Method for separating a take-up roll and a substrate film

Abstract

A laminated film (90) of a winding roll (1) has a release film having a base film (91) and a release agent layer (92), and a ceramic green sheet having green sheet portions (931, 932) each disposed along a length direction of the laminated film (90), a recess (94) being formed on the release agent layer (92) to be sandwiched by the green sheet portions (931, 932). The laminated film (90) is wound on a shaft core (80) in a reciprocating winding manner with a size having a swing width (α). When viewed in a cross section orthogonal to the length direction of the laminated film (90), the swing width (α) is, for example, a size larger than a width (β1) from a rim end of the laminated film (90) on a first end portion (E1) side to an inner edge of the first green sheet portion (931).

Description

Technical Field

[0001] This invention relates to a method for separating a take-up roller and a substrate film. Background Technology

[0002] In recent years, from the perspectives of protecting Earth's resources and environmental protection, efforts to curb waste generation, reuse, and recycle are being made in various fields to build a circular society.

[0003] For example, Patent Document 1 discloses a method for removing a coating layer, comprising: a step of cutting a laminated film having a substrate film and a coating layer into thin pieces; a step of separating the laminated film into the substrate film and the coating layer by immersing the cut laminated film in warm water in a stirring tank and stirring; a substrate film recycling step of recycling the separated substrate film; and a coating layer recycling step of recycling the residue of the separated coating layer, wherein the coating layer comprises an intermediate layer and a release agent layer, the intermediate layer being disposed between the substrate film and the release agent layer.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2023-148863 Summary of the Invention

[0007] The technical problem that the invention aims to solve

[0008] In the removal method described in Patent Document 1, the laminated film is cut into thin pieces and then immersed in warm water, thereby promoting the separation of the coating layer from the laminated film.

[0009] The laminated films described in Patent Document 1 include, for example, laminated films used in the manufacturing process of multilayer ceramic capacitors (MLCCs). Laminated films used in the manufacturing process of MLCCs typically have a structure in which a ceramic green sheet is further partially attached to a release film having a substrate film and a release agent layer.

[0010] Thus, the structures of laminated membranes are diverse, therefore, in the technology of separating substrate membranes from laminated membranes, it is necessary to develop new separation methods that correspond to the structures of laminated membranes.

[0011] The purpose of this invention is to provide a take-up roller capable of easily separating a substrate film from a laminated film having a structure in which ceramic green sheets are attached to a release film, and a method for separating the substrate film.

[0012] Technical solutions for solving technical problems

[0013] [1] A take-up roller comprising a core and an elongated laminated film wound around the outer periphery of the core, wherein the laminated film comprises: a release film having a substrate film and a release agent layer; and a ceramic green sheet, wherein the substrate film, the release agent layer, and the ceramic green sheet are arranged sequentially, and the ceramic green sheet has at least a first green sheet portion attached to a first end side in the width direction of the laminated film and a second green sheet portion attached to a second end side opposite to the first end side, the first green sheet portion and the second green sheet portion being respectively arranged along the length direction of the laminated film, wherein the release agent layer... A recess formed on the layer by the first green sheet portion and the second green sheet portion is formed thereon. The laminated film is wound on the core in a reciprocating winding manner with a swing width α. When viewed in a cross section orthogonal to the length direction of the laminated film, the swing width α is a dimension larger than the width β1 from the edge of the laminated film on the first end side to the inner edge of the first green sheet portion, or a dimension larger than the width β2 from the edge of the laminated film on the second end side to the inner edge of the second green sheet portion, or a dimension larger than both the width β1 and the width β2.

[0014] [2] According to the take-up roller described in [1] above, wherein the ceramic green sheet has a plurality of third green sheet portions attached to the release agent layer along the width direction of the laminated film, one end of the third green sheet portion in the length direction is connected to the first green sheet portion, the other end of the third green sheet portion in the length direction is connected to the second green sheet portion, and a recess is formed on the release agent layer that is surrounded by the first green sheet portion, the second green sheet portion and the two third green sheet portions.

[0015] [3] According to the take-up roller described in [2] above, at least one of the multiple corners of the recess is in communication with the outside.

[0016] [4] The take-up roller according to any one of [1] to [3] above, wherein the laminated film further comprises an intermediate layer disposed between the substrate film and the release agent layer.

