EP0110074B1 - Multiple coating process for moving webs - Google Patents

Multiple coating process for moving webs Download PDF

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Publication number
EP0110074B1
EP0110074B1 EP83110161A EP83110161A EP0110074B1 EP 0110074 B1 EP0110074 B1 EP 0110074B1 EP 83110161 A EP83110161 A EP 83110161A EP 83110161 A EP83110161 A EP 83110161A EP 0110074 B1 EP0110074 B1 EP 0110074B1
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EP
European Patent Office
Prior art keywords
layer
coating
layers
viscosity
web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP83110161A
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German (de)
French (fr)
Other versions
EP0110074B2 (en
EP0110074A3 (en
EP0110074A2 (en
Inventor
Günther Dr. Koepke
Hans Dipl.-Ing. Frenken
Heinrich Dipl.-Ing. Bussmann
Kurt Browatzki
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Agfa Gevaert AG
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Agfa Gevaert AG
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Publication of EP0110074A2 publication Critical patent/EP0110074A2/en
Publication of EP0110074A3 publication Critical patent/EP0110074A3/en
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    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/007—Slide-hopper coaters, i.e. apparatus in which the liquid or other fluent material flows freely on an inclined surface before contacting the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/57—Three layers or more the last layer being a clear coat
    • B05D7/572—Three layers or more the last layer being a clear coat all layers being cured or baked together
    • B05D7/5723—Three layers or more the last layer being a clear coat all layers being cured or baked together all layers being applied simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/58—No clear coat specified
    • B05D7/582—No clear coat specified all layers being cured or baked together
    • B05D7/5823—No clear coat specified all layers being cured or baked together all layers being applied simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/06—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00—Sheets
    • B05D2252/02—Sheets of indefinite length
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7411—Beads or bead coating
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7481—Coating simultaneously multiple layers
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7492—Slide hopper for head or curtain coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S430/00—Radiation imagery chemistry: process, composition, or product thereof
    • Y10S430/136—Coating process making radiation sensitive element

