JP4693396B2 - Die head manufacturing and assembly method - Google Patents

Description

The present invention applies a coating liquid to an object to be coated such as a web or a plate in a color filter manufacturing process, an organic EL element manufacturing process, a fuel cell manufacturing process, a photomask manufacturing process, a packaging material manufacturing process, and the like. manufacturing operation of the die head to be used for, regarding the assembling process.

  Conventionally, as shown in FIG. 4 (a), a die head 3 is disposed opposite to a web (object to be coated) 2 that is supported by a backup roll 1 and is running, and the coating liquid is formed into a film from the die head 3. A coating apparatus that discharges and applies to a plate, as shown in FIG. 4B, a die head 3 is disposed opposite to a plate material or sheet (object to be coated) 5 placed on a surface plate 4, and the die head A coating apparatus is known in which the die head 3 is moved relative to the plate material or the sheet 5 on the surface plate 4 while the coating liquid is ejected in a film form from 3. As shown in FIGS. 5 and 6, the die head 3 used in this type of coating apparatus includes a first die block 7 and a second die block 8, and the first die block 7 and the second die block 8. Are formed with gap wall surfaces 7 a and 8 a for forming the slit gap 9, and mating surfaces 7 b and 8 b for abutting each other for assembly, and a manifold 10 is formed on one die block 8. The two die blocks 7 and 8 are combined with their mating surfaces 7b and 8b, and spaced apart in the longitudinal direction (in this specification, the discharge width direction indicated by the arrow XX direction is referred to as the longitudinal direction). The bolts 11 arranged at a plurality of locations are fastened and integrated to form a slit gap 9 for discharging the coating liquid between the gap wall surfaces 7a and 8a.

  In the die head 3 having this structure, the die blocks 7 and 8 are made thick in order to increase the rigidity of the die blocks 7 and 8 so as not to bend, and the gap wall surface 7a of each die block 7 and 8 is used. , 8a and mating surfaces 7b, 8b are made to be flat surfaces with high accuracy, that is, the straightness and flatness are precisely processed, and the die blocks 7, 8 are assembled together with the mating surfaces 7b, 8b. Thus, the gap dimension d of the slit gap 9 formed between the gap wall surfaces 7a and 8a is set to a predetermined value and constant in the longitudinal direction of the die head. Moreover, the specification of the bolt 11 used here is a necessary surface pressure that does not cause liquid leakage between the mating surfaces 7b and 8b of the die blocks 7 and 8 by fastening the bolt 11 with an appropriate torque of the bolt. When the die head is assembled, the bolt 11 is fastened with an appropriate torque of the bolt, and the reproducibility of the bolt fastening is obtained by using the appropriate torque.

  However, since the conventional die head uses such thick die blocks 7 and 8, the weight is very large. Therefore, generally, when the die width is 600 mm or more, the heavy die head must be carried by a hand lifter or a crane. In other words, the workability when attaching the die head and cleaning is extremely poor.

  Therefore, as shown in FIG. 8, the present inventors use die blocks 7A and 8A having a reduced thickness to measure the die head, and use a plurality of bolts 11 to set the appropriate torque of the bolts. Used to conclude. However, if the die blocks 7A and 8A are thinned, the rigidity is reduced, and therefore the die blocks 7A and 8A are bent by the fastening force of the bolts 11, and the deflection amounts at both end regions of the tip of the die blocks 7A and 8A are particularly large. As a result, as shown in FIG. 8 with the slit gap tip exaggerated, the gap dimension d of the slit gap 9 is constant in the longitudinal direction as shown in FIG. However, after the bolt is tightened, as shown in FIG. 8B, the slit gap 9 has a profile in which the gap dimension d is larger in both end regions than in the central region, and the distribution of the deflection amount in the longitudinal direction of the die head occurs. It has been found. In the figure, the difference in the amount of deflection at an arbitrary position in the longitudinal direction is indicated by Δd with reference to the region having the smallest gap size at the center. Since the slit gap 9 has a profile that spreads in both end regions as described above, it affects the coating accuracy and must be avoided as much as possible. In order to prevent this phenomenon, it is only necessary to prevent the deflection generated in the die blocks 7A and 8A. For this purpose, the tightening torque of the bolts 11 mainly at the end regions of the die head may be decreased. When the tightening torque of the bolts 11 is decreased, The surface pressure between the mating surfaces 7b and 8b may be reduced to cause liquid leakage, and the bolts may be tightened with a torque lower than the appropriate torque of the bolts. As shown in FIG. 9, the reproducibility of fastening of the bolt is high at the time of fastening with the appropriate torque, and the fastening reproducibility is lowered even if it is separated from the appropriate torque to either the high or low side. For this reason, when tightening bolts with a torque lower than the appropriate torque, the reproducibility of fastening is low, and the slit gap when disassembling and reassembling the die head for different reassembly results in a different profile for each reassembly. This results in a disadvantage that the reproducibility of the film thickness variation is low.