[0017] [5] A method for separating a substrate film includes: a step of preparing a take-up roller as described in any one of [1] to [4] above; a take-up roller treatment step of treating the take-up roller by immersing it in treatment water or exposing it to water vapor; a step of releasing the laminated film from the take-up roller after the take-up roller treatment step; and a step of separating the substrate film from the released laminated film.

[0018] [6] According to the method for separating the substrate film described in [5] above, the treatment water used when immersing the take-up roller in the take-up roller treatment process is water or an alkaline aqueous solution.

[0019] [7] According to the separation method of the substrate film described in [5] or [6] above, there is a step of winding the substrate film separated from the laminated film after the separation step, and the release step to the winding step is performed in a roll-to-roll manner.

[0020] According to one aspect of the present invention, a take-up roller capable of easily separating a substrate film from a laminated film having a structure on which ceramic green sheets are attached, and a method for separating the substrate film, are provided. Attached Figure Description

[0021] Figure 1 This is a perspective view of the laminated film wound around the take-up roller of the first embodiment.

[0022] Figure 2 From Figure 1 A cross-sectional view of the laminated film observed along line II-II.

[0023] Figure 3 This is a cross-sectional view of a laminated film according to one embodiment.

[0024] Figure 4 This is a schematic cross-sectional view of the take-up roller according to the first embodiment.

[0025] Figure 5 This is an example of a hypothetical unfolded diagram of a laminated film that maintains the deformed state when unwound from the core in the first embodiment.

[0026] Figure 6 This diagram shows the state of the take-up roller of the first embodiment immersed in the treatment water.

[0027] Figure 7 This is a schematic diagram of the removal apparatus used in the separation process of the first embodiment.

[0028] Figure 8A This is a diagram showing the state of the take-up roller of the first embodiment exposed to water vapor.

[0029] Figure 8B This is a diagram showing the state of the take-up roller of the first embodiment exposed to water vapor.

[0030] Figure 8C This is a diagram showing the state of the take-up roller of the first embodiment exposed to water vapor.

[0031] Figure 9 This is a schematic diagram of a removal device used in the separation process of one embodiment. Detailed Implementation

[0032] In this specification, the use of ordinal numbers such as "first" and "second" is for the purpose of distinguishing structures and does not imply order. In this specification, expressions without ordinal numbers, such as "green slice section," are collective terms for the first green slice section, the second green slice section, and the third green slice section, and are used when providing a common description of green slice sections marked with ordinal numbers such as "first," "second," and "third."

[0033] [First Implementation]

[0034] (Take-up roller)

[0035] The first embodiment will be described based on the accompanying drawings.

[0036] In the first embodiment, the X-axis, Y-axis, and Z-axis are orthogonal to each other. The X-axis and Y-axis are axes within a defined plane, and the Z-axis is an axis orthogonal to the defined plane.

[0037] The take-up roller of the first embodiment includes a shaft core and an elongated laminated film wound around the outer peripheral surface of the shaft core. First, the elongated laminated film will be described.

[0038] Figure 1 This is a perspective view of the laminated film 90 wound around the take-up roller 1 of the first embodiment. Figure 2 From Figure 1 A cross-sectional view of the laminated film at line II-II during observation.

[0039] The laminated film 90 has a release film 95 and a ceramic green sheet 93. The release film 95 has a substrate film 91 and a release agent layer 92. The laminated film 90 is sequentially configured with the substrate film 91, the release agent layer 92 and the ceramic green sheet 93.

[0040] The ceramic green sheet 93 has at least a first green sheet portion 931 attached to the first end E1 side in the width direction (X-axis direction) of the laminated film 90 and a second green sheet portion 932 attached to the second end E2 side opposite to the first end E1.

[0041] The first green sheet portion 931 and the second green sheet portion 932 are respectively arranged along the length direction (Y-axis direction) of the laminated film 90, and a recess 94 is formed on the release agent layer 92 that is sandwiched between the first green sheet portion 931 and the second green sheet portion 932.

[0042] exist Figure 1In this case, the ceramic green sheet 93 also has a plurality of third green sheet portions 933 attached to the release agent layer 92 along the width direction (X-axis direction) of the laminated film 90. One end of the third green sheet portion 933 in the length direction (X-axis direction) is connected to the first green sheet portion 931, and the other end of the third green sheet portion 933 in the length direction is connected to the second green sheet portion 932. A recess 94 is formed on the release agent layer 92, which is surrounded by the first green sheet portion 931, the second green sheet portion 932, and the two third green sheet portions 933. Each recess 94 has four corner portions 94A.

