Method for producing laminate, method for producing polymer film, and laminate

Abstract

A method for efficiently and uniformly manufacturing a laminate having a layer of a polymer film with a plurality of through holes of a specific shape is provided. In the manufacturing method of the laminate of the present invention, the laminate has a layer of a polymer film with a plurality of through holes of a specific shape, and in the manufacturing method, a mold is arranged on one side of which a plurality of recesses are formed, and the opening shape of the recesses is a specific shape of the through holes of the polymer film, and a coating material is applied to the surface of the mold with the recesses, and the coating material applied to the portion other than the recesses remains on the surface of the mold, while the coating material applied to the recesses falls into the recesses, and the coating material is dried to form a polymer film with the portion corresponding to the recesses as through holes, and the support is pressed against the mold through the polymer film, and the polymer film and the support are peeled off from the mold together.

Description

Technical Field

[0001] The present invention relates to a method for producing a laminated body having a polymer film layer with a plurality of through-holes of a specific shape formed therein, and to the laminated body thereof, and a method for producing a polymer film layer with a plurality of through-holes of a specific shape formed therein. Background Art

[0002] In recent years, in various fields such as the medical field, the pathological diagnosis field, and the environmental field, the importance of the technology of manufacturing a membrane filter formed with fine through holes is increasing. In particular, in the medical field and the pathological diagnosis field, in order to efficiently separate cells of a specific size from a blood sample or a cell suspension and perform a diagnosis, a membrane filter with through holes of a single micron size arranged evenly is required. In addition, in the environmental field, in the separation of viruses, bacteria, asbestos, etc., there is a high demand for filters formed with tiny through holes. As a technology for forming through holes in a resin, a hole forming technology using a laser, an ion beam, and etching is proposed, and a punching processing technology using a columnar mold is used for the development of products such as cell separation membranes and virus separation membranes.

[0003] As a thin film having through holes, there is a method of forming a nano-sized through hole by irradiating an ion beam and then enlarging the through hole by wet etching to form a nano-sized to micro-sized through hole (for example, Patent Document 1).

[0004] In addition, as a thin film having through holes, there is the following method: particles having a diameter the same as that of the through holes are arranged on a substrate, the particles are made to be in a state where the surface other than the upper surface is covered with a liquid polymer material, and the particles are dissolved after the polymer material is solidified, thereby obtaining a polymer film having through holes formed on the substrate (for example, Patent Document 2).

[0005] In addition, as a laminate having through holes, there is the following method: water droplets are generated in a liquid hydrophobic polymer material applied to a non-woven fabric, and the water droplets are evaporated after the hydrophobic polymer is solidified, thereby obtaining a laminate having through holes formed by a non-woven fabric and a hydrophobic polymer film having through holes (for example, patent document 3).

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2017-18881

[0009] Patent Document 2: Japanese Patent Application No. 2013-540569

[0010] Patent Document 3: Japanese Patent Application Publication No. 2012-6010 Summary of the invention

[0011] Problems to be solved by the invention

[0012] However, in the method for manufacturing a thin film having through holes described in Patent Document 1, it is difficult to irradiate the ion beam in an even arrangement and accurately irradiate the ion beam in a direction perpendicular to the surface of the thin film, so there are problems such as irregular hole diameters of the through holes and bonding with adjacent through holes. In addition, since etching is required after irradiation with the ion beam, there is also a problem of complicated processes and the need for large equipment.

[0013] In addition, in the method for manufacturing a thin film having through holes described in Patent Document 2, since it is difficult to arrange particles for forming through holes at equal intervals on a substrate, there is a problem that the arrangement of the through holes becomes irregular. Furthermore, since the diameter of the through holes varies depending on the thickness of the polymer material when the particles are coated with the polymer material, it is difficult to control the pore size. Moreover, since the particles need to be dissolved at the end of the process, there is a problem of low productivity.

