Slot die coating apparatus
10610881 ยท 2020-04-07
Assignee
Inventors
- Dong Kwon Choi (Gunpo-si, KR)
- Ok Jin Kim (Hwaseong-si, KR)
- Dong Hoon KIM (Seoul, KR)
- Jang Hwan Lee (Seoul, KR)
- Young Min Lee (Gunpo-si, KR)
- Young Jin Kim (Suwon-si, KR)
- Tae Su Chun (Gwangju, KR)
Cpc classification
B05C11/1007
PERFORMING OPERATIONS; TRANSPORTING
B05C11/10
PERFORMING OPERATIONS; TRANSPORTING
B05C5/0225
PERFORMING OPERATIONS; TRANSPORTING
B05C5/0254
PERFORMING OPERATIONS; TRANSPORTING
B05C11/1005
PERFORMING OPERATIONS; TRANSPORTING
B05C5/0258
PERFORMING OPERATIONS; TRANSPORTING
International classification
B05C5/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a slot die coating apparatus. A slot die coating apparatus according to an embodiment of the present invention includes: a slot die configured to perform a coating process by applying ink to a substrate; an image capturing unit disposed adjacent to the slot die and configured to capture a state of the slot die and a state of ink applied to the substrate during the coating process; and a control unit configured to compare an image captured by the image capturing unit with a reference image and control an operation of the slot die and a transfer of the substrate.
Claims
1. A slot die coating apparatus comprising: a slot die configured to perform a coating process by applying ink to a substrate; an image capturer disposed adjacent to the slot die and configured to capture an image in real time showing a state of the slot die and a state of the ink applied to the substrate during the coating process; an electronic controller configured to compare the image captured by the image capturer with a reference image and control in real time an operation of the slot die, a vertical position of the slot die, and a transfer of the substrate; and a slot die driver connected to the slot die and configured to move the vertical position of the slot die by driving the slot die, wherein the image capturer comprises: at least one first camera disposed at at least one side end of the slot die and configured to capture a meniscus of ink discharged from the slot die; at least one second camera disposed at at least one of a front end and a rear end of the slot die relative to a transfer direction of the substrate and configured to capture a shape of coating bead and a gap between the slot die and the substrate; and an image capturing driver configured to drive the at least one second camera to reciprocate along a length direction of the slot die, wherein the electronic controller is configured to compare the meniscus of the ink captured by the at least one first camera with a first reference image, and compare the shape of the coating bead and the gap between the slot die and the substrate captured by the at least one second camera with a second reference image, and the electronic controller is configured to control the operation of the slot die, the vertical position of the slot die, and the transfer of the substrate according to a comparison result of the electronic controller by adjusting at least one of an ink flow rate, a slot die height, or a transfer speed of the substrate.
2. The slot die coating apparatus of claim 1, wherein the slot die comprises: a first body having a length corresponding to a width of the substrate and defining a space in which the ink supplied from an outside source is accommodated; a second body having a length corresponding to the first body and forming a discharge port, through which the ink is discharged, when coupled to the first body; and at least one diffuser disposed adjacent to the discharge port and configured to diffuse the ink discharged through the discharge port.
3. The slot die coating apparatus of claim 2, wherein the slot die further comprises a shim plate disposed between the first body and the second body and having a plurality of slits opened in a downward direction at positions adjacent to the discharge port.
4. The slot die coating apparatus of claim 1, further comprising a pattern capturer disposed adjacent to the slot die and configured to capture in real time at least one coating pattern provided in the substrate during the coating process, wherein the electronic controller is configured to compare the at least one coating pattern captured by the pattern capturer with a reference pattern and controls in real time the operation of the slot die and the transfer of the substrate.
5. The slot die coating apparatus of claim 4, wherein the pattern capturer comprises: at least one third camera disposed at the front end of the slot die along the transfer direction of the substrate and configured to capture a first coating pattern provided in the substrate before the coating process; and at least one fourth camera disposed at the rear end of the slot die along the transfer direction of the substrate and configured to capture the first coating pattern and a second coating pattern provided in the substrate after the coating process, wherein the electronic controller is configured to compare the first coating pattern captured by the at least one third camera with a first reference image, compare the first coating pattern with the second coating pattern captured by the at least one fourth camera, and control the operation of the slot die and the transfer of the substrate.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(11) Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings in such a manner that the present invention can be easily carried out by those skilled in the art to which the present invention pertains.
(12) Detailed description of well-known functions and structures incorporated herein may be omitted to avoid obscuring the subject matter of the present invention. This aims to omit unnecessary description so as to make the subject matter of the present invention clearer.
(13) For the same reason, some of elements are exaggerated, omitted, or simplified in the drawings, and in practice, the elements may have sizes and/or shapes different from those shown in drawings. The same reference numbers are used to refer to the same or like parts throughout the specification and the drawings.
(14) Hereinafter, a slot die coating apparatus 1 according to embodiments of the present invention will be described in detail with reference to the accompanying drawings.