In addition to a die head having a structure in which the slit gap is adjusted by adjusting the bolt tightening torque, a die head having a structure in which the opening of the slit gap on the die discharge side is adjusted by an air cylinder is proposed in Japanese Patent Laid-Open No. 2000-334359. ing. However, in this die head, the gap dimension is adjusted by generating an elastic strain in the part where the slit gap is formed. However, when the strain is generated, the coating accuracy is improved at the time of assembly every time after die cleaning or the like. Reproducibility cannot be obtained. In addition, surface quality defects may occur depending on the state of droplets held at the tip of the die, and coating conditions such as improving the coating speed or increasing the accuracy of coating film thickness distribution by partial correction of only the tip There is also a problem that improvement is difficult. Japanese Patent Laid-Open No. 2003-24857 proposes a method of adjusting the opening of the slit gap on the die discharge side with a wedge. However, in this method as well, surface quality defects may occur due to variations in the droplet holding state at the die tip. In addition, when a wedge is used to perform operations such as opening and closing the opening, the elastic deformation region of the material is used, but when elastic strain occurs, the operating range is limited and the internal slit accuracy is repolished. There is a problem that needs to be corrected.
JP 2000-334359 A JP 2003-24857 A

The present invention has been made in view of such problems, and a bolt for assembling the first die block and the second die block has a tightening torque capable of securing a desired surface pressure on the mating surface of the two and the appropriateness of the bolt. by tightening torque, high accuracy gap dimension of the slit gap die head longitudinal direction (e.g., accurate to within 0.1 [mu] m) manufactured of holder Iheddo it is possible to place a constant, to provide an assembly method Let it be an issue.

The invention according to claim 1 of the present invention, which has been made to solve the above problems, comprises a gap wall surface for forming a slit gap and a mating surface for assembling each other, and the mating surfaces are combined with each other. The first die block and the second die block having a configuration in which a slit gap for discharging a coating liquid is formed between the gap wall surfaces, and the first die block and the second die block are positioned on the mating surface. And a method of manufacturing and assembling a die head having a plurality of bolts that are fastened to each other at a plurality of positions spaced apart in the longitudinal direction. The first die block and the second die block are combined with the mating surface. When the bolts are aligned and tightened with the appropriate torque applied to the bolts, The amount of the die head in the longitudinal direction by structural analysis and the gap wall surface between the first die block and the second die block based on the deflection amount distribution derived from the structural analysis result. Precision machining into a shape in which the gap dimension is constant in the longitudinal direction when the occurrence of the problem, and then fastening the first die block and the second die block to the bolt by applying an appropriate torque of the bolt. It is characterized by having.

In the method of manufacturing and assembling the die head of the present invention, the distribution of the amount of deflection generated when the first die block and the second die block are fastened by applying an appropriate torque to the bolt in advance is determined by structural analysis, and the first die block and By configuring the gap wall surface of the second die block into a shape that takes into account the deflection distribution, both the first die block and the second die block are tightened by applying appropriate torque to the bolts. The gap dimension of the slit gap formed between them can be made uniform in the longitudinal direction of the die head, and the film thickness variation can be extremely reduced by using the die head manufactured and assembled by the method of the present invention . In addition, since the bolt is fastened with the appropriate torque of the bolt, it is excellent in reproducibility of fastening, and when the die head is disassembled for cleaning etc. and reassembled, the reproducibility of the gap dimension is good, The gap can be made uniform in the longitudinal direction of the die head. Furthermore, even if deflection occurs when the first and second die blocks are fastened, the gap dimension can be made uniform in the longitudinal direction of the die block, so that the first and second die blocks can be made thinner and the die head can be made lighter. To improve handling.