[0043] In the laminated film 90, the substrate film 91 and the release agent layer 92 may or may not be in direct contact. Figure 1 and Figure 2 In this case, the substrate film 91 is in direct contact with the release agent layer 92, and the release agent layer 92 is in direct contact with the green sheet portions 931, 932, and 933.

[0044] The laminated film 90 is used in the manufacture of ceramic green sheets and is a laminated film obtained by peeling off a portion of the ceramic green sheet. Ceramic green sheets are used, for example, in the manufacture of multilayer ceramic capacitors (MLCCs).

[0045] exist Figure 1 In this structure, the first green sheet portion 931, the second green sheet portion 932, and the third green sheet portion 933 are residues of the ceramic green sheet 93, and the recess 94 is a space formed by peeling off a portion of the ceramic green sheet 93. The release agent layer 92 is exposed from the bottom of the recess 94.

[0046] Next, the take-up roller 1 of the first embodiment will be described.

[0047] Figure 4 This is a conceptual cross-sectional view of the take-up roller 1 as viewed through a section passing through the centerline 80C of the spindle 80. The take-up roller 1 includes a spindle 80 and a laminated film 90 wound around the outer peripheral surface of the spindle 80. An insertion hole 82 is provided in the central portion of the spindle 80.

[0048] Figure 4 In the middle, the laminated film 90 is wound on the outer peripheral surface of the core 80 in a reciprocating winding manner with a swing width α.

[0049] Figure 5 This is an example of a hypothetical unfolded diagram of a laminated film 90 that maintains its deformed state when unwound from the core 80.

[0050] The take-up roller 1 in the first embodiment is a roller formed by winding a laminated film 90 in a reciprocating winding manner with a swing width α.

[0051] The width of the take-up roller 1, the width of the laminated film 90, and the oscillation width α satisfy the following mathematical expression (Equation 1). Figure 5In this case, the shape of the laminated film 90 along its length is a sine wave (period P1).

[0052] The width of take-up roller 1 = the width of the laminated film 90 + the swing width α... (Mathematical formula 1)

[0053] A winding process in which the laminated film 90 is periodically moved along the width direction of the core 80 is called reciprocating winding. In this specification, the width-direction movement distance in reciprocating winding is referred to as the "oscillation width α". That is, the sum of the width of the laminated film 90 and the oscillation width α is the width of the take-up roller 1 (see reference). Figures 4-5 ).

[0054] The dimensions of the laminated film 90, for example, its width (distance from the first end E1 to the second end E2), are 100 mm or more and 1000 mm or less, preferably 200 mm or more and 600 mm or less. Furthermore, the length of the laminated film 90 in the take-up roller 1 is, for example, 50 m or more and 30,000 m or less, preferably 100 m or more and 10,000 m or less. The laminated film 90 may also be a laminated film of a predetermined length formed by connecting multiple laminated films.

[0055] The width β1 from the edge of the laminated film 90 at the first end E1 side to the inner edge of the first green sheet portion 931, and the width β2 from the edge of the laminated film 90 at the second end E2 side to the inner edge of the second green sheet portion 932, are, for example, 1 mm or more and 60 mm or less, preferably 2 mm or more and 30 mm or less. Their widths can be the same or different. The outer edge 931E of the first green sheet portion 931 can be located at the same position as the edge of the laminated film 90, or it can be... Figure 1 As shown, it is located at a position separated from the edge of the laminated film 90. When the outer edge 931E of the first green sheet portion 931 is located away from the edge of the laminated film 90, the distance D1 between the edge of the laminated film 90 and the outer edge 931E of the first green sheet portion 931 is, for example, 1 mm or more and 30 mm or less, preferably 3 mm or more and 10 mm or less. The distance D2 between the outer edge 932E of the second green sheet portion 932 and the edge of the laminated film 90 is also the same (see reference). Figures 1-2 ).

[0056] In addition, the width D of the first raw film section 931 11 The width D of the second raw film section 932 21 And the width D of the third raw film section 933, which will be described later. 31 For example, the thickness is 1mm or more and 30mm or less, preferably 2mm or more and 20mm or less (refer to...). Figures 1-2 ).