Definitions

  • the invention relates to a method for applying, in a substantially mixture-free manner, a plurality of layers to a web which is continuously guided past a coating location, using a bead-forming coating device with a sliding surface coating head.
  • a multilayer process that is important for the photographic industry is the cascade coating process, in which one or more layers flow downwards simultaneously on an inclined surface and are fed over a bead of the continuously moving web over a short distance between a coating edge and a web. Processes of this type are also referred to in the literature as bead coating processes.
  • DE-A 2 712 055 describes a method in which a lowermost layer with a low viscosity and low wet application is applied under a layer with a higher viscosity and a higher layer thickness. Any layer package can then be built up on these two lower layers. It is required that the lower two layers should be made of the same materials or materials that do not show photographic effects when mixed together. On the other hand, the mixing of these layers is required during the casting.
  • the viscosities of the first layer should be between 1-10 mPas and the second layer between 10-100 mPas and the layer thicknesses of the first layer should be between 2-12 micrometers, the second layer between 15-30 micrometers.
  • mixing of the two layers due to vortex formation in the meniscus is disadvantageous, which means that there are possibilities of error in the photographic layer.
  • Another limitation of the method arises from the requirement that the first and second layers should either consist of the same material or of materials that do not produce any effects photographically. With this method, speeds of up to 3.55 m per s or 210 m / min can be achieved.
  • the publication DE-A 2 820 708 refers to the disadvantages of the process according to DE-A 2 712 055 mentioned above, in particular to the fact that the layers become slightly unstable when the viscosity is very low. This instability can be prevented to a certain extent by applying a vacuum under the bead between the caster and the web, but these instabilities limit the web speed.
  • it is therefore proposed to choose a material for the lower layer which is normally highly viscous and becomes low-viscosity and thin under shear stress and thus only has the desired low viscosity in the critical coating area, namely in the area of the bead or meniscus.
  • this process requires a special choice of material for the bottom layer, which is not in any case compatible with the photographic purpose of the entire layer structure.
  • the invention has for its object to provide a method of the type mentioned, with which it is easily possible to achieve a high coating speed without the layers being mixed with one another or the choice of substances for the layer structure being restricted, and this photographically effective layer package consists of layers that have a high solids content and a high viscosity and thus a special low wet application and a shortening of the drying time is made possible.
  • an acceleration layer with a viscosity range of 1-20 mPas and a layer thickness of 2-30 ⁇ m is arranged under one or more higher-viscosity layers in such a way that the bead formation over a gap width between Sliding surface coating head and web to be coated of 100-400 11 m, preferably between 100-200 ⁇ m, and that a vacuum of up to 8 mbar, preferably up to 3 mbar, is applied under the coating bead.
  • an acceleration layer with a viscosity of 2-10 mPas, preferably of 2-3 mPas and a layer thickness of 2.5-10 11 m, in particular of 2.5-5 1 1 m, is selected.
  • the lower, low-viscosity, so-called acceleration layer flows between the photographically effective layer package and the coating device and takes over the connection between the layer package and the webs which are continuously passed past the coating point and are to be coated.
  • the narrow gap distance remarkably smoothes the bead into an arc at high web speeds in which no eddies are created.
  • the web is evenly wetted, but mixing of the lowest acceleration layer with the layer or layers above is avoided.
  • the negative pressure under the gap between the web and the sliding surface casting head is kept very low and can in some cases be set to less than 1 mbar.
  • This type of process implementation makes it possible to use highly viscous solutions with a high solids content and thus a low layer thickness at high pouring speeds in the layer package and thus to save energy in the drying system.
  • a method which is particularly advantageous in relation to very high coating speeds is characterized in that a further low-viscosity layer is arranged as a spreading layer over the low-viscosity acceleration layer and over the higher-viscosity layer or layers.
  • This preferably has a viscosity of 1-10 mPas and a layer thickness of 5-20 11 m.
  • the spreading layer which is known per se from US Pat. No. 2,932,855, covers the layer package as the uppermost layer during its formation, the coating and after the coating.
  • the combination of the acceleration layer and the spreading layer enables excellent casting quality with layer packages that otherwise cannot be cast or can only be cast at low coating speeds. Furthermore, it was surprising that when the process was used in the cascade coating process, there was no mixing of the layers and therefore there was also no fear of a deterioration in the casting quality. It was also surprising that this acceleration layer can be set so thin with regard to layer thickness and viscosity that there were no adverse consequences in the further operations, such as when the layers solidified. Furthermore, it was surprising that by using a thin, low-viscosity spreading layer, highly viscous layer packets that tend to contract can be spread perfectly. Above all, however, it was surprising that when using the combination of acceleration layer and spreading layer with the cascade or bead coating process, casting speeds of 400 m / min (6-7 m / s) and more could be achieved.
  • These relationships can be estimated by a calculation. This can be done, for example, with two layers, one of which has a viscosity of 500 mPas and the other of which has a viscosity of 2 mPas.
  • the thicker layer should be applied to the web with a layer thickness of 100 ⁇ m at a web speed of 330 m / min.
  • the thinner layer may be applied as a second layer with 2 ⁇ m.
  • the thicker layer When running on the cascade, the thicker layer then has a speed of 7.9 m / min with a layer thickness of 5730 1 1 m.
  • the layer package is applied in reverse order, ie the layer with the viscosity of 2 mPas as the lower layer and the layer with the viscosity of 500 mPas as the upper layer, it can be seen that the upper layer of 500 mPas is about a factor of 2 is accelerated and reaches a speed of 16.84 m / min. This also explains the term acceleration layer.
  • the layer thickness of the highly viscous layer is reduced to 1809 1 1m, ie by a factor of 3. This means that in order to obtain the correct web application, it only has to be stretched by a factor of 18, whereas in the first case a stretching by the factor should be 57. This high stretching then leads to the breakage of the layer.
  • the bead coating process layer-specific and geometric requirements of the coating device must be combined. Particularly important for the bead coating process is the correct choice of the distance between the casting edge and the web and the choice of the vacuum under the bead.
  • a small distance between the coating device and the web is necessary.-This small distance is a prerequisite for achieving the good casting quality, as is the possible and necessary low negative pressure, which is down to zero when the coating is carried out according to the method according to the invention or can be reduced to almost zero.
  • a certain length of the last run-off area must not be undercut in order to enable the acceleration layer to work.
  • the type of layer composition for the acceleration layer i.e. any polymer solutions e.g. Gelatin, cellulose derivatives, polysaccharides or, in certain cases, wetting agent solutions can be used.
  • the layer thickness of these solutions can advantageously be chosen so that there is no adverse influence on the layer package - in the case of photographic materials, that is to say the photographically active emulsion layers.
  • FIG. 1 shows a section through a cascade pourer for carrying out the bead coating process.
  • 1 consists of several blocks 13, 14, which are arranged parallel to each other, screwed together and laterally delimited by end plates and include distributor chambers 5, through which the coating liquids 7, 8, 11 via feed channels and metering device (not shown) enter the caster and rise for distribution over the caster width in the column to the outlet slots 9.1 to 9.4.
  • the coating materials 8, 11 flow downward from the outlet slots on the inclined surfaces 3 and lie over the coating materials already flowing out one step below.
  • the acceleration layer 7, which is characteristic of this method, emerges from the exit slit 9. 1, which is closest to the cast bead or meniscus 10.
  • the layer package from the exit slots 9.2 to 9.4 rests on this acceleration layer 7 during the last part of the inclined surfaces 3.
  • the uppermost exit slot 9.4 above the planned layer structure from the slots 9.2 and 9.3 becomes the spreading layer 8 fed. It guarantees a perfectly spread position of the layer package by preventing the formation of an interface between the layer package and air.
  • acceleration layer 7, layer package 11 and spreading layer 8 bridges the meniscus (application bead) of the foundry edge 4 and is guided in such a way that only a minimal suction depth for the bead 10 is generated. It is thereby achieved that the photographically effective layer package 11 lies in a sheet on the substrate to be coated and the accelerating layer 7 between the coating edge 4 and the web 1 forms only a very small bead 10, which is completely sufficient to withstand even high coating speeds to achieve a very good wetting of the web 1 on the casting roll 6.
  • the acceleration layer 7 brings about a considerable reduction in the acceleration forces which act on the layer package 11 to be applied, so that the layer package 11 can be coated on the web 1 without qualitative impairment by the acceleration forces.
  • the spreading layer 8 shields the upper side of the layer package 11 at the interfaces from the ambient air and prevents the highly viscous layers 11 from contracting and thus smoothes the surface of the web coating 2.
  • the considerable and surprising advantage of the method according to the invention for the cascade pouring lies in the unexpected increase in the pouring speeds for highly viscous coating materials 11, which is further increased by the additional spreading layer. Casting qualities of high quality are achieved.
  • acceleration layer 7 and the spreading layer 8 require only small amounts of surface-active substances. In certain cases, these layers can also be used without surface-active substances.
  • the method of the invention can be used for coating coherent webs of paper, plastic, glass, wood and fabric.
  • the method is particularly suitable for pouring photographic emulsions onto photographic supports.
  • All conventional sheet materials can be used for the production of photographic materials, for example film sheets made of cellulose nitrate, cellulose triacetate, polyvinyl acetate, polycarbonate, polyethylene terephthalate, polystyrene and the like, as well as a wide variety of paper sheets with or without plastic coatings on their surfaces.
  • the process can be used to apply both photographic layers which contain silver halides as photosensitive compounds and those which contain photosensitive dyes or photoconductive zinc oxides and titanium dioxide.
  • the layers may also contain additives other than those known in the field of photographic layer production, e.g. Carbon black, matting agents such as silicon dioxide or polymeric development aids and the like.
  • the photographic layers can also contain various hydrophilic colloids as binders.
  • colloids are, in addition to proteins such as gelatin, cellulose derivatives, polysaccharides such as starch, sugar, dextran or agar. Synthetic polymers such as polyvinyl alcohol or polyacrylamide or mixtures of such binders can also be used.
  • the coating method of the invention is of course also applicable to the production of non-photographic layers, e.g. for the production of magnetic clay layers or other layers of paint and lacquer.
  • the layers to be applied had the following composition:
  • the coating speed limit was already reached at 50 m / min using a vacuum of 7 mbar. The casting quality was bad. A paper web with a PE coating was used as the material to be coated.
  • the layers to be applied had the following composition:
  • a pouring speed of 100 m / min was achieved, with a negative pressure of 6 mbar being applied.
  • the distance from the caster to the web was 175 ⁇ m.
  • the quality of the coating on the paper base with PE coating was good.
  • the pouring speed was 130 m / min at a negative pressure of 7 mbar.
  • the casting distance could be varied from 100-200 11m with good casting quality.
  • the pouring speed was 200 m / min at a negative pressure of 4 mbar and a casting distance of 175 ⁇ m.
  • the casting quality of the shift package was good.
  • a 6 layer caster was used for the bead application process.
  • the layers to be applied had the following composition:
  • the casting speed was 100 m / min at a negative pressure of 4 mbar and a casting distance of 175 ⁇ m.
  • the casting quality of the shift package was good.
  • a coating device according to FIG. 1 was used as a pourer for the bead application process for a three-layer casting.
  • the coating data for the individual layers were
  • Casting speeds of v 400 m / min and more could be achieved.
  • the negative pressure applied between the foundry edge 4 and the web 1 was only 1 mbar at a distance from the pouring edge 4 to the web 1 of 175 ⁇ m.
  • Cellulose triacetate was used as the web material. The casting quality was good.
  • a coating device according to FIG. 1 was used as a pourer for the bead application process for a four-layer casting.
  • the casting dates for the individual layers were:
  • a casting speed of v 400 m / min could be achieved.
  • the vacuum applied was 1 mbar with a pourer / web distance of 175 ⁇ m.
  • Cellulose triacetate was used as the base.
  • the casting quality was very good.
  • a caster according to FIG. 1 was used as the caster for the bead application process for a three-layer cast.
  • the casting dates of the individual layers were as follows:
  • a casting speed of v 250 m / min could be achieved.
  • the vacuum applied was 4.5 mbar at a pourer / web distance of 175 ⁇ m.
  • PE paper was used as a base. The casting quality was good.
  • the spreading layer enables a further improvement in the casting quality and an increase in the coating speed; no mixing occurred between the individual layers and between the acceleration layer and the layer above.
  • the spreading layer also does not mix with the underlying photographic layer.

Description

Die Erfindung betrifft ein Verfahren zum im wesentlichen vermischungsfreien Auftragen mehrerer Schichten auf eine an einer Beschichtungsstelle kontinuierlich vorbeigeführten Bahn unter Verwendung einer einen Wulst bildenden Beschichtungsvorrichtung mit einem Gleitflächenbeschichtungskopf.The invention relates to a method for applying, in a substantially mixture-free manner, a plurality of layers to a web which is continuously guided past a coating location, using a bead-forming coating device with a sliding surface coating head.