FIG. 1 is a schematic cross-sectional view of a die head manufactured and assembled by a manufacturing and assembling method according to a preferred embodiment of the present invention, and FIG. 2 is a schematic exploded perspective view of the die head. A die head generally indicated by reference numeral 13 includes a first die block 17 and a second die block 18, and each of the first die block 17 and the second die block 18 is provided with a slit gap 19. Gap wall surfaces 17a and 18a and mating surfaces 17b and 18b for assembling each other are formed, and a manifold 20 is formed on one die block 18. The manifold 20 may be either a coat hanger type or a straight type. The die head 13 further includes a plurality of the first die block 17 and the second die block 18 in a state in which the mating surfaces 17b and 18b are abutted with each other at a position of the mating surface and a plurality of locations spaced in the longitudinal direction. The bolt 21 is provided. The die blocks 17 and 18 are made of a material having high hardness (HRC: about 30 to 60) and a relatively high Young's modulus, such as stainless steel, silicon alloy, and ceramic, which are easy to perform precision processing. The thickness of the die blocks 17 and 18 is made thinner than before in consideration of weight reduction. The specifications and the number of bolts 21 used to fasten the die blocks 17 and 18 are determined so that the die blocks 17 and 18 can be fastened with a necessary surface pressure when fastened with appropriate bolt torque.

  The mating surfaces 17b and 18b of the first die block 17 and the second die block 18 are processed into flat surfaces with high accuracy. For example, the straightness and flatness of the mating surfaces 17b and 18b are both within 3 μm. On the other hand, although the gap wall surfaces 17a and 18a for forming the slit gap 19 are processed with high accuracy, they are not flat surfaces with high accuracy, but the first is when the bolt 21 is fastened with the appropriate torque of the bolt. In addition, precision processing is performed into a curved shape in consideration of the distribution of the amount of deflection generated at the tips of the second die blocks 17 and 18. This shape is determined as follows. 3A, assuming that the gap wall surfaces 17a and 18a of the first and second die blocks 17 and 18 are accurate flat surfaces, the first and second die blocks 17 and 18 In a state where the mating surfaces 17b and 18b (see FIG. 1) are merely abutted and bolt fastening is not performed, the gap wall surfaces 17a and 18a are parallel and the gap dimension d is uniform in the longitudinal direction. When the first and second die blocks 17, 18 are fastened with an appropriate torque of the bolt 21, the first and second die blocks 17, 18 are deflected, and as shown in FIG. Is narrow at the center in the longitudinal direction and wide at both ends. Therefore, the distribution of the deflection amount at the tips of the first and second die blocks 17 and 18, for example, the central position where the deflection amount is the smallest is taken as the reference point, and the longitudinal direction from the reference point at an arbitrary position in the longitudinal direction is perpendicular to the longitudinal direction. The displacement Δd in the direction is obtained in advance by structural analysis, and the gap wall surfaces 17a and 18a are made to have a curved surface opposite to the curved surface having the deflection amount distribution (for example, Δd), that is, as shown in FIG. Thus, precision machining is performed so that the surface is displaced in the direction opposite to the displacement Δd. Accordingly, when the first die block 17 and the second die block 18 are merely abutted at the mating surfaces 17b and 18b, and the fastening torque by the bolt 21 is not applied, the gap wall surfaces 17a and 18a are as shown in FIG. The slit gap 19 has a profile that is wide at the center and narrow at both ends.

  The first and second die blocks 17 and 18 having the gap wall surfaces 17a and 18a precisely machined in such a shape are brought into contact with the mating surfaces 17b and 18b and fastened by applying an appropriate torque to the bolt 21 to be integrated. Is done. As a result of this fastening, the first and second die blocks 17 and 18 have deflections at the tips thereof and cancel the gap wall 17a and 18a in advance with the curvature applied in anticipation of the amount of deflection. , 18a are linear, and the gap dimension d is extremely uniform in the longitudinal direction of the die head.

  Thus, while the obtained die head 13 is comparatively lightweight, the gap dimension d can be made extremely uniform in the longitudinal direction of the die head, the variation in coating film thickness can be made extremely small, and thin film precision coating can be performed. Since the proper torque of the bolt can be used as the tightening torque of 21, the reproducibility of fastening is excellent, and even when disassembled and reassembled, the gap dimension d can be made extremely uniform in the longitudinal direction of the die head, and the coating film thickness varies. It is possible to apply a thin film with a very small thickness.