(15)
(16) As illustrated in
(17) The slot die 100 may perform a coating process by applying ink to a substrate 10. As described above, the coating process using the slot die 100 has advantages in that coating can be performed on the substrate 10 having a wide width all at once, there is no change in ink viscosity and no introduction of foreign matter because ink is not exposed to air in the process of supplying ink from an ink storage tank (not illustrated) to the slot die 100, and stability and reproducibility of ink coating is excellent.
(18) As illustrated in
(19) The image capturing unit 200 may be disposed adjacent to the slot die 100 and may capture a state of the slot die 100 and a state of ink applied to the substrate 10 during the coating process. The image capturing unit 200 may use a complementary metal-oxide semiconductor (CMOS) camera, a charge-coupled device (CCD) camera, or the like. As illustrated in
(20) Referring to
(21) For example, the control unit 300 may adjust a flow rate of ink supplied to the slot die 100 or may adjust a position of the slot die 100, so as to adjust a state of ink discharged from the slot die 100 and applied to the substrate 10. Alternatively, the control unit 300 may adjust a transfer speed of the substrate 10 so as to adjust a state of ink discharged from the slot die 100 and applied to the substrate 10. Although not illustrated, a substrate transfer unit (not illustrated) for transferring the substrate 10 may be provided at a position adjacent to the slot die coating apparatus 1 (below the slot die coating apparatus 1 in the example of
(22) Hereinafter, the structure of the slot die 100 provided in the slot die coating apparatus 1 according to an embodiment of the present invention will be described in detail with reference to
(23)
(24)
(25) As illustrated in
(26) The at least one diffuser 130 may be disposed at a position adjacent to the discharge port 112 and may diffuse ink discharged through the discharge port 112. As such, since the diffuser 130 which assists in diffusing the ink is provided in the slot die 100, it is possible to uniformly apply the ink discharged from the discharge port 112 of the slot die 100 to the substrate 10.
(27) As illustrated in
(28) Meanwhile, as illustrated in
(29)
(30)
(31) The shim plate 140 may be disposed between the first body 110 and the second body 120, and a plurality of slits 141 opened in a downward direction may be formed at positions adjacent to the discharge port 112. As illustrated in
(32) Meanwhile, the image capturing unit 200 of the slot die coating apparatus 1 according to an embodiment of the present invention may include at least one first camera 210 disposed at at least one end of both ends of the slot die 100, and at least one second camera 220 and 230 disposed at at least one of a front end and a rear end of the slot die 100 along the transfer direction of the substrate 10.
(33) That is, the first camera 210 may be disposed at all or part of both ends along a length direction of the slot die 100 formed to be long and may capture a meniscus of ink discharged from the slot die 100, and the second cameras 220 and 230 may be disposed at all or part of both sides along a width direction of the slot die 100 and may capture a a shape of coating bead between the slot die 100 and the substrate 10. The first camera 210 and the second cameras 220 and 230 may be provided in plurality if necessary.
(34) The control unit 300 may compare the meniscus of ink captured by the at least one first camera 210 with a first reference image, compare the shape of the coating bead between the slot die 100 and the substrate 10 captured by the at least one second camera 220 and 230 with a second reference image, and control the operation of the slot die 100 and the transfer of the substrate 10.
(35) Hereinafter, the structure and the operation of the image capturing unit 200 provided in the slot die coating apparatus 1 according to an embodiment of the present invention will be described in detail with reference to
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(38) As illustrated in
(39) The control unit 300 may compare the actually captured meniscus M1 of the ink 20 with a first reference image M0 preset with respect to a normal condition, determine a state of the slot die 100 and a state of the ink 20 applied to the substrate 10, and adjust a flow rate of the ink 20 supplied to the slot die 100 and a transfer speed of the substrate so that the actually captured meniscus M1 of the ink 20 is matched with the first reference image M0.
(40) In addition, as illustrated in
(41) The control unit 300 may compare the actually captured shape of the coating bead between the slot die 100 and the substrate 10 with a second reference image preset with respect to a normal condition, determine a state of the slot die 100 and a state of the ink 20 applied to the substrate 10, and control the operation of the slot die 100 and the transfer of the substrate 10 so that the actually captured shape of the coating bead between the slot die 100 and the substrate 10 is matched with the second reference image. For example, as illustrated in
(42) Meanwhile,
(43) Meanwhile, the image capturing unit 200 of the slot die coating apparatus 1 according to an embodiment may further include a capturing driving unit 240 that drives at least one second camera 220 to reciprocate along the length direction of the slot die 100.
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(45) Unlike the image capturing unit 200 illustrated in
(46) That is, the two second cameras 220 provided in the image capturing unit 200 illustrated in
(47) Although not illustrated in detail, the capturing driving unit 240 may include a driving actuator 241 that generates a straight or rotating driving force, and a fixing block 242 that fixes the second camera 220, is connected to the driving actuator 241, is driven by the driving actuator 241, and reciprocates between both sides of the slot die 100. Preferably, the driving actuator 241 may be implemented by using a linear motion system that converts a rotating driving force generated by a driving motor (not illustrated) into a straight driving force by a ball screw (not illustrated).