[0014] In addition, in the manufacturing method of the laminated body with through holes recorded in patent document 3, a hydrophobic solvent containing a polymer material is applied to a non-woven fabric containing water, water droplets are generated from the non-woven fabric in the hydrophobic solvent containing the polymer material, and through holes of the same size as the water droplets are formed in the polymer material. However, in this method, it is difficult to arrange the water droplets at equal intervals, and it is also difficult to control the size of the water droplets. If the size and arrangement of the through holes are not particularly problematic, it is good, but if it is a filter for efficiently filtering a filter object of a specific size, there is a problem sometimes because the uniformity of the through holes and the uniformity of the arrangement are required.

[0015] The present invention provides a method for manufacturing a laminate having a polymer film with a plurality of through holes of a specific shape by making the size of the through holes uniform and the arrangement of the through holes uniform. In addition, the present invention provides a method for manufacturing a polymer film with a plurality of through holes of a specific shape by making the size of the through holes uniform and the arrangement of the through holes uniform.

[0016] Means for solving problems

[0017] The manufacturing method of the laminated body of the present invention for solving the above-mentioned problems is a manufacturing method of the laminated body having a layer of a polymer film with a plurality of through holes of specific shapes, wherein a mold is arranged, the mold having a plurality of recesses formed on one side surface, and the opening shape of the recesses is a specific shape of the through holes, a coating material is applied to the surface of the mold with the recesses formed, and the coating material applied to the portion other than the recesses remains on the surface of the mold while the coating material applied to the recessed portion falls into the recessed portion, the coating material is dried, thereby forming a polymer film with portions corresponding to the recesses as through holes, a support body is pressed against the mold through the polymer film, and the polymer film is peeled off from the mold together with the support body to obtain a laminated body formed by the support body and the polymer film.

[0018] In the method for producing a polymer film of the present invention, a polymer film having a plurality of through-holes of a specific shape is obtained by peeling off a polymer film from the surface of a support of a laminate obtained by the method for producing a laminate of the present invention.

[0019] In the laminate of the present invention, a polymer film having a plurality of through-holes of a specific shape is directly laminated on one surface of a support having a plurality of through-holes, and components constituting the polymer film do not enter the through-holes of the support.

[0020] Effects of the Invention

[0021] According to the present invention, after forming through holes on the polymer film that are roughly the same shape as the opening of the recessed portion of the mold and have uniform size and arrangement, the polymer film is transferred to a support body, thereby being able to manufacture a layer stack of polymer films having multiple through holes formed in specific shapes.

[0022] Since laser or ion beam is not used to form the through hole as in the prior art, the equipment cost during manufacturing can be reduced, and the manufacturing cost can be reduced. In addition, in order to form the through hole, the process of dissolving particles and the like is omitted in the subsequent process, so complicated processes are not required in the manufacture of the laminate, and the productivity can be improved. In addition, in the present invention, since the shape and size of the through hole can be controlled to be roughly the same as the opening shape of the concave portion of the mold, through holes of various shapes can be formed by changing the opening shape of the mold used, thereby expanding the use.

[0023] Furthermore, in the present invention, a polymer thin film having through-holes of a specific shape can be produced efficiently, uniformly, and stably. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] [ Figure 1 ] Figure 1This is a schematic diagram of an example of a laminate having a polymer film layer having through-holes formed therein, which is obtained by the method for producing a laminate of the present invention.

[0025] [ Figure 2 ] Figure 2 This is a schematic diagram of an example of a mold used in the present invention.

[0026] [ Figure 3 ] Figure 3 It is a diagram schematically illustrating the method for producing the laminated body of the present invention.

[0027] [ Figure 4 ] Figure 4 This is a laser microscope photograph of a partial area of ​​the surface of a mold in the production process of the laminate of the present invention.

[0028] [ Figure 5 ] Figure 5 This is a schematic cross-sectional view showing an example of a production apparatus that embodies the method for producing a laminated body of the present invention. DETAILED DESCRIPTION

[0029] The method for manufacturing a laminate of the present invention is described using the accompanying drawings. In the method for manufacturing a laminate of the present invention, a laminate having a layer of a polymer film having a plurality of through holes of a specific shape is obtained by sequentially performing the following steps: (1) a step of configuring a mold, wherein the mold is a mold having a plurality of recesses formed on one side, and the opening shape of the recesses is a specific shape; (2) a step of applying a coating material to the surface of the mold having the openings, and allowing the coating material applied to the recessed portion to fall into the recessed portion while the coating material applied to the portion other than the recessed portion remains on the surface of the mold; (3) a step of drying the coating material to form a polymer film having through holes in the portion corresponding to the recessed portion; (4) a step of pressing a support body against the mold via the polymer film; and (5) a step of peeling the polymer film from the mold together with the support body.