Ein für die photographische Industrie bedeutendes Mehrschichtenverfahren ist das KaskadenBeschichtungsverfahren, bei dem auf einer schrägen Fläche eine oder mehrere Schichten gleichzeitig abwärts fliessen und über einen geringen Abstand zwischen einer Beschichtungskante und einer Bahn über einen Wulst der kontinuierlich vorbeibewegten Bahn zugeführt werden. Verfahren dieser Art werden in der Literatur auch als Wulstbeschichtungsverfahren bezeichnet.A multilayer process that is important for the photographic industry is the cascade coating process, in which one or more layers flow downwards simultaneously on an inclined surface and are fed over a bead of the continuously moving web over a short distance between a coating edge and a web. Processes of this type are also referred to in the literature as bead coating processes.

Erfahrungen haben gezeigt, dass nach heutigen Ansprüchen mit dem Kaskaden- oder Wulstbeschichtungsverfahren nur Begiessgeschwindigkeiten erreicht werden können, die nach wirtschaftlichen Gesichtspunkten in vielen Fällen nicht ausreichend hoch sind. Insbesondere bei höheren Viskositäten der Beschichtungsmassen und bei höherer Feststoffkonzentration in den Beschichtungsmassen ist, wie die allgemeine Erfahrung zeigt, mit einem Absinken der Begiessgeschwindigkeit zu rechnen. Andererseits sind jedoch hohe Feststoffkonzentrationen und damit verbundene hohe Viskositäten insofern interessant, als damit die durch Trocknung zu entfernende Wassermenge erniedrigt und Trocknungsenergie gespart wird, so dass die Anlage kostengünstiger produzieren kann. Nicht zuletzt ergeben höhere Viskositäten auch bessere Begussqualitäten, da durch diese eine Minderung der an der Giessstelle erzielten guten Gussqualität im Verlauf der Erstarrung und Trocknung verhindert wird.Experience has shown that, according to today's demands, the cascade or bead coating process can only achieve casting speeds that are in many cases not sufficiently high from an economic point of view. As general experience shows, a drop in the pouring rate can be expected, especially when the viscosities of the coating compositions are higher and the solids concentration in the coating compositions is higher. On the other hand, however, high solids concentrations and the associated high viscosities are interesting in that they reduce the amount of water to be removed by drying and save drying energy, so that the plant can produce more cost-effectively. Last but not least, higher viscosities also result in better casting qualities, since these prevent the good casting quality achieved at the casting point from being reduced in the course of solidification and drying.

Es sind daher Anstrengungen unternommen worden, um diese Nachteile zu beseitigen und eine hohe Begiessgeschwindigkeit bei hohen Viskositäten zu erreichen. In der DE-A 2 712 055 wird ein Verfahren beschrieben, in welchem eine unterste Schicht mit niedriger Viskosität und geringem Nassauftrag unter eine Schicht mit höherer Viskosität und höherer Schichtdicke aufgebracht wird. Auf diese beiden unteren Schichten kann dann ein beliebiges Schichtpaket aufgebaut werden. Es wird gefordert, dass die unteren beiden Schichten aus gleichen Materialien oder solchen Materialien aufgebaut werden sollen, die keine photographischen Effekte zeigen, wenn sie sich miteinander mischen. Andererseits wird die Vermischung dieser Schichten bei dem Beguss gefordert. Nach der Beschreibung sollen die Viskositäten der ersten Schicht zwischen 1-10 mPas und der zweiten Schicht zwischen 10-100 mPas und die Schichtdicken der ersten Schicht zwischen 2-12 Micrometer, der zweiten Schicht zwischen 15-30 Micrometer liegen. Bei diesem Verfahren ist eine Vermischung der beiden Schichten durch eine Wirbelbildung im Meniskus nachteilig, wodurch Fehlermöglichkeiten in der photographischen Schicht gegeben sind. Eine weitere Einschränkung durch das Verfahren ergibt sich aus der Forderung, dass die erste und zweite Schicht entweder aus dem gleichen Material oder aus Materialien bestehen sollen, die photographisch keine Effekte hervorrufen. Mit diesem Verfahren werden nur Geschwindigkeiten bis zu 3,55 m pro s oder 210 m/min erreicht.Efforts have therefore been made to overcome these disadvantages and to achieve a high pouring rate with high viscosities. DE-A 2 712 055 describes a method in which a lowermost layer with a low viscosity and low wet application is applied under a layer with a higher viscosity and a higher layer thickness. Any layer package can then be built up on these two lower layers. It is required that the lower two layers should be made of the same materials or materials that do not show photographic effects when mixed together. On the other hand, the mixing of these layers is required during the casting. According to the description, the viscosities of the first layer should be between 1-10 mPas and the second layer between 10-100 mPas and the layer thicknesses of the first layer should be between 2-12 micrometers, the second layer between 15-30 micrometers. In this method, mixing of the two layers due to vortex formation in the meniscus is disadvantageous, which means that there are possibilities of error in the photographic layer. Another limitation of the method arises from the requirement that the first and second layers should either consist of the same material or of materials that do not produce any effects photographically. With this method, speeds of up to 3.55 m per s or 210 m / min can be achieved.

In der Druckschrift DE-A 2 820 708 wird auf die Nachteile des Verfahrens nach der oben genannten DE-A 2 712 055 hingewiesen, insbesondere darauf, dass bei sehr niedriger Viskosität die Schichten leicht instabil werden. Diese Instabilität kann bis zu einem gewissen Grad durch das Anlegen eines Vakuums unter dem Wulst zwischen Giesser und Bahn verhindert werden, jedoch begrenzen diese Instabilitäten die Bahngeschwindigkeit. In dieser Druckschrift wird daher vorgeschlagen, für die untere Schicht ein Material zu wählen, das normalerweise hochviskos ist und unter Scherbelastung niedrigviskos und dünnflüssig wird und somit nur im kritischen Beschichtungsbereich, nämlich in Bereich des Wulstes oder Meniskus, die erwünschte niedrige Viskosität besitzt. Dieses Verfahren erfordert jedoch eine besondere Materialauswahl für die unterste Schicht, die nicht in jedem Fall für den photographischen Zweck des gesamten Schichtaufbaus verträglich ist.The publication DE-A 2 820 708 refers to the disadvantages of the process according to DE-A 2 712 055 mentioned above, in particular to the fact that the layers become slightly unstable when the viscosity is very low. This instability can be prevented to a certain extent by applying a vacuum under the bead between the caster and the web, but these instabilities limit the web speed. In this publication it is therefore proposed to choose a material for the lower layer which is normally highly viscous and becomes low-viscosity and thin under shear stress and thus only has the desired low viscosity in the critical coating area, namely in the area of the bead or meniscus. However, this process requires a special choice of material for the bottom layer, which is not in any case compatible with the photographic purpose of the entire layer structure.

In der englichen Patentschrift 2 070 459 wird ein weiteres Verfahren beschrieben, welches das Verhältnis der Viskositäten der ersten und zweiten Schicht zueinander in engen Grenzen festlegt und zwar sollen die Viskositäten der Schichten das Verhältnis 111 = (0,9-1,1)rlz besitzen, wobei sich die Viskositäten dieser beiden Schichten ausserdem noch unter der Einwirkung von Scherkräften in verschiedener Weise so verändern sollen, dass die Viskosität der ersten Schicht stärker verringert wird, als die der zweiten Schicht. Auch bei diesem Verfahren ist die Wahl der Schichtzusammensetzung nicht mehr frei.In the narrow patent specification 2 070 459 a further method is described, which specifies the ratio of the viscosities of the first and second layers to one another within narrow limits, specifically the viscosities of the layers should have the ratio 111 = (0.9-1.1) r lz have, the viscosities of these two layers should also change under the action of shear forces in different ways so that the viscosity of the first layer is reduced more than that of the second layer. With this method too, the choice of layer composition is no longer free.