[0057] The width D of the recess 9494 For example, the length is 80mm or more and 980mm or less, preferably 140mm or more and 580mm or less. The length L of a recess 94 when the third green sheet portion 933 is provided. 94 For example, the diameter is 100mm or more and 1000mm or less, preferably 200mm or more and 600mm or less (refer to...). Figure 1 ).

[0058] The swing width α (a value that is twice the amplitude) of the take-up roller 1 is preferably 3 mm or more and 100 mm or less, more preferably 10 mm or more and 50 mm or less. If the swing width is too narrow, it will be difficult to introduce treatment water or water vapor into the recess 94. If the swing width is too wide, it will be difficult to achieve a balance of tension in the various parts of the take-up roller 1 and thus make it difficult to take up the roller.

[0059] The cycle length of the take-up roller 1 is preferably 150 mm or more and 5000 mm or less, more preferably 200 mm or more and 4000 mm. Figure 5 In this case, the cycle of take-up roller 1 is P1.

[0060] When the take-up roller 1 has a third green sheet portion 933, one cycle of the take-up roller 1 is relative to the length L of the recess 94 of the laminated film 90. 94 Preferably, the size is 1 to 10 times that of the original size, and more preferably 2 to 4 times that of the original size.

[0061] The winding diameter of the winding roller 1 (including the diameter of the winding roller 1 including the shaft core 80) is, for example, 100 mm or more and 1500 mm or less, preferably 150 mm or more and 1000 mm or less.

[0062] In having Figure 4 , Figure 5 In the reciprocating winding with the swing width α and period P1 shown, one side of the laminated film 90 along its length is repeatedly wound with alternating high and low tension, while the other side (opposite to the first side) is repeatedly wound with alternating low and high tension. The portion wound with low tension becomes a slack winding, forming a gap between the laminated films 90 (in the Z direction). If the take-up roller 1 in this state is immersed in the treatment water TW, the treatment water TW can be easily guided from the gap formed by the slack winding into the interior of the recess 94.

[0063] The laminated film 90 constituting the take-up roller 1 can be wound around the core 80 such that the ceramic green sheet 93 side becomes the core 80 side (see reference). Figure 4 Alternatively, the ceramic green sheet 93 of the laminated film 90 can be wound around the core 80 in such a way that the side of the ceramic green sheet 93 becomes the opposite side of the core 80.

[0064] In the take-up roller 1 of this embodiment, it is preferable that at least one of the multiple corner portions 94A of the recess 94 is in communication with the outside. The communication of the corner portion 94A with the outside can be confirmed, for example, by observing the winding state of the laminated film 90 in a cross section passing through the center line 80C of the shaft core 80.

[0065] Corner 94A being connected to the outside means that, within the take-up roller 1, corner 94A is not clamped by the first green sheet portion 931 or the second green sheet portion 932 and the substrate film 91, and the flow of liquids and gases is not obstructed. Based on this state, by immersing the take-up roller 1 in processing water (… Figure 4 In the middle, TW) or exposed to water vapor, the treated water or water vapor is introduced into the recess 94 from at least one side of the first end E1 and the second end E2 of the laminated membrane 90 via the corner 94A.

[0066] For example, if Figure 1 The laminated film 90 shown is wound in a reciprocating winding manner with a swing width α. Figure 4 The shaft core 80 shown has a corner 94A that communicates with the outside and a corner that does not communicate with the outside, respectively, on the first end E1 side and the second end E2 side. Figure 4 The text only indicates the corner 94A that is connected to the outside. Figure 4 In the process, the laminated films 90 located on the first end E1 side each have a corner portion 94A that communicates with the outside, and a gap is formed between the corner portion 94A and the laminated film 90 located directly below it. The width of this gap (gap width 94B) is preferably 1 mm or more in the X coordinate, more preferably 2 mm or more and 100 mm or less.

[0067] [Second Implementation]

[0068] (Separation method of substrate membrane)

[0069] The method for separating the substrate film according to the second embodiment includes: a step of preparing the take-up roller of the first embodiment; a take-up roller treatment step of treating the take-up roller by immersing it in treatment water; a step of releasing the laminated film from the take-up roller after the take-up roller treatment step; and a step of separating the substrate film from the released laminated film (hereinafter also referred to as the separation step).