[0030] Reference Figure 1 . Figure 1 This is a schematic diagram of a laminated body obtained by the method for producing a laminated body 30 of the present invention. Figure 1 (a) is a schematic diagram of a cross section of the stacked body 30. Figure 1 (b) is a schematic diagram of the stacked body 30 viewed from above. Figure 1 As shown in (a) of FIG. 1 , the laminate 30 is a structure in which the polymer film 16 and the support 31 are laminated and integrated. Figure 1 As shown in (b) in FIG. 1 , when the laminate 30 is viewed from above, a region which is similar to the region of the mold 11 (see FIG. 1 ) is formed on the polymer film 16. Figure 2The through hole 16a has a shape that is substantially the same as the opening shape of the recess 15a in (a)). When a mesh such as a nonwoven fabric is used as the support 31, by providing holes in the support 31 having a cross-sectional area larger than that of the through hole 16a of the polymer film 16, the strength of the laminate can be improved without hindering the characteristics of the through hole 16a of the polymer film 16.

[0031] Next, refer to Figure 2 and Figure 3 An example of a method for producing the laminated body 30 will be described. Figure 2 This is a schematic diagram of an example of a mold used in the present invention. Figure 2 (a) is a plan view of a mold in which the opening shape of the recess is circular. Figure 2 (b) is a cross-sectional view of a mold in which the opening shape of the recess is circular. Figure 2 (c) is a plan view of a mold in which the opening shape of the recess is a polygon. Figure 2 (d) is a cross-sectional view of a mold in which the opening shape of the recess is a polygon. Figure 2 As shown, the mold 11 is formed with a concave portion 15a on one side of the surface 15b, and the opening shape of the concave portion 15a is circular (see Figure 2 (a)) or polygons (see Figure 2 Although not shown in the figure, it is also preferred to adopt an elliptical shape as the opening shape.

[0032] Figure 3 2 is a diagram schematically illustrating a method for manufacturing a laminate of the present invention. As a preparatory stage, a coating material 23 containing a polymer material is prepared and filled into a tank of a coating material supply mechanism connected to a coating unit 21. In addition, a mold 11 is fixed on a flat mounting table 22 and is adsorbed on the mounting table 22 by a negative pressure generating device (not shown).

[0033] Next, the distance between the discharge front end surface of the coating unit 21 and the surface 15b of the mold 11 is set at a predetermined distance, and the coating material supply mechanism is set in advance so that the feeding conditions of the coating material 23 correspond to the film thickness. Figure 3 (a) in the figure.

[0034] Then, the driving shaft and the coating material supply mechanism of the coating unit 21 are driven to uniformly apply the coating material 23 so as to cover at least the surface 15b of the mold 11. At this time, the opening of the recessed portion 15a of the mold 11 is also coated with the coating material 23 ( Figure 3 (b) in the figure.

[0035] Then, while the coating material 23 remains on the surface 15b of the mold 11, the coating material 23 located at the opening of the recess 15a is dropped into the recess 15a of the mold 11 by the weight of the coating material 23 or the dropping mechanism 24, so that the coating material 23 remains only on the surface 15b of the mold 11 ( Figure 3 (c) in the figure.

[0036] Then, by drying the coating material 23 on the mold 11 , the polymer film 16 having the through holes 16 a having substantially the same shape as the surface 15 b of the mold 11 , that is, substantially the same shape as the opening of the recessed portion 15 a of the mold 11 is obtained.

[0037] Then, the support body 31 is arranged substantially parallel to the surface 15b of the mold 11, and the surface of the support body 31 is brought into contact with the polymer film 16 using a pressing mechanism (not shown). Figure 3 (d) in the figure.

