are both small, the thickness of a film of the coating liquid CL transferred to the outer surface of the liquid crystal panel substrate S tends to be small. The oriented film formed by applying the coating liquid CL to the outer surface of the liquid crystal panel substrate S does not offer a sufficient anchoring effect, which is an effect of regulating a state of orientation of liquid crystal molecules, if the thickness of the film is sufficiently uniform but is too small. It is preferable, from this point of view, that the thickness of the film of the coating liquid CL applied to the outer surface of the liquid crystal panel substrate S be determined to be a thickness that is at least needed to give the oriented film a thickness for offering the anchoring effect. It is preferable, for this reason, that the contact pressure of the doctor roll 13 to the anilox roll 12 be adjusted properly.
As described above, the method of producing the liquid crystal panel substrate (printed substrate) S according to the first embodiment includes rotating the anilox roll 12 having the first recesses 17 formed on its outer surface supplied with the coating liquid CL and rotating the plate cylinder 14 fitted with the flexographic plate (printing plate) 15 having the second recesses 18 formed on its outer surface in contact with the outer surface of the anilox roll 12, to transfer the coating liquid CL from the first recesses 17 to the second recesses 18 and hold the coating liquid CL in the second recesses 18, and rotating the plate cylinder 14 while keeping the outer surface of the flexographic plate 15 in contact with the substrate surface of the liquid crystal panel substrate (printed substrate) S to transfer the coating liquid CL held in the second recesses 18 to the substrate surface of the liquid crystal panel substrate S. According to the method, the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is determined to be the ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller).
According to this method, the coating liquid CL supplied to the outer surface of the anilox roll 12 and held in the first recesses 17 is transferred from the first recesses 17 to the second recesses 18 and is held therein as the anilox roll 12 and the plate cylinder 14, the anilox roll 12 having its outer surface kept in contact with the outer surface of the flexographic plate 15, are rotated. Afterward, as the plate cylinder 14 with the flexographic plate 15 having its outer surface kept in contact with the substrate surface of the liquid crystal panel substrate S is rotated, the coating liquid CL in the second recesses 18 is transferred to the substrate surface of the liquid crystal panel substrate S. For the first recesses 17 formed on the outer surface of the anilox roll 12 as well as the second recesses 18 formed on the outer surface of the flexographic plate 15, the maximum volume of the coating liquid CL that the recesses can hold is defined as “maximum volume of the coating liquid held by the recesses per unit area on the outer surface”. If the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is compared with the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to find that the former maximum volume is excessively large or the latter maximum volume is excessively small, the second recesses 18 of the flexographic plate 15 fail to completely hold the coating liquid CL. This may lead to “film thickness irregularity”, which refers to a phenomenon that the thickness of a film of the coating liquid CL transferred to the liquid crystal panel substrate S becomes large locally. If the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is compared with the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to find that the former maximum volume is excessively small or the latter maximum volume is excessively large, on the other hand, the coating liquid CL held in the second recesses 18 of the flexographic plate 15 becomes insufficient in volume. This may lead to “faint”, which refers to formation of mottled patterns made up of spots where the coating liquid CL is transferred to the liquid crystal panel substrate S and spots where the coating liquid CL is not transferred to the liquid crystal panel substrate S.
However, the ratio “MAV2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 17 per unit area on the outer surface of the anilox roll 12 is determined to be the ratio ranging from 0.50 to 2.00 (0.50 or larger and 2.00 or smaller). This ratio ensures a proper volume of the coating liquid CL transferred to the liquid crystal panel substrate S. Specifically, determining the above ratio “MVA2/MVA1” to be equal to or larger than 0.50 hardly allows the coating liquid CL transferred from the first recesses 17 of the anilox roll 12 to the second recesses 18 of the flexographic plate 15 to become excessive in volume, and therefore allows the second recesses 18 of the flexographic plate 15 to hold the coating liquid CL properly. This is preferable for achieving the uniform thickness of a film of the coating liquid CL transferred to the liquid crystal panel substrate S. Determining the above ratio “MVA2/MVA1” to be equal to or smaller than 2.00, on the other hand, hardly allows the coating liquid CL transferred from the first recesses 17 of the anilox roll 12 to the second recesses 18 of the flexographic plate 15 to become insufficient in volume, and therefore allows the second recesses 18 of the flexographic plate 15 to hold a sufficient volume of the coating liquid CL. This prevents formation of a spot where the coating liquid CL is not transferred to the liquid crystal panel substrate S. As a result, it becomes easier to transfer the coating liquid CL to the liquid crystal panel substrate S, as a film with a uniform thickness. Note that, even if the ratio “MVA2/MVA1” is determined to be within the above value ranges, adjusting the printing pressure of the flexographic plate 15 to the liquid crystal panel substrate S may be preferable in some cases, for example.