[0070] <Preparation Process>

[0071] The preparation process is the process of preparing the take-up roller 1 of the first embodiment. The take-up roller 1 is a roller formed by winding the laminated film 90 in a reciprocating winding manner with a swing width α.

[0072] As a conventional method of winding the laminated film 90, examples include fixing the core 80 and periodically oscillating the film winding guide to wind the laminated film 90 onto the core 80, and fixing the film winding guide and periodically oscillating the core 80 to wind the laminated film 90. Therefore, an imaginary unfolded diagram is shown when the positional relationship of the wound laminated film 90 is maintained and it is unwound from the core 80. Figure 5 Thus, the laminated film 90 has a wave shape with period and amplitude (half the width of the swing). As for the wave shape of the take-up roller 1 in this embodiment, a sine wave is preferred, but a triangular wave or a rectangular wave may also be used.

[0073] <Creator Roll Processing>

[0074] The take-up roll treatment process is a process of treating the take-up roll by immersing it in treatment water.

[0075] In the winding roll processing step, the treatment water used when impregnating the winding roll is preferably water or an alkaline aqueous solution.

[0076] In the second embodiment, the container in which the take-up roller 1 is immersed in the treatment water is sometimes referred to as an immersion container.

[0077] In the winding roll processing step, when water is used as the treatment water, the impregnation container is, for example, a water tank. When an alkaline aqueous solution is used as the treatment water, the impregnation container is, for example, an alkali treatment tank. When superheated water is used as the treatment water, the impregnation container is a pressure vessel.

[0078] (Water treatment)

[0079] First, let's explain the situation regarding the use of water for water treatment.

[0080] The water used for treatment refers to the liquid used to immerse the take-up roll in the take-up roll treatment process. In this embodiment, the water used for treatment refers to ordinary water, i.e., preferably industrial water, which can be purified water or distilled water. Alternatively, it can be water from the reuse of wastewater used in various industrial production processes, or water from the reuse of wastewater used in this embodiment. When reusing wastewater, appropriate regeneration treatment can be performed.

[0081] From the viewpoint of improving operational efficiency, water used for treatment may appropriately contain additional functional additives, but preferably not. Examples of additives include surfactants and water-soluble organic solvents. When water used for treatment contains additives, the concentration of the active ingredient of the additive in the treated water is preferably 0.2% by mass or less, more preferably 0.1% by mass or less, relative to the total amount of treated water. Furthermore, the water used for treatment is preferably not water in which additives have been intentionally added.

[0082] In addition, since wastewater can be treated through simple regeneration, the water used as treatment water can contain alkaline and acidic substances as an additive. In this case, it is preferable that the pH of the treatment water is above 5.8 and below 8.6 to meet the standard discharge criteria (other items) based on the Water Pollution Prevention Law.

[0083] In the second embodiment, by immersing the take-up roller in treatment water, both sides of the laminated film can be wetted entirely with the treatment water. This improves the permeability of water to the interface between the release agent layer and the substrate film, resulting in easy separation of the substrate film from the laminated film. Water permeation to the interface between the release agent layer and the substrate film is easily induced into the interior of the take-up roller 1 (specifically, the recess 94 of the laminated film 90) by reciprocating winding of the laminated film, and therefore can also be achieved in roller form.

[0084] Furthermore, since the release agent layer tends to have low affinity for water, the take-up roll treatment process is preferably performed while applying ultrasonic vibration to the treatment water. This promotes the guidance of water into the take-up roll 1 and the removal of air from the take-up roll 1.

[0085] In the take-up roll processing step, when the processed water is prepared for use as warm water, the take-up roll processing step can be a step of immersing the take-up roll in warm water contained in a container, a step of adding warm water to the container containing the take-up roll, or a step of heating the water to a specified temperature after containing the water and the take-up roll in the container. A known heater can be used to heat the water.

[0086] When the treated water is used as warm water, the temperature of the treated water is preferably 80°C or higher and 100°C or lower, more preferably 90°C or higher and 100°C or lower.

[0087] In the take-up roll processing step, after the water temperature reaches the target temperature, the take-up roll is held in the processing water for a specified time at that temperature. In this specification, the holding time of the take-up roll in the processing water from the time the target temperature is reached is defined as the immersion time of the take-up roll.

[0088] The immersion time of the take-up roller is preferably 5 minutes or more, more preferably 30 minutes or more. The immersion time of the take-up roller is preferably 10 days or less, more preferably 24 hours or less.