[0038] Then, by peeling the support 31 from the mold 11 , the polymer film 16 is transferred from the surface 15 b of the mold 11 to the surface of the support 31 , thereby obtaining a laminate 30 composed of the support 31 and the polymer film 16 .

[0039] The mold 11 used in the manufacturing method of the present invention is preferably formed of a material having chemical resistance to chemicals such as solvents for the coating material 23, and has a uniform thickness in order to uniformly apply the coating material 23. Here, chemical resistance means that in a test in accordance with JIS-K-6258 (2003 edition), when the mold 11 is immersed in a chemical for the coating material 23 at room temperature for 72 hours, the volume change rate is 5% or less. If there is no chemical resistance, the surface of the mold 11 may swell due to the chemical, which may hinder the peeling of the polymer film 16, so it is preferable to have chemical resistance. As materials having chemical resistance, it is preferred to use polyester resins such as polyethylene terephthalate, polyethylene 2,6-naphthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, cycloolefin resins, polyamide resins, polyimide resins, polyether resins, polyesteramide resins, polyetherester resins, acrylic resins, polyurethane resins, polycarbonate resins, or polyvinyl chloride resins.

[0040] The shape of the recess 15a of the mold 11 is an opening shape substantially the same as the through hole 16a to be formed in the polymer film 16. The area of ​​the opening shape (the opening area viewed from the surface 15b side) is preferably 0.01 μm 2 ~100μm 2The range is more preferably 0.25 μm 2 ~10μm 2 By opening a 0.01 μm 2 ~100μm 2 The through hole 16a has a cross-sectional area, so that when used as a filter, it can reduce the pressure loss during filtration while filtering a filter object of a specific size. In addition, the depth of the recess 15a of the mold 11 is preferably in the range of 1μm to 100μm. As long as it is above 1μm, there is enough volume for only the coating material 23 to fall in, so the through hole 16a can be formed under the condition that the coating material 23 does not overflow from the recess 15a and cause the recess 15a of the mold 11 to be connected to the polymer film 16 on the surface 15b. In addition, if it is less than 100μm, it is not so difficult to make the mold 11, so it is not easy to cause the problem of deformation of the recess 15a of the mold 11 and uneven surface 15b of the mold 11.

[0041] The mold 11 can be made by hot embossing, UV embossing, injection molding, extrusion molding, etc., as long as it can give a fine concave shape to the film. In particular, hot embossing is preferably used because it has a wide selection of mold materials and a high degree of freedom in the concave shape.

[0042] The coating material 23 may be a material obtained by heat-melting the polymer material that is the main component of the polymer film 16, or a material obtained by dissolving the polymer material in a solvent. However, in consideration of the ease of coating such as liquid feeding and maintenance, it is preferred to use a material obtained by dissolving the polymer material in a solvent.

[0043] The coating unit 21 may be any one that can uniformly coat the coating material 23 including a polymer material on the mold 11 , and preferably uses a slit die, spin coating, rod coating, or dip coating. In particular, a slit die is preferably used because it can also be continuously coated on a roller-shaped mold.

[0044] In the process of dropping the coating material 23 into the opening of the recess 15a of the mold 11, it is preferable to separate the polymer film 16 formed on the surface 15b of the mold 11 from the polymer film formed on the wall and bottom of the recess 15a of the mold 11. If the polymer film 16 formed on the surface 15b of the mold 11 is connected to the polymer film formed on the wall of the recess 15a of the mold 11, the shape of the through hole 16a may not be a specific shape. In addition, if it is connected to the polymer film formed on the bottom of the recess 15a of the mold 11, the through hole 16a may not be formed.

[0045] In the process of causing the coating material 23 to fall into the opening of the recess 15a of the mold 11, the coating material 23 located at the opening of the recess 15a of the mold 11 may be allowed to fall naturally into the recess 15a after coating, or the coating material 23 may be forced to fall into the recess 15a using a falling mechanism 24 such as vibration or air. When the coating material 23 located at the opening of the recess 15a is allowed to fall naturally into the recess 15a by the weight of the coating material 23 alone, it may take time for the coating material 23 to fall into the recess 15a depending on the physical properties of the coating material 23. When it takes time for the coating material 23 to fall into the recess 15a, air may be applied to the surface of the mold 11 to vibrate the mold 11, so that only the fabric material 23 located at the opening of the recess 15a can be quickly dropped into the recess 15a while the coating material 23 on the surface 15b maintains its shape.