Schliesslich ist es aus der US-A-3 573 965 bekannt, beim Giessen von Schichten mit einem Extrudergiesser Beschichtungsflüssigkeiten mit einer Viskosität von 20 mPas vorzusehen und zwischen den Rändern der einzelnen Auslassöffnungen, die am Extrudergiesser für jede einzelne Schicht vorhanden sind, und der Bahn einen Abstand von ca. 300 11m vorzusehen. Derartige Extrudergiesser lassen jedoch keinen Antrag geschlossener Schichtpakete an die Bahn zu; vielmehr findet dort der Schichtaufbau erst auf der Bahn statt.Finally, it is known from US-A-3,573,965 to provide coating liquids with a viscosity of 20 mPas when casting layers with an extruder caster and between the edges of the individual outlet openings which are present on the extruder caster for each individual layer and the web provide a distance of approx. 300 11m. Such extrusion casters, however, do not allow closed layers to be applied to the web; rather, the layer build-up takes place there only on the train.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren der eingangs genannten Art zu schaffen, mit dem es auf einfache Weise möglich ist, eine hohe Beschichtungsgeschwindigkeit zu erreichen, ohne dass die Schichten miteinander vermischt werden oder die Wahl der Substanzen zum Schichtaufbau eingeschränkt ist und das photographisch wirksame Schichtpaket aus Schichten besteht, die einen hohen Feststoffanteil und eine hohe Viskosität besitzen und somit ein besonders geringer Nassauftrag und eine Verkürzung der Trocknungszeit ermöglicht wird.The invention has for its object to provide a method of the type mentioned, with which it is easily possible to achieve a high coating speed without the layers being mixed with one another or the choice of substances for the layer structure being restricted, and this photographically effective layer package consists of layers that have a high solids content and a high viscosity and thus a special low wet application and a shortening of the drying time is made possible.

Ausgehend von einem Verfahren der eingangs genannten Art wird die Aufgabe erfindungsgemäss dadurch gelöst, dass unter einer oder mehren höherviskosen Schichten eine Beschleunigungsschicht mit einem Viskositätsbereich von 1-20 mPas und einer Schichtdicke von 2-30 µm angeordnet wird, dass die Wulstbildung über eine Spaltbreite zwischen Gleitflächenbeschichtungskopf und zu beschichtender Bahn von 100-400 11m, bevorzugt zwischen 100-200 µm durchgeführt wird, und dass unter dem Beschichtungswulst eine Unterdruck bis zu 8 mbar, vorzugsweise bis zu 3 mbar, angelegt wird.Starting from a method of the type mentioned at the outset, the object is achieved according to the invention in that an acceleration layer with a viscosity range of 1-20 mPas and a layer thickness of 2-30 µm is arranged under one or more higher-viscosity layers in such a way that the bead formation over a gap width between Sliding surface coating head and web to be coated of 100-400 11 m, preferably between 100-200 µm, and that a vacuum of up to 8 mbar, preferably up to 3 mbar, is applied under the coating bead.

Bei einer bevorzugten Durchführung des Verfahrens wird eine Beschleunigungsschicht mit einer Viskosität von 2-10 mPas, bevorzugt von 2-3 mPas und einer Schichtdicke von 2,5-10 11m, insbesondere von 2,5-5 11m gewählt.In a preferred implementation of the method, an acceleration layer with a viscosity of 2-10 mPas, preferably of 2-3 mPas and a layer thickness of 2.5-10 11 m, in particular of 2.5-5 1 1 m, is selected.

Die untere niedrigviskose sogenannte Beschleunigungsschicht fliesst zwischen dem photographisch wirksamen Schichtpaket und der Beschichtungseinrichtung und übernimmt die Verbindung zwischen dem Schichtpaket und den kontinuierlich an der Beschichtungsstelle vorbeigeführten Bahnen, die zu beschichten sind.The lower, low-viscosity, so-called acceleration layer flows between the photographically effective layer package and the coating device and takes over the connection between the layer package and the webs which are continuously passed past the coating point and are to be coated.

Der enge Spaltabstand glättet in erstaunlicher Weise bei hohen Bahngeschwindigkeiten den Wulst zu einem Bogen, in dem keine Wirbel entstehen. Die Bahn wird gleichmässig benetzt, aber eine Vermischung der untersten Beschleunigungsschicht mit der oder den darüberliegenden Schichten wird vermieden. Der Unterdruck unter dem Spalt zwischen der Bahn und dem Gleitflächengiesskopf wird sehr gering gehalten und kann in manchen Fällen auf weniger als 1 mbar eingestellt werden.The narrow gap distance amazingly smoothes the bead into an arc at high web speeds in which no eddies are created. The web is evenly wetted, but mixing of the lowest acceleration layer with the layer or layers above is avoided. The negative pressure under the gap between the web and the sliding surface casting head is kept very low and can in some cases be set to less than 1 mbar.

Diese Art der Verfahrensdurchführung ermöglicht es, im Schichtpaket hochviskose Lösungen mit hohem Feststoffgehalt und somit geringer Schichtdicke bei hohen Begiessgeschwindigkeiten zu verwenden und damit Energie in der Trocknungsanlage einzusparen.This type of process implementation makes it possible to use highly viscous solutions with a high solids content and thus a low layer thickness at high pouring speeds in the layer package and thus to save energy in the drying system.

Ein besonders in Bezug auf sehr hohe Beschichtungsgeschwindigkeiten vorteilhaftes Verfahren zeichnet sich dadurch aus, dass über der niedrigviskosen Beschleunigungsschicht und über der bzw. den höherviskosen Schichten eine weitere niedrigviskose Schicht als Spreitungsschicht angeordnet wird. Diese weist vorzugsweise eine Viskosität von 1-10 mPas und eine Schichtdicke von 5-20 11m auf. Dabei deckt die Spreitungsschicht, die für sich aus der US-A-2 932 855 vorbekannt ist, als oberste Schicht das Schichtpaket während dessen Entstehung, der Beschichtung und nach der Beschichtung ab.A method which is particularly advantageous in relation to very high coating speeds is characterized in that a further low-viscosity layer is arranged as a spreading layer over the low-viscosity acceleration layer and over the higher-viscosity layer or layers. This preferably has a viscosity of 1-10 mPas and a layer thickness of 5-20 11 m. The spreading layer, which is known per se from US Pat. No. 2,932,855, covers the layer package as the uppermost layer during its formation, the coating and after the coating.