The doctor roll 13 is disposed such that it rotates while being in contact with the outer surface of the anilox roll 12. The doctor roll 13 thus draws an excess portion of the coating liquid CL supplied to the outer surface of the anilox roll 12. In this configuration, the coating liquid CL supplied to the outer surface of the anilox roll 12 is drawn by the doctor roll 13 that rotates while being in contact with the outer surface of the anilox roll 12. By properly adjusting the contact pressure of the doctor roll 13 to the anilox roll 12, therefore, a given volume of the coating liquid CL can be held outside the first recesses 17 on the outer surface of the anilox roll 12. Using the doctor roll 13 offers the following advantage. Even when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses 18 per unit area on the outer surface of the flexographic plate 15 to the maximum volume MVA1 of the coating liquid CL held in the first recesses 17 per unit area on the outer surface of the anilox roll 12 is larger than 1.70 and equal to or smaller than 2.00, by adjusting the contact pressure of the doctor roll 13 to the anilox roll 12, in addition to the coating liquid CL held in the first recesses 17 on the outer surface of the anilox roll 12, the coating liquid CL held outside the first recesses 17 is transferred to the second recesses 18 of the flexographic plate 15. A case where the coating liquid CL transferred to the second recesses 18 is insufficient in volume, therefore, hardly occurs. As a result, development of “faint” is suppressed.
The plate cylinder 14 is rotated as the stage 16 sucking and holding the liquid crystal panel substrate S is moved relative the plate cylinder 14. As a result, the coating liquid CL held in the second recesses 18 of the flexographic plate 15 is transferred to the substrate surface of the liquid crystal panel substrate S. In this configuration, the plate cylinder 14 does not need to be moved. Thus, the coating liquid CL held in the second recesses 18 of the flexographic plate 15 can be transferred to the substrate surface of the liquid crystal panel substrate S as the outer surface of the flexographic plate 15 is kept in contact with the outer surface of the anilox roll 12. In this configuration, compared with a configuration in which the stage 16 is not moved, the size of the flexographic printing apparatus 10 increases. For this reason, this configuration is applied preferably to a case where the liquid crystal panel substrate S is small-sized (e.g., a case where the size of the liquid crystal panel substrate S, which is a mother substrate, is equal to or smaller than the size of the 4.5th generation version).
The resin solution containing the oriented film forming resin that orients liquid crystal molecules or the insulative resin is used as the coating liquid CL, and the liquid crystal panel substrate (display panel substrate) S making up the liquid crystal panel (display panel) is used as the printed substrate coated with the coating liquid CL. In this configuration, the resin solution, i.e., the coating liquid CL is transferred to the substrate surface of the liquid crystal panel substrate S, i.e., printed substrate to form an oriented film on the substrate surface of the liquid crystal panel substrate S. The oriented film formed on the substrate surface of the liquid crystal panel substrate S is improved in film thickness uniformity. This improves the display quality of the liquid crystal panel.
A second embodiment will be described with reference to
As shown in
As shown in
As shown in
The flexographic printing apparatus 110 according to the second embodiment has the above structure. A method of flexographic printing of an oriented film using the flexographic printing apparatus 110, that is, an example of a method of producing the liquid crystal panel substrate S will then be described.