[0046] Figure 4 An example of a laser microscope photograph of a partial area of ​​the surface of the mold 11 in the production process of the laminate of the present invention is shown. Figure 4 (a) is a laser microscope photograph of a partial region of the surface 15b of the mold 11 before the coating material 23 is applied. Figure 4 (b) is a laser microscope photograph of a partial region of the mold 11 in a state where the polymer film 16 is formed. Figure 4 In (a), the surface 15b of the mold 11 is white and the recessed portion 15a is black. Figure 4 In (b), the polymer films 16 and 16c turn white. Figure 4 As shown in (a) and (b), the coating material 23 is evenly coated on the surface 15b of the mold 11 to form a polymer film 16. In the recess 15a of the mold 11, the polymer film 16c formed by the coating material 23 introduced from the opening is accumulated on the side and bottom of the recess 15a. The boundary between the polymer film 16 and the polymer film 16c turns black, and it can be seen that the polymer film 16 and the polymer film 16c are not connected. By transferring only the polymer film 16 on the surface 15b of the mold 11 to the support 31, it is possible to obtain a laminated body formed by the polymer film 16 and the support 31 having a through hole 16a with a shape roughly the same as the opening shape of the recess 15a of the mold 11.

[0047] The support 31 of the present invention preferably has adhesive force in order to peel off the polymer film 16 from the surface 15b of the mold 11 and make it firmly adhere to the support 31. In the case of no adhesive force, sometimes the polymer film 16 will not be peeled off from the surface 15b of the mold 11 and will remain on the mold 11 side, or even if it can be peeled off, it will not be integrated with the support 31 but will be peeled off.

[0048] As the material used as the support body 31 with adhesiveness, it is preferred to use styrene-butadiene rubber system, silicone system, ethylene-vinyl acetate copolymer system, polyolefin system, amorphous poly-α-olefin system, synthetic rubber system, polyamide system, polyester system, polyurethane system, etc. in the resin. In the case where the support body 31 is a material without adhesiveness, it is also possible to heat the polymer film 16 and the support body 31 for heat fusion, or to treat the polymer film 16 or the support body 31 to improve the adhesion between the polymer film 16 and the support body 31. As a treatment method for improving the adhesion of the polymer film 16 or the support body 31, a wet process of impregnating the polymer film 16 or the support body 31 with an adhesive can be used, and a dry process based on surface modification such as corona treatment and plasma treatment can also be used. As the material of the support body 31 without adhesiveness, it is also preferred to use metal materials such as stainless steel, nickel, aluminum, copper, and brass.

[0049] The support 31 preferably has a through hole having a larger cross-sectional area than the through hole 16a of the polymer film 16. Specifically, when the laminate 30 is viewed from the support 31 side, the opening area S1 (μm 2 ) and the total opening area S2 (μm 2 ) ratio (S2 / S1) becomes 0.05 or more. If S2 / S1 is 0.05 or more, the air and liquid entering the stack 30 from the polymer film 16 side will not be blocked by the polymer film 16 or the support body 31 and can easily pass through the stack 30, which can reduce the pressure loss of the stack 30 and can give full play to the characteristics of the through holes of the polymer film 16. S2 / S1 is more preferably 0.1 or more. On the other hand, the upper limit of S2 / S1 is not particularly limited, but if the area of ​​the portion other than the through hole 16a of the polymer film 16 is small and the thickness of the polymer film 16 is thin, sometimes the polymer film 16 is stretched and ruptured due to insufficient strength, so S2 / S1 is preferably 0.5 or less. If S2 / S1 is 0.5 or less, the area of ​​the portion other than the through hole 16a of the polymer film 16 is large enough, so the strength of the polymer film 16 can be ensured. S2 / S1 is more preferably 0.3 or less. As the support body 31 , a base material having through holes such as nonwoven fabric and mesh can be used, but a mesh can be preferably used because the opening shape of the through holes of the support body 31 can be easily controlled.