Überraschenderweise zeigte sich, dass die Kombination aus Beschleunigungsschicht und Spreitungsschicht eine hervorragende Begussqualität ermöglicht mit Schichtpaketen, die sonst nicht oder nur bei niedrigen Beschichtungsgeschwindigkeiten zu vergiessen sind. Weiterhin war überraschend, dass bei Anwendung des Verfahrens in dem Kaskadenbeschichtungsverfahren keinerlei Vermischung der Schichten eintrat und somit ebenfalls keine Verschlechterung der Begussqualität zu befürchten war. Weiterhin war überraschend, dass diese Beschleunigungsschicht so dünn hinsichtlich Schichtdicke und Viskosität eingestellt werden kann, dass nachteilige Folgen in den weiteren Arbeitsgängen, wie bei der Erstarrung der Schichten, nicht auftraten. Weiterhin war überraschend, dass durch den Einsatz einer dünnen niedrigviskosen Spreitungsschicht hochviskose Schichtpakete, die zum Zusammenziehen neigen, einwandfrei gespreitet werden können. Vor allem war aber überraschend, dass bei Anwendung der Kombination aus Beschleunigungsschicht und Spreitungsschicht mit dem Kaskaden- oder Wulstbeschichtungsverfahren Begiessgeschwindigkeiten von 400 m/min (6-7 m/s) und mehr erreicht werden konnten.Surprisingly, it was found that the combination of the acceleration layer and the spreading layer enables excellent casting quality with layer packages that otherwise cannot be cast or can only be cast at low coating speeds. Furthermore, it was surprising that when the process was used in the cascade coating process, there was no mixing of the layers and therefore there was also no fear of a deterioration in the casting quality. It was also surprising that this acceleration layer can be set so thin with regard to layer thickness and viscosity that there were no adverse consequences in the further operations, such as when the layers solidified. Furthermore, it was surprising that by using a thin, low-viscosity spreading layer, highly viscous layer packets that tend to contract can be spread perfectly. Above all, however, it was surprising that when using the combination of acceleration layer and spreading layer with the cascade or bead coating process, casting speeds of 400 m / min (6-7 m / s) and more could be achieved.

Eine Erklärung für dieses Verhalten kann vielleicht so gegeben werden:

  • Bei hohen Beschichtungsgeschwindigkeiten wird das auf der Kaskade ablaufende Schichtpaket auf der kurzen Strecke des Wulstes oder des Meniskus d.h. des Abstandes zwischen Giesser und Bahn sehr hoch beschleunigt und hierbei verstreckt. Dabei wirken auf das Schichtpaket sehr grosse Kräfte ein, die bei höheren Geschwindigkeiten zu einem teilweisen Zerreissen des Schichtpaketes bzw. zu Instabilitäten in dem Schichtpaket führen. Durch die Beschleunigungsschicht wird nun in einem ersten Effekt erreicht, dass die Geschwindigkeit des Schichtpaketes auf der Ablauffläche der Kaskade durch die Beschleunigungsschicht stark erhöht wird. In einem zweiten Effekt werden die beim Auftreffen auf die vorbeibewegten Bahnen auftretenden Kräften durch die Beschleunigungsschicht aufgefangen, beziehungsweise nur zeitlich verzögert wirksam. Durch diese Effekte liesse sich auch die gute Gussqualität erklären, denn das Schichtpaket, das für das photographische Material qualitätsbestimmend ist, wird durch keinerlei Einwirkung im Meniskus oder bei Berührung mit der Bahn in seiner Qualität gestört.
An explanation for this behavior can perhaps be given as follows:
  • At high coating speeds, the layer package running on the cascade is accelerated and stretched very high over the short distance of the bead or the meniscus, ie the distance between the caster and the web. Very large forces act on the layer package, which at higher speeds lead to a partial tearing of the layer package or to instabilities in the layer package. The first effect of the acceleration layer is that the speed of the layer package on the running surface of the cascade is greatly increased by the acceleration layer. In a second effect, the forces that occur when the webs that move past it are absorbed by the acceleration layer, or act only with a time delay. These effects could also explain the good casting quality, because the quality of the layer package, which determines the quality of the photographic material, is not disturbed by any influence in the meniscus or by contact with the web.

Diese Verhältnisse lassen sich durch eine Berechnung abschätzen. Dies kann beispielsweise mit zwei Schichten, wovon die eine eine Viskosität von 500 mPas und die andere eine Viskosität von 2 mPas hat, geschehen. Die dickere Schicht soll auf die Bahn mit einer Schichtdicke von 100 µm mit einer Bahngeschwindigkeit von 330 m/min aufgetragen werden. Die dünnere Schicht möge als zweite Schicht mit 2 µm aufgetragen werden. Es ergibt sich dann beim Ablauf auf der Kaskade für die dickere Schicht eine Geschwindigkeit von 7,9 m/min bei einer Schichtdicke von 5730 11m. Trägt man das Schichtpaket in umgekehrter Folge auf, d.h. die Schicht mit der Viskosität 2 mPas als die untere Schicht und die Schicht mit der Viskosität 500 mPas als die obere Schicht, so zeigt sich, dass die obere Schicht von 500 mPas etwa um den Faktor 2 beschleunigt wird und eine Geschwindigkeit von 16,84 m/min erreicht. Damit wird auch die Bezeichnung Beschleunigungsschicht erklärt.These relationships can be estimated by a calculation. This can be done, for example, with two layers, one of which has a viscosity of 500 mPas and the other of which has a viscosity of 2 mPas. The thicker layer should be applied to the web with a layer thickness of 100 µm at a web speed of 330 m / min. The thinner layer may be applied as a second layer with 2 µm. When running on the cascade, the thicker layer then has a speed of 7.9 m / min with a layer thickness of 5730 1 1 m. If the layer package is applied in reverse order, ie the layer with the viscosity of 2 mPas as the lower layer and the layer with the viscosity of 500 mPas as the upper layer, it can be seen that the upper layer of 500 mPas is about a factor of 2 is accelerated and reaches a speed of 16.84 m / min. This also explains the term acceleration layer.

Weiterhin wird die Schichtdicke der hochviskosen Schicht auf 1809 11m reduziert, d. h. etwa um den Faktor 3. Dies bedeutet, dass diese Schicht, um den richtigen Bahnauftrag zu ergeben nur noch um den Faktor 18 verstreckt werden muss, wohingegen im ersten Fall eine Verstreckung um den Faktor 57 erfolgen müsste. Diese hohe Verstreckung führt dann zum Bruch der Schicht.Furthermore, the layer thickness of the highly viscous layer is reduced to 1809 1 1m, ie by a factor of 3. This means that in order to obtain the correct web application, it only has to be stretched by a factor of 18, whereas in the first case a stretching by the factor should be 57. This high stretching then leads to the breakage of the layer.