First, as shown in
When the anilox roll 112 and the plate cylinder 114 rotate in their respective directions reverse to each other, as shown in
A second comparative test described below has been conducted to obtain knowledge about a way in which the state of the coating liquid CL transferred to the outer surface of the produced liquid crystal panel substrate S changes when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is changed. In the second comparative test, the liquid crystal panel substrate S is produced using the flexographic printing apparatus 110 according to the second embodiment under conditions in which the above ratio “MVA2/MVA1” varies, and the finished state of a coating film CL (oriented film) formed on the outer surface of the produced liquid crystal panel substrate S is evaluated by a worker who visually checks the coating film CL. The same evaluation criteria as used in the first comparative test of the first embodiment are adopted in the second comparative test. The results of the second comparative test are indicated in a table shown in
The results of the second comparative test will be described mainly through comparison with the results of the first comparative test of the first embodiment. As indicated in
As described above, according to the second embodiment, the doctor blade 19 in contact with the outer surface of the anilox roll 112 scrapes an excess portion of the coating liquid CL supplied to the outer surface of the anilox roll 112, and the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is determined to be the ratio ranging from 0.50 to 1.70 (0.50 or larger and 1.70 or smaller). In this configuration, because the doctor blade 19, compared with the doctor roll, hardly deforms when the size of the liquid crystal panel substrate S is increased, using the doctor blade 19 is preferable for producing the liquid crystal panel substrate S of a large size. In addition, because the doctor blade 19 scrapes an excess portion of the coating liquid CL supplied to the outer surface of the anilox roll 112, the coating liquid CL hardly remains outside the first recesses 117 on the outer surface of the anilox roll 112. Under this condition, the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is determined to be the ratio ranging from 0.50 to 1.70 (0.50 or larger and 1.70 or smaller). When the doctor blade 19 is used, specifically, in a case where the ratio “MVA2/MVA1” is larger than 1.70 and equal to or smaller than 2.00, the coating liquid CL transferred from the first recesses 117 of the anilox roll 112 to the second recesses of the flexographic plate 115 becomes insufficient in volume, which may lead to development of “faint”. However, determining the ratio “MVA2/MVA1” to be equal to or smaller than 1.70 hardly allows the coating liquid CL transferred from the first recesses 117 of the anilox roll 112 to the second recesses of the flexographic plate 115 to become insufficient in volume, thus suppressing development of “faint”. Note that, even if the ratio “MVA2/MVA1” is the ratio ranging from 0.50 to 1.70 (0.50 or larger and 1.70 or smaller), for example, adjusting the printing pressure of the flexographic plate 115 to the liquid crystal panel substrate S may be preferable in some cases.
It is more preferable that the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is determined also to be a ratio ranging from 0.90 to 1.40 (0.90 or larger and 1.40 or smaller). When the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is determined to be equal to or larger than 0.50 and smaller than 0.90 or to be larger than 1.40 and equal to or smaller than 1.70, not adjusting the printing pressure of the flexographic plate 115 to the liquid crystal panel substrate S may lead to development of “film thickness irregularity” or “faint”. However, when the ratio “MVA2/MVA1”, i.e., the ratio of the maximum volume MVA2 of the coating liquid CL held by the second recesses per unit area on the outer surface of the flexographic plate 115 to the maximum volume MVA1 of the coating liquid CL held by the first recesses 117 per unit area on the outer surface of the anilox roll 112 is determined to be the ratio ranging from 0.90 to 1.40 (0.90 or larger and 1.40 or smaller), a proper volume of the coating liquid CL transferred to the liquid crystal panel substrate S is ensured without adjusting the printing pressure of the flexographic plate 115 to the liquid crystal panel substrate S, and therefore development of “film thickness irregularity” or “faint” is suppressed. This offers high productivity.
The plate cylinder 114 is rotated while being moved relative to the stage 116 sucking and holding the liquid crystal panel substrate S. As a result, the coating liquid CL held in the second recesses of the flexographic plate 115 is transferred to the substrate surface of the liquid crystal panel substrate S. In this configuration, because the stage 116 does not need to be moved, an increase in the size of the flexographic printing apparatus (production apparatus) 110 is avoided. This configuration is, therefore, preferable for a case where the liquid crystal panel substrate S is large-sized.
A third embodiment will be described with reference to
As shown in
The technology described herein is not limited to the embodiments described above and with reference to the drawings. The following embodiments may be included in the technical scope.
(1) The plating of the anilox roll may be made of a chromic material. It is preferable in such a case that the first recesses formed on the surface of the plating made of the chromic material be each made into a pyramidal shape. In other words, it is preferable that the plating made of the chromic material be of a pyramidal meshed structure.
(2) The first recesses may be formed into diamond-shaped patterns, groove-like helical patterns, or the like.
(3) Each of the above embodiments is described as the case where the dispenser that supplies the coating liquid to the anilox roll is provided. However, a tank holding the coating liquid therein and a fountain roll that draws the coating liquid from the tank to supply the coating liquid to the anilox roll may be provided in place of the dispenser.
(4) The coating liquid may not contain the oriented film forming resin and contain the insulative resin.
(5) The technology described herein may be applied to a case where a display panel substrate making up a display panel different from the liquid crystal panel is subjected to printing. The technology described herein may also be applied to a case where a substrate different from the display panel substrate is subjected to printing.
Number | Date | Country | Kind |
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2018-042863 | Mar 2018 | JP | national |