[0050] The pressure loss of the support body 31 when filtering gas or liquid is preferably smaller than the pressure loss of the polymer membrane 16. If the pressure loss of the support body 31 is smaller than the pressure loss of the polymer membrane 16, the pressure loss of the stack 30 does not change much compared with the pressure loss of the polymer membrane 16, so the stack 30 can exert the characteristics of the through hole 16a without hindering filtration.

[0051] The opening shape of the through hole 16a of the polymer film 16 is substantially the same as the opening shape of the recess 15a of the mold 11. When the opening shape of the recess 15a of the mold 11 is circular, the opening shape of the through hole 16a of the polymer film 16 is circular, when it is polygonal, it is polygonal, and when it is elliptical, it is elliptical. For example, when the laminate 30 is used for filtering, the shape of the through hole 16a of the polymer film 16 can be changed by selecting the opening shape of the mold 11 according to the shape and hardness of the object to be filtered.

[0052] Furthermore, even when the polymer film 16 is peeled off from the support 31 and handled as a separate film, the polymer film 16 can be peeled off from the support 31 of the laminate 30 without causing wrinkles or cracks, thereby obtaining the polymer thin film 17 having through-holes.

[0053] There is no particular limitation on the polymer material used for the polymer film 16. For example, polyester resins such as polyethylene terephthalate, polyethylene 2,6 naphthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyolefin resins such as polyethylene, polystyrene, polypropylene, polyisobutylene, polybutene, polymethylpentene, polyamide resins, polyimide resins, polyether resins, polyesteramide resins, polyetherester resins, acrylic resins, polycarbonate resins, or polyvinyl chloride resins are preferably used.

[0054] In the method for manufacturing a laminate having through holes of the present invention, after coating the coating material 23 on the mold 11 having the recessed portion 15a, the laminate 30 is manufactured by transferring the polymer film 16 on the surface 15b of the mold 11 to the support 31. At this time, a single-piece mold 11 or a roll-shaped mold can be used. In the case of using a roll-shaped mold, it has a feature of being superior in productivity than using a single-piece mold 11.

[0055] The laminate of the present invention can be obtained by using, for example, Figure 5 The device shown is manufactured by the process. Figure 5 It is a schematic cross-sectional view showing an example of a manufacturing apparatus for manufacturing a roll-shaped laminated body 90 , and illustrates an apparatus using a roll-shaped mold 51 .

[0056] A series of manufacturing operations of the manufacturing apparatus 50 for using the laminate 90 are as follows. The roll-shaped mold 51 is unwound from the unwinding roll 61 and becomes in a state of being wound around the winding roll 62 via the paths of the coating unit 21, the drying unit 80, the transfer unit 65, and the peeling unit 66. The roll-shaped support 52 is unwound from the unwinding roll 71 and becomes in a state of being wound around the winding roll 72 via the paths of the transfer unit 65 and the peeling unit 66. The mold 51 is given a constant tension required for conveyance by the mold supply mechanism 60 and is conveyed at a prescribed speed by the rotation of the drive roll 65b. The support 52 is given a constant tension required for conveyance by the support supply mechanism 70, is clamped together with the mold 51 by the drive roll 65b and the clamping roll 65a in the transfer unit 65, and after being conveyed while being in close contact with the mold 51, is peeled from the mold 51 by the peeling unit 66 and wound around the winding roll 72. While the mold 51 and the support 52 are being conveyed, the coating material 23 is coated in such a manner as to cover the surface of the mold 51 having the recess formed thereon by the coating unit 21. Next, the coating material 23 at the opening of the recess of the mold 51 is caused to fall into the recess by the dropping mechanism 24. Next, the coating material 23 is dried by the drying unit 80 to obtain the polymer film 76 having through holes formed therein with substantially the same shape as the surface of the mold 51, that is, substantially the same shape as the opening shape of the recess of the mold 51. Next, the mold 51 is brought into close contact with the support 52 with the polymer film 76 therebetween by the transfer unit 65. Next, the polymer film 76 is transferred from the surface of the mold 51 to the support 52 side by the peeling unit 66 to obtain the laminate 30 formed of the support 52 and the polymer film 76. The mold 51 after peeling the polymer film 76 from the surface is directly wound around the winding roll 62, and the roll-shaped laminate 90 is wound around the winding roll 72. The above operations are continuously performed.