Im Wulstbeschichtungsverfahren müssen schichtspezifische und geometrische Voraussetzungen der Beschichtungsvorrichtung kombiniert werden. Besonders wichtig für das Wulstbeschichtungsverfahren ist die richtige Wahl des Abstandes zwischen der Giesserkante und der Bahn und die Wahl des Unterdruckes unter dem Wulst. Für die Wulstbeschichtung nach dem vorliegenden Verfahren ist ein kleiner Abstand zwischen Beschichtungseinrichtung und Bahn notwendig.-Dieser kleine Abstand ist zur Erreichung der guten Gussqualität Voraussetzung ebenso wie der damit mögliche und erforderliche geringe Unterdruck, der bei Ausführung der Beschichtung nach dem erfindungsgemässen Verfahren bis auf Null oder fast bis auf Null reduziert werden kann. Weiterhin darf eine bestimmte Länge der letzten Ablauffläche nicht unterschritten werden, um der Beschleunigungsschicht ihre Wirkung zu ermöglichen. Durch die Wahl des kleinen Abstandes zwischen Bahn und Giesseinrichtung ist aber die Möglichkeit gegeben, die Art der Schichtzusammensetzung für die Beschleunigungsschicht frei zu wählen, d.h. es können beliebige Polymerlösungen z.B. Gelatine, Cellulosederivate, Polysaccharide oder auch in bestimmten Fällen Netzmittellösungen verwendet werden. Die Schichtstärke dieser Lösungen kann hierbei vorteilhaft so gewählt werden, dass eine nachteilige Beeinflussung des Schichtpaketes - bei photographischen Materialien also der photographisch wirksamen Emulsionsschichten - nicht erfolgt.In the bead coating process, layer-specific and geometric requirements of the coating device must be combined. Particularly important for the bead coating process is the correct choice of the distance between the casting edge and the web and the choice of the vacuum under the bead. For the bead coating according to the present method, a small distance between the coating device and the web is necessary.-This small distance is a prerequisite for achieving the good casting quality, as is the possible and necessary low negative pressure, which is down to zero when the coating is carried out according to the method according to the invention or can be reduced to almost zero. Furthermore, a certain length of the last run-off area must not be undercut in order to enable the acceleration layer to work. However, by choosing the small distance between the web and the casting device, it is possible to freely choose the type of layer composition for the acceleration layer, i.e. any polymer solutions e.g. Gelatin, cellulose derivatives, polysaccharides or, in certain cases, wetting agent solutions can be used. The layer thickness of these solutions can advantageously be chosen so that there is no adverse influence on the layer package - in the case of photographic materials, that is to say the photographically active emulsion layers.

Der Effekt der Spreitungsschicht, die eine weitere Erhöhung der Beschichtungsgeschwindigkeit, insbesondere bei hohen Viskositäten, erlaubt, lässt sich folgendermassen erläutern: Hochviskose Giesslösungen haben die Eigenschaft, sich unter Einwirkung der Oberflächenspannung zusammenzuziehen. Diese Tendenz kann abgebaut werden durch die dünne Spreitungsschicht, die die Oberfläche der hochviskosen Schichten abdeckt.The effect of the spreading layer, which allows a further increase in the coating speed, especially at high viscosities, can be explained as follows: Highly viscous casting solutions have the property of contracting under the influence of surface tension. This tendency can be reduced by the thin spreading layer that covers the surface of the highly viscous layers.

Im folgenden wird das Verfahren zur Erstellung von mehrschichtigen Beschichtungen anhand einer Zeichnung an dem Beispiel der Beschichtung photographischer Materialien näher erläutert.In the following, the method for producing multilayer coatings is explained in more detail using a drawing using the example of coating photographic materials.

Fig.1 zeigt einen Schnitt durch einen Kaskadengiesser zur Durchführung des Wulstbeschichtungsverfahrens.1 shows a section through a cascade pourer for carrying out the bead coating process.

Der Kaskadengiesser nach Fig. 1 besteht in bekanntem Aufbau aus mehreren Blöcken 13, 14, die parallel zueinander angeordnet, miteinander verschraubt und durch Stirnplatten seitlich begrenzt sind und Verteilerkammern 5 einschliessen, durch die die Beschichtungsflüssigkeiten 7, 8, 11 über Zuführkanäle und Dosiereinrichtung (nicht dargestellt) in den Giesser eintreten und zur Verteilung über die Giesserbreite in Spalte zu den Austrittsschlitzen 9,1 bis 9,4 aufsteigen.1 consists of several blocks 13, 14, which are arranged parallel to each other, screwed together and laterally delimited by end plates and include distributor chambers 5, through which the coating liquids 7, 8, 11 via feed channels and metering device (not shown) enter the caster and rise for distribution over the caster width in the column to the outlet slots 9.1 to 9.4.

Die Beschichtungsmaterialien 8, 11 fliessen aus den Austrittsschlitzen auf den geneigten Flächen 3 nach unten und legen sich über die bereits unten, eine Stufe tiefer ausfliessenden Beschichtungsmaterialien. Aus dem Austrittsschlitz 9,1, der dem Begiesswulst oder Meniskus 10 am nächsten liegt, tritt die für dieses Verfahren charakteristische Beschleunigungsschicht 7 aus. Das Schichtpaket aus den Austrittschlitzen 9,2 bis 9,4 ruht während des letzten Teils der geneigten Flächen 3 auf dieser Beschleunigungsschicht 7. Aus dem obersten Austrittsschlitz 9,4 über dem geplanten Schichtaufbau aus den Schlitzen 9,2 und 9,3 wird die Spreitungsschicht 8 zugeführt. Sie garantiert eine einwandfreie gespreitete Lage des Schichtpaketes dadurch, dass sie die Entstehung einer Grenzfläche zwischen Schichtpaket und Luft verhindert. Der gesamte Aufbau aus Beschleunigungsschicht 7, Schichtpaket 11 und Spreitungsschicht 8 überbrückt den Meniskus (Antragswulst) der Giesserkante 4 und wird so geführt, dass nur eine minimale Einsaugtiefe für den Wulst 10 erzeugt wird. Dadurch wird erreicht, dass das photographisch wirksame Schichtpaket 11 sich in einem Bogen auf die zu beschichtete Unterlage auflegt und die Beschleunigungsschicht 7 zwischen der Beschichtungskante 4 und der Bahn 1 nur einen sehr geringen Wulst 10 bildet, der vollkommen ausreichend ist, um auch bei hohen Beschichtungsgeschwindigkeiten eine sehr gute Benetzung der Bahn 1 auf der Giesswalze 6 zu erreichen. Während der Benetzung der Bahn 1 leistet die Beschleunigungsschicht 7 eine erhebliche Verringerung der Beschleunigungskräfte, die auf das aufzutragende Schichtpaket 11 wirken, so dass das Schichtpaket 11 ohne qualitative Beeinträchtigung durch die Beschleunigungskräfte auf die Bahn 1 beschichtet werden kann. Die Spreitungsschicht 8 schirmt die obere Seite des Schichtpaketes 11 an den Grenzflächen gegen die Umgebungsluft ab und verhindert das Zusammenziehen der hochviskosen Schichten 11 und glättet somit die Oberfläche der Bahnbeschichtung 2.The coating materials 8, 11 flow downward from the outlet slots on the inclined surfaces 3 and lie over the coating materials already flowing out one step below. The acceleration layer 7, which is characteristic of this method, emerges from the exit slit 9. 1, which is closest to the cast bead or meniscus 10. The layer package from the exit slots 9.2 to 9.4 rests on this acceleration layer 7 during the last part of the inclined surfaces 3. The uppermost exit slot 9.4 above the planned layer structure from the slots 9.2 and 9.3 becomes the spreading layer 8 fed. It guarantees a perfectly spread position of the layer package by preventing the formation of an interface between the layer package and air. The entire structure of acceleration layer 7, layer package 11 and spreading layer 8 bridges the meniscus (application bead) of the foundry edge 4 and is guided in such a way that only a minimal suction depth for the bead 10 is generated. It is thereby achieved that the photographically effective layer package 11 lies in a sheet on the substrate to be coated and the accelerating layer 7 between the coating edge 4 and the web 1 forms only a very small bead 10, which is completely sufficient to withstand even high coating speeds to achieve a very good wetting of the web 1 on the casting roll 6. During the wetting of the web 1, the acceleration layer 7 brings about a considerable reduction in the acceleration forces which act on the layer package 11 to be applied, so that the layer package 11 can be coated on the web 1 without qualitative impairment by the acceleration forces. The spreading layer 8 shields the upper side of the layer package 11 at the interfaces from the ambient air and prevents the highly viscous layers 11 from contracting and thus smoothes the surface of the web coating 2.