(48) Meanwhile, the slot die coating apparatus 1 according to an embodiment of the present invention may further include a slot die driving unit 400 that is connected to the slot die 100 and moves the position of the slot die 100 by driving the slot die 100 according to the result of comparison between the image captured by the image capturing unit 200 and the reference image.
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(50) As described above, the control unit 300 may compare the images captured by the image capturing unit 200 during the coating process, that is, the meniscus of the ink 20 discharged from the slot die 100 (first camera 210) and the shape of coating bead between the slot die 100 and the substrate 10 (second cameras 220 and 230) with the reference image, determine a state of the slot die 100 and a state of the ink 20 applied to the substrate 10, and adjust the position of the slot die 100 so as to control the operation of the slot die 100.
(51) As illustrated in
(52) Meanwhile, as described above, in the case of the roll-to-roll printing apparatus that performs the coating process by using the slot die 100, a film-type substrate 10 (hereinafter, collectively referred to as a film F) may be deformed by external conditions. Thus, in order to improve the coating uniformity of the ink 20, it is necessary to determine a state of the film F, as well as the state of the slot die 100 and the state of the ink 20 applied to the film F during the coating process.
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(54) As illustrated in
(55) The unwinder 31 may be disposed adjacent to the slot die coating apparatus 1 and may supply the film F to the slot die coating apparatus 1 by continuously unwinding the film F. In addition, the rewinder 32 may be disposed adjacent to the slot die coating apparatus 1 and may continuously rewind the film F supplied after the coating process has been finished in the slot die coating apparatus 1.
(56) In addition, the plurality of transfer rollers 33, 34, and 35 may be disposed between the unwinder 31 and the slot die coating apparatus 1, between the slot die coating apparatus 1 and the rewinder 32, and the like and may guide the transfer of the film F.
(57) Although not illustrated in detail, the control unit 300 may perform control so that the transfer speed of the film F supplied from the unwinder 31 to the slot die coating apparatus 1 and the transfer speed of the film F recovered from the slot die coating apparatus 1 to the rewinder 32 are constantly maintained. In addition, although not illustrated in detail, a tension measurement unit (not illustrated) such as a load cell may be provided between sections where the film F is transferred, that is, the unwinder 31, the slot die coating apparatus 1, the rewinder 32, and the plurality of transfer rollers 33, 34, and 35.
(58) As illustrated in
(59)
(60) As illustrated in
(61) As illustrated in
(62)
(63) As illustrated in
(64) That is, in the case of the slot die coating apparatus 1 illustrated in
(65) As described above, in the case of the slot die coating apparatus according to an embodiment of the present invention, it is possible to monitor the state of the slot die and the state of the ink applied to the substrate in real time and thinly and uniformly apply the ink to the substrate by controlling the operation of the slot die and the transfer of the substrate by capturing the state of the slot die and the state of the ink applied to the substrate by using the image capturing unit while the coating process using the slot die is performed. In addition, since the image capturing unit is configured by the first camera that captures the meniscus of the ink discharged from the slot die and the second camera that captures the shape of coating bead between the slot die and the substrate, the state of the slot die and the state of the ink applied to the substrate can be captured and monitored in real time during the coating process. In addition, since the diffuser for diffusing the ink is provided in the discharge port of the slot die, it is possible to further improve the coating uniformity of the ink with respect to the substrate. Furthermore, since the operation of the slot die and the transfer of the substrate are controlled in real time by capturing the coating pattern provided in the substrate by using the pattern capturing unit while the coating process using the slot die is performed, it is possible to control the register with respect to the film-type substrate, thereby improving the quality of products produced through the coating process.
(66) Meanwhile, the coating apparatus that performs the coating process on the substrate by using the slot die has been described as an example, but the present invention is not limited thereto. The present invention can be applied to various processes and technical fields as long as the apparatus performs a process on a substrate by discharging ink by using a slot die. Furthermore, the coating apparatus that performs the coating process on the film-type substrate by using the slot die in the slot die coating apparatus has been described as an example, but the present invention is not limited thereto. The present invention can be applied to various processes and technical fields as long as the apparatus performs a process on a substrate by discharging ink by using a slot die.
(67) Meanwhile, preferred embodiments of the present invention have been described and illustrated in the drawings. Although specific terms are used herein, all such terms are intended to have the same meaning as commonly understood in order to fully convey the concept of the present invention and for better understanding of the present invention and should not be taken as limiting the scope of the present invention. It is apparent to those skilled in the art that various modifications or alterations can be made thereto without departing from the scope of the present invention.
INDUSTRIAL APPLICABILITY
(68) The present invention is applicable to technical fields relating to a slot die coating apparatus, and more particularly, to a slot die coating apparatus which is capable of monitoring a state of a slot die and a state of ink applied to a substrate in real time and is capable of uniformly and thinly applying ink to the substrate.