  T type of structure which fastens first and second die blocks 17, 18 made of stainless steel (SUS420-J2) of length 700mm x height 60mm x thickness 20mm with 14 M8 bolts 21 (material SUS316) A die head was prepared. The manifold 20 formed on one die block 18 was semicircular with a diameter of 6 mm. The distribution of the deflection amount when the die head was fastened with an appropriate torque of 195 kgf · cm of the M8 bolt 21 was determined by structural analysis. As a result, the gap dimension d of the slit gap 19 was 3 μm at both ends compared to the center portion. I found it spreading. Accordingly, the gap wall surfaces 17a and 18a of the first and second die blocks 17 and 18 were precisely machined into a concave shape in which the central portion was recessed by 1.5 μm as compared to both ends. Thereafter, the die blocks 17 and 18 were fastened with 14 bolts 21 at 195 kgf · cm, which is the appropriate torque of the bolts 21, and the gap dimension d was measured. It was within 1 μm. When this die head was once disassembled and reassembled, and the bolt fastening torque at that time was 195 kgf · cm which is an appropriate torque, the variation in the gap dimension d in the longitudinal direction was still within 0.1 μm. Thus, according to the present invention, it was confirmed that the variation in the gap dimension in the longitudinal direction can be suppressed to within 0.1 μm.

  The preferred embodiments and examples of the present invention have been described above, but these are for the purpose of explaining the present invention and do not limit the present invention. The present invention is not limited to the scope of the claims. It goes without saying that various changes can be made.

Schematic sectional view of a die head manufactured and assembled by a manufacturing and assembling method according to a preferred embodiment of the present invention. 1 is a schematic exploded perspective view of the die head shown in FIG. (A) is a schematic plan view exaggerating the shape of the slit gap when the gap wall surface is assumed to be an accurate flat surface and the first and second die blocks are simply butted and the bolt is not fastened. b) is a schematic plan view showing an exaggerated shape of the slit gap when the bolts are fastened to the first and second die blocks shown in (a) with appropriate torque, and (c) is an embodiment of the present invention. Schematic plan view showing the slit gap when the first and second die blocks of the die head after precision processing in FIG. (A), (b) is the schematic side view which shows the application | coating style to the web and board | plate material which respectively used the die head. Schematic sectional view of a conventional die head FIG. 5 is a schematic exploded perspective view of the die head shown in FIG. Schematic sectional view of a die head having a die block with a reduced thickness (A) is a schematic plan view exaggerating the shape of the slit gap when the first and second die blocks of the die head shown in FIG. 7 are simply butted and the bolt is not fastened, and (b) is ( Schematic plan view showing the slit gap when the first and second die blocks shown in a) are tightened with an appropriate torque, with the shape exaggerated. Graph showing the relationship between bolt fastening torque and fastening repeatability

Explanation of symbols

13 Die head 17 First die block 18 Second die block 17a, 18a Gap wall surface 17b, 18b Mating surface 19 Slit gap 20 Manifold 21 Bolt

Claims (1)

Each has a gap wall for forming a slit gap and a mating surface for assembling each other, and a slit gap for discharging the coating liquid between the gap wall surfaces when the mating surfaces are combined with each other. A plurality of first die blocks and second die blocks having a structure to be formed, and a plurality of the first die block and the second die block that are fastened to each other at a plurality of locations that are spaced apart in the longitudinal direction at the position of the mating surface. A method of manufacturing and assembling a die head having a bolt , wherein the first die block and the second die block are aligned with each other, and the bolt is tightened by applying an appropriate torque of the bolt. The distribution in the die head longitudinal direction of the amount of deflection generated at the tip of the gap wall surface is obtained by structural analysis in advance. The gap wall surface of the first die block and the second die block is shaped so that the gap dimension is constant in the longitudinal direction when the deflection occurs based on the deflection amount distribution derived from the structural analysis result. A die head manufacturing and assembling method characterized by comprising a step of precision machining, and thereafter a step of fastening the first die block and the second die block to the bolt by applying an appropriate torque of the bolt .

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