[0089] The water used for treatment can be superheated water. Superheated water refers to water that has been heated to a temperature exceeding 100°C under pressure. When using superheated water to treat the water, the winding roller treatment process involves placing the winding roller and water in a pressure vessel, heating the water, and pressurizing the pressure vessel to a pressure higher than one atmosphere. The water placed in the pressure vessel can be of the same quality as the "normal water" described in the winding roller treatment process of the second embodiment. Therefore, in the winding roller treatment process, the superheated water used as treatment water is obtained by heating "normal water" under pressure.

[0090] In the winding roll processing step, the air pressure inside the pressure vessel and the temperature of the heated water (superheated water) are determined according to Boyle-Charlie's law, and preferably within the following ranges.

[0091] From the viewpoint of easily wetting superheated water into the interface between the substrate film and the release agent layer, the pressure inside the pressure vessel is preferably 1.2 atmospheres or more, more preferably 1.4 atmospheres or more. From the viewpoint of suppressing the melting of the resin component contained in the release film, the pressure inside the pressure vessel is preferably 9.9 atmospheres or less, more preferably 4.7 atmospheres or less. The pressure inside the pressure vessel is adjusted by a pressure regulating valve or the like.

[0092] From the viewpoint of facilitating the wetting of hot water at the interface between the substrate film and the release agent layer, the temperature of the hot water is preferably 105°C or higher, more preferably 110°C or higher. From the viewpoint of suppressing the melting of the resin components contained in the release film, the temperature of the hot water is preferably 180°C or lower, more preferably 150°C or lower.

[0093] In the take-up roll processing step, the holding time of the take-up roll in superheated water (the immersion time of the take-up roll) from the time the water temperature reaches the target temperature is preferably 5 minutes or more, and more preferably 10 minutes or more. In addition, the immersion time of the take-up roll in superheated water is preferably 60 minutes or less, and more preferably 40 minutes or less.

[0094] Next, the use of alkaline aqueous solutions as treatment water will be explained.

[0095] Examples of alkaline aqueous solutions include one or more aqueous solutions selected from sodium hypochlorite aqueous solution, sodium hydroxide aqueous solution, and potassium hydroxide aqueous solution. The alkaline aqueous solution is preferably a sodium hydroxide aqueous solution or a potassium hydroxide aqueous solution, and more preferably a potassium hydroxide aqueous solution.

[0096] Alkaline aqueous solutions may further contain auxiliaries. Examples of auxiliaries include surfactants, water-soluble inorganic compounds, water-soluble organic compounds, and water-soluble solvents. Specifically, examples of auxiliaries include nonionic surfactants, water-soluble inorganic salts, water-soluble organic salts, water-soluble polymers, polysaccharides, alcohols, glycols, and water-soluble organic solvents. Examples of glycols include ethylene glycol, diethylene glycol, and propylene glycol. Examples of water-soluble organic solvents include dimethylformamide (DMF), dimethyl sulfoxide (DMSO), and ethers of ethylene glycol (various cellosols). Auxiliaries can be used alone or in combination of two or more.

[0097] The temperature of the alkaline aqueous solution is preferably 5°C or higher, more preferably 20°C or higher. The temperature of the alkaline aqueous solution is preferably 100°C or lower, more preferably 80°C or lower.

[0098] In the winding roll processing step, the concentration of the alkaline aqueous solution when the winding roll 1 is immersed in the alkaline aqueous solution is preferably 0.5% by mass or more, more preferably 1.0% by mass or more, and even more preferably 3.0% by mass or more. The concentration of the alkaline aqueous solution is preferably 60% by mass or less, more preferably 55% by mass or less, even more preferably 50% by mass or less, even more preferably 47% by mass or less, and even more preferably 45% by mass or less. It should be noted that when the alkaline aqueous solution contains additives, the concentration of the alkaline aqueous solution refers to the total concentration of the alkaline components in the alkaline aqueous solution.

[0099] In the winding roller processing step, the time for which the winding roller 1 is immersed in the alkaline aqueous solution is preferably 5 minutes or more, more preferably 30 minutes or more. The time for which the winding roller 1 is immersed in the alkaline aqueous solution is preferably 10 days or less, more preferably 24 hours or less.

[0100] In the winding roller processing