[0057] The laminated bodies 30 and 90 obtained by the manufacturing method of the laminated body of the present invention are directly laminated with the polymer membranes 16 and 76 on the surfaces of the supports 31 and 52 without the interposition of an adhesive layer or the like. In addition, in the manufacturing process of the laminated bodies 30 and 90, the coating material 23 as a component constituting the polymer membranes 16 and 76 is not coated on the surfaces of the supports 31 and 52, so the polymer material constituting the polymer membranes 16 and 76 does not enter the through holes of the supports 31 and 52. In the manufacturing method of the laminated body described in the above-mentioned patent document 3, since a hydrophobic solvent containing a polymer material is coated on the non-woven fabric, the polymer material will enter the openings of the non-woven fabric anyway, and the openings of the non-woven fabric as the support layer of the obtained laminated body become smaller due to the entering polymer material. Therefore, when the laminated body is used for filtering purposes, the effective area of ​​filtration becomes smaller. Since the components constituting the polymer membrane 16, 76 of the stacked bodies 30, 90 of the present invention do not enter the through holes of the support bodies 31, 52, the opening area of ​​the through holes of the polymer membrane 16, 76 and the opening area of ​​the through holes of the support bodies 31, 52 remain exactly as designed and do not change. When the stacked bodies 30, 90 are used for filtering purposes, they can exhibit filtering performance as designed.

[0058] Example

[0059] [Example 1]

[0060] The material of the mold 11 is a cycloolefin polymer film (trade name: ZeonorFilm ZF14, manufactured by Zeon Corporation). The structure of the recess 15a of the mold 11 is configured as follows: the opening shape is a circle with a diameter of 3 μm, and the depth is a columnar shape of 10 μm, and the recess 15a is arranged in a square with a pitch of 10 μm. The width and length of the mold 11 are both prepared to be 100 mm, and the coating material 23 is placed on a vacuum adsorption plate in a coating-capable manner, and adsorbed and fixed.

[0061] The support 31 was made of SBS (trade name: Tufprene A, manufactured by Asahi Kasei Corporation) having adhesiveness, which was processed into a nonwoven fabric using a melt spinning device.

[0062] The coating material 23 was prepared by dissolving polycarbonate (manufactured by Mitsubishi Engineering-Plastics Corporation) as a polymer material in acetone (CAS No. 67-64-1 manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), and the concentration of polycarbonate was 5.0 mass % based on the entire coating material 23 .

[0063] The coating unit 21 is spaced 100 μm from the surface of the mold 11, and the coating material 23 is applied at such a discharge rate that the thickness of the polymer film 16 after drying becomes 800 nm. After application, the coating material 23 falls into the recess 15a of the mold 11 by its own weight.

[0064] During the drying, the polymer film 16 was formed by using a drying space whose temperature was adjusted to a constant temperature of 40° C., taking advantage of the volatility of acetone.

[0065] The support 31 and the polymer film 16 were overlapped so as to be in contact with each other and pressed at a pressure of 0.2 MPa for 60 seconds.

[0066] Next, the support 31 is peeled off from the mold 11 , and the polymer film 16 is transferred to the support 31 , thereby obtaining a laminated body composed of the support 31 and the polymer film 16 .

[0067] The obtained laminate was observed, and it was confirmed that through holes having substantially the same shape as the opening shape of the recessed portion 15 a of the mold 11 were formed in the polymer film 16 .

[0068] [Example 2]

[0069] The materials of the mold 11 and the coating material 23 are the same as those of Example 1. The structure of the recess 15a of the mold 11 is as follows: the opening shape is a square with a side of 10 μm and a columnar shape with a depth of 5 μm, and the recess 15a is arranged in a square with a pitch of 15 μm. The width and length of the mold 11 are both prepared to be 100 mm, and the coating material 23 is placed on a vacuum adsorption plate in a manner that allows coating, and is adsorbed and fixed.