Der erhebliche und überraschende Vorteil des Verfahrens nach der Erfindung liegt für den Kaskadenbeguss in der unerwarteten Steigerung der Begiessgeschwindigkeiten für hochviskose Beschichtungsmaterialien 11, die durch die zusätzliche Spreitungsschicht noch weiter gesteigert wird. Dabei werden Begussqualitäten von hoher Qualität erreicht.The considerable and surprising advantage of the method according to the invention for the cascade pouring lies in the unexpected increase in the pouring speeds for highly viscous coating materials 11, which is further increased by the additional spreading layer. Casting qualities of high quality are achieved.

Weiterhin zeigt sich überraschenderweise, dass oberflächenaktive Stoffe in den photographisch aktiven Beschichtungsmaterialien 11 nicht mehr erforderlich sind, wodurch Kosteneinsparungen möglich sind.Furthermore, it has surprisingly been found that surface-active substances are no longer required in the photographically active coating materials 11, as a result of which cost savings are possible.

Selbst die Beschleunigungsschicht 7 und die Spreitungsschicht 8 benötigen nur geringe Mengen an oberflächenaktiven Stoffen. In bestimmten Fällen können auch diese Schichten ohne oberflächenaktive Stoffe eingesetzt werden.Even the acceleration layer 7 and the spreading layer 8 require only small amounts of surface-active substances. In certain cases, these layers can also be used without surface-active substances.

Mit diesem Verfahren können Bahnen mit einer Vielzahl von z. B. zwölf oder mehr Schichten mit verschiedensten Beschichtungsmaterialien beschichtet werden.With this method, webs with a variety of z. B. twelve or more layers with various coating materials can be coated.

Prinzipiell lässt sich das Verfahren der Erfindung zur Beschichtung zusammenhängender Bahnen aus Papier, Kunststoff, Glas, Holz und Gewebe anwenden. Besonders eignet sich das Verfahren, wie bereits erwähnt, zum Beguss photographischer Schichtträger mit photographischen Emulsionen.In principle, the method of the invention can be used for coating coherent webs of paper, plastic, glass, wood and fabric. As already mentioned, the method is particularly suitable for pouring photographic emulsions onto photographic supports.

Zur Herstellung photographischer Materialien können alle üblichen bahnförmigen Materialien verwendet werden, zum Beispiel Filmbahnen aus Cellulosenitrat, Cellulosetriacetat, Polyvinylacetat, Polycarbonat, Polyethylenterephthalat, Polystyrol und dergleichen, sowie die verschiedensten Papierbahnen mit oder ohne Kunststoffbeschichtungen auf ihren Oberflächen.All conventional sheet materials can be used for the production of photographic materials, for example film sheets made of cellulose nitrate, cellulose triacetate, polyvinyl acetate, polycarbonate, polyethylene terephthalate, polystyrene and the like, as well as a wide variety of paper sheets with or without plastic coatings on their surfaces.

Nach dem Verfahren können sowohl photographische Schichten aufgetragen werden, die als lichtempfindliche Verbindungen Silberhalogenide enthalten als auch solche, die lichtempfindliche Farbstoffe oder photoleitfähige Zinkoxide und Titandioxid enthalten. Die Schichten können auch andere Zusätze enthalten, als die auf dem Gebiet der Herstellung photographischer Schichten bekannten, z.B. Russ, Mattierungsmittel wie Siliziumdioxid oder polymere Entwicklungshilfsmittel und dergleichen.The process can be used to apply both photographic layers which contain silver halides as photosensitive compounds and those which contain photosensitive dyes or photoconductive zinc oxides and titanium dioxide. The layers may also contain additives other than those known in the field of photographic layer production, e.g. Carbon black, matting agents such as silicon dioxide or polymeric development aids and the like.

Die photographischen Schichten können auch verschiedene hydrophile Kolloide als Bindemittel enthalten. Beispiele für derartige Kolloide sind ausser Proteinen wie Gelatine, Cellulosederivate, Polysaccharide, wie Stärke, Zucker, Dextran oder Agar-Agar. Weiter sind synthetische Polymere, wie Polyvinylalkohol oder Polyacrylamid oder Mischungen solcher Bindemittel anwendbar. Darüber hinaus ist das Beschichtungsverfahren der Erfindung selbstverständlich auch für die Herstellung nichtphotographischer Schichten anwendbar, wie z.B. zur Herstellung von Magnettonschichten oder anderer Farb- und Lackschichten.The photographic layers can also contain various hydrophilic colloids as binders. Examples of such colloids are, in addition to proteins such as gelatin, cellulose derivatives, polysaccharides such as starch, sugar, dextran or agar. Synthetic polymers such as polyvinyl alcohol or polyacrylamide or mixtures of such binders can also be used. In addition, the coating method of the invention is of course also applicable to the production of non-photographic layers, e.g. for the production of magnetic clay layers or other layers of paint and lacquer.

Anhand von Beispielen sollen einige Möglichkeiten von Beschichtungen dargestellt werden. Die Beispiele sind nur eine Auswahl und können daher nur einen Überblick geben, der keinen Anspruch auf Vollständigkeit erhebt. Die in den nachfolgenden Beispielen gezeigten Tabellen verwenden Symbole mit folgender Bedeutung:

  • 11 = Viskosität [mPas]
  • σ = Oberflächenspannung [m N/m]
  • 5 = Nassauftrag auf der Bahn [11m]
  • v = Bahngeschwindigkeit [m/min]
Some examples of coatings are to be presented using examples. The examples are only a selection and can therefore only give an overview that does not claim to be complete. The tables shown in the following examples use symbols with the following meaning:
  • 11 = viscosity [mPas]
  • σ = surface tension [m N / m]
  • 5 = wet application on the web [ 11 m]
  • v = web speed [m / min]

Beispiel 1example 1

Eine Beschichtungseinrichtung nach Fig. 1 wurde für das Wulstantragsverfahren eingesetzt. Die anzutragenden Schichten zeigten folgende Zusammensetzung:

Figure imgb0001
1 was used for the bead application process. The layers to be applied had the following composition:
Figure imgb0001

Die Beschichtungsgeschwindigkeitsgrenze wurde bereits bei 50 m/min erreicht, wobei ein Unterdruck von 7 mbar verwendet wurde. Die Begussqualität war schlecht. Als zu beschichtendes Material wurde eine Papierbahn mit PE-Beschichtung verwendet.The coating speed limit was already reached at 50 m / min using a vacuum of 7 mbar. The casting quality was bad. A paper web with a PE coating was used as the material to be coated.

Beispiel 2Example 2

Eine Beschichtungseinrichtung nach Fig. 1 wurde für das Wulstantragsverfahren eingesetzt. Die anzutragenden Schichten zeigten folgende Zusammensetzung:

Figure imgb0002
1 was used for the bead application process. The layers to be applied had the following composition:
Figure imgb0002

Es konnte eine Begiessgeschwindigkeit von 100 m/min erreicht werden, wobei ein Unterdruck von 6 mbar angelegt wurde. Der Abstand der Giesseinrichtung von der Bahn betrug 175 µm. Die Qualität der Beschichtung auf der Papierunterlage mit PE-Beschichtung war gut.A pouring speed of 100 m / min was achieved, with a negative pressure of 6 mbar being applied. The distance from the caster to the web was 175 µm. The quality of the coating on the paper base with PE coating was good.