[0070] As the material of the support 31, a nylon mesh (manufactured by SEFER) having a wire diameter of 51 μm and a mesh size of 100 μm was used.

[0071] The coating material 23 is applied at a discharge rate such that the thickness of the polymer film 16 after drying becomes 1 μm, with the coating unit 21 and the surface of the mold 11 being 100 μm apart. After application, the coating material 23 falls into the recess 15a of the mold 11 by its own weight.

[0072] During the drying, the polymer film 16 was formed by using a drying space whose temperature was adjusted to a constant temperature of 40° C., taking advantage of the volatility of acetone.

[0073] The support 31 and the polymer film 16 were overlapped so as to be in contact with each other, and were pressed at a pressure of 0.2 MPa for 60 seconds while being heated at 130°C.

[0074] Next, the support 31 is peeled off from the mold 11 , and the polymer film 16 is transferred to the support 31 , thereby obtaining a laminated body 30 composed of the support 31 and the polymer film 16 .

[0075] The obtained laminated body 30 was observed, and it was confirmed that a through hole having a shape substantially the same as the opening shape of the recessed portion 15a of the mold 11 was formed in the polymer film 16. When the laminated body 30 was observed from the support body 31 side, it was confirmed that the opening area S1 (μm 2 ) and the total opening area S2 (μm) of the through hole of the polymer film 16 observed through the one through hole 2 ) ratio (S2 / S1) becomes 0.49.

[0076] Industrial Applicability

[0077] The laminate obtained by the manufacturing method of the laminate of the present invention has a layer of a polymer membrane with through holes of uniform size and high opening rate, so it is possible to filter objects of specific size. For example, it is most suitable as a filter for separating or extracting rare cells in a blood sample, rare cells in a cell suspension, etc. In addition, by selecting a material with high permeability, the separated cells can be observed through the filter state, so it can also be used for pathological diagnosis.

[0078] Description of Reference Numerals

[0079] 11, 51: Mould

[0080] 15a: concave part

[0081] 15b: Surface

[0082] 16, 16c, 76: polymer film

[0083] 17: Polymer film

[0084] 21: Coating unit

[0085] 22: Loading table

[0086] 23: Coating material

[0087] 24: Falling into the institution

[0088] 30, 90: laminated body

[0089] 31, 52: Support body

[0090] 50: Manufacturing device

[0091] 60: Mold supply mechanism

[0092] 61, 71: Unwinding roller

[0093] 62, 72: Winding roller

[0094] 65: Transfer unit

[0095] 65a: clamping roller

[0096] 65b: driving roller

[0097] 66: Stripping unit

[0098] 70: Support body supply mechanism

[0099] 80: Drying unit

Claims

1. A method for producing a laminate having a layer of a polymer film having a plurality of through-holes of a specific shape, wherein: A mold is provided, wherein a plurality of recesses are formed on one surface of the mold, and the opening shape of the recesses is a specific shape of the through-holes of the polymer film. The coating material is applied to the surface of the mold where the recessed portion is formed, and the coating material applied to the portion other than the recessed portion remains on the surface of the mold, while the coating material applied to the recessed portion falls into the recessed portion. The coating material is dried to form a polymer film in which portions corresponding to the recessed portions serve as through holes, pressing the support body onto the mold via the polymer film, The polymer film is peeled off from the mold together with the support, thereby obtaining a laminate consisting of the support and the polymer film.

2. The method for producing a laminate according to claim 1, in, The opening shape of the concave portion is circular, elliptical or polygonal.

3. The method for producing a laminate according to claim 1 or 2, in, The support body has adhesive force.

4. The method for producing a laminate according to claim 1 or 2, in, The pressure loss of the support body is smaller than the pressure loss of the polymer film.

5. The method for producing a laminate according to claim 3, in, The pressure loss of the support body is smaller than the pressure loss of the polymer film.

6. Method for manufacturing polymer film, in, A polymer film having a plurality of through-holes of a specific shape formed therein is obtained by peeling off a polymer film from the surface of a support of a laminate obtained by the method for producing a laminate according to any one of claims 1 to 5.

Images