Beispiel 3Example 3

Ein Giesser nach Fig. 1 wurde für das Wulstantragsverfahren eingesetzt. Die angetragenen Schichten zeigten folgende Zusammensetzung:

Figure imgb0003
1 was used for the bead application process. The applied layers showed the following composition:
Figure imgb0003

Die Begiessgeschwindigkeit betrug 130 m/min bei einem Unterdruck von 7 mbar. Der Giesserabstand konnte von 100-200 11m variiert werden bei guter Gussqualität.The pouring speed was 130 m / min at a negative pressure of 7 mbar. The casting distance could be varied from 100-200 11m with good casting quality.

Beispiel 4Example 4

Ein Giesser nach Fig. 1 wurde für das Wulstantragsverfahren eingesetzt. Die angetragenen Schichten zeigten folgende Zusammensetzung:

Figure imgb0004
1 was used for the bead application process. The applied layers showed the following composition:
Figure imgb0004

Die Begiessgeschwindigkeit betrug 200 m/min bei einem Unterdruck von 4 mbar und einem Giesserabstand von 175 µm. Die Begussqualität des Schichtpaketes war gut.The pouring speed was 200 m / min at a negative pressure of 4 mbar and a casting distance of 175 µm. The casting quality of the shift package was good.

Beispiel 5Example 5

Ein Giesser für 6 Schichten wurde für das Wulstantragsverfahren eingesetzt. Die anzutragenden Schichten zeigten folgende Zusammensetzung:

Figure imgb0005
Die Begiessgeschwindigkeit betrug 100 m/min bei einem Unterdruck von 4 mbar und einem Giesserabstand von 175 um. Die Begussqualität des Schichtpaketes war gut.A 6 layer caster was used for the bead application process. The layers to be applied had the following composition:
Figure imgb0005
 The casting speed was 100 m / min at a negative pressure of 4 mbar and a casting distance of 175 µm. The casting quality of the shift package was good.

Beispiel 6Example 6

Eine Beschichtungseinrichtung nach Fig. 1 wurde als Giesser für das Wulstantragsverfahren für einen dreischichtigen Beguss verwendet. Die Beschichtungsdaten für die einzelnen Schichten waren

Figure imgb0006
A coating device according to FIG. 1 was used as a pourer for the bead application process for a three-layer casting. The coating data for the individual layers were
Figure imgb0006

Es konnten Begiessgeschwindigkeiten von v = 400 m/min und mehr erreicht werden. Der angelegte Unterdruck zwischen der Giesserkante 4 und der Bahn 1 betrug nur 1 mbar bei einem Abstand der Giesskante 4 zur Bahn 1 von 175 µm. Als Bahnmaterial wurde Cellulosetriacetat verwendet. Die Begussqualität war gut.Casting speeds of v = 400 m / min and more could be achieved. The negative pressure applied between the foundry edge 4 and the web 1 was only 1 mbar at a distance from the pouring edge 4 to the web 1 of 175 μm. Cellulose triacetate was used as the web material. The casting quality was good.

Beispiel 7Example 7

Für eine Beschichtung wie unter Beispiel 6 wurde als Bahnmaterial ein mit Polyethylen beschichtetes Papier verwendet. Die Begiessgeschwindigkeit war v = 400 m/min. Es zeigte sich keine Abreisstendenz der Beschichtung. Die Begussqualität war gut.For a coating as in Example 6, a paper coated with polyethylene was used as the web material. The pouring speed was v = 400 m / min. There was no tendency for the coating to tear off. The casting quality was good.

Beispiel 8Example 8

Eine Beschichtungseinrichtung nach Fig. 1 wurde als Giesser für das Wulstantragsverfahren für einen vierschichtigen Beguss verwendet. Die Begussdaten für die einzelnen Schichten waren:A coating device according to FIG. 1 was used as a pourer for the bead application process for a four-layer casting. The casting dates for the individual layers were:

Figure imgb0007
Es konnte eine Begiessgeschwindigkeit von v = 400 m/min erreicht werden. Der angelegte Unterdruck betrug 1 mbar bei einem Giesser/ Bahn-Abstand von 175 µm. Als Unterlage wurde Cellulosetriacetat verwendet. Die Begussqualität war sehr gut.
Figure imgb0007
 A casting speed of v = 400 m / min could be achieved. The vacuum applied was 1 mbar with a pourer / web distance of 175 µm. Cellulose triacetate was used as the base. The casting quality was very good.

Beispiel 9Example 9

Ein Giesser nach Fig. 1 wurde als Giesser für das Wulstantragsverfahren für einen dreischichtigen Guss verwendet. Die Begussdaten der einzelnen Schichten waren folgende:A caster according to FIG. 1 was used as the caster for the bead application process for a three-layer cast. The casting dates of the individual layers were as follows:

Figure imgb0008
Es konnte eine Begiessgeschwindigkeit von v = 250 m/min erreicht werden. Der angelegte Unterdruck betrug 4,5 mbar bei einem Giesser/ Bahn-Abstand von 175 µm. Als Unterlage wurde PE-Papier verwendet. Die Begussqualität war gut.
Figure imgb0008
 A casting speed of v = 250 m / min could be achieved. The vacuum applied was 4.5 mbar at a pourer / web distance of 175 µm. PE paper was used as a base. The casting quality was good.

Die aufgeführten Beispiele zeigten nur einen Teil des Anwendungsbereiches. Andere Bahnunterlagen, grössere und kleinere Anzahlen von Schichten sowie andere Beschichtungsmaterialien sind unter Anpassung der Beschleunigungsschicht bezüglich Viskosität und Schichtdicke möglich.The examples listed only show part of the scope. Other web documents, larger and smaller numbers of layers as well as other coating materials are possible by adjusting the acceleration layer with regard to viscosity and layer thickness.

Durch die Spreitungsschicht wird eine weitere Verbesserung der Begussqualität und eine Erhöhung der Beschichtungsgeschwindigkeit möglich, zwischen den einzelnen Schichten und zwischen der Beschleunigungsschicht und der darüberliegenden Schicht traten keinerlei Vermischungen auf. Auch die Spreitungsschicht vermischt sich nicht mit der darunter liegenden photographischen Schicht.The spreading layer enables a further improvement in the casting quality and an increase in the coating speed; no mixing occurred between the individual layers and between the acceleration layer and the layer above. The spreading layer also does not mix with the underlying photographic layer.

Claims (4)

1. Process for the application, substantially free from intermixing, of more than one layer on a web moved continuously past a coating point using a coating device which has a sliding surface coating head ans forms a bead, characterised in that an accelerating layer with a viscosity range of 1-20 mPa.s and a layer thickness of 2-30 11m is arranged underneath one or more relatively high viscosity layers, in that the bead formation is carried out over a gap width between the sliding surface coating head and the web to be coated of 100-400 µm, preferably of between 100-200 wm, and in that a vacuum of up to 8 mbar, preferably up to 3 mbar, is applied underneath the coating bead.
2. Process according to Claim 1, characterised in that the accelerating layer has a viscosity of 2-10 mPa.s, preferably 2-3 mPa.s, and a layer thickness of 2.5-10 µm, preferably 2.5-5 µm.
3. Process according to one of the preceding claims, characterised in that a further low viscosity layer is arranged as a spreading layer above the relatively high viscosity layer or layers.
4. Process according to Claim 3, characterised in that the spreading layer has a viscosity of 1-10 mPa.s and a layer thickness of 5-20 µm.
EP83110161A 1982-10-21 1983-10-12 Multiple coating process for moving webs Expired - Lifetime EP0110074B2 (en)

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JPS59100434A (en) 1984-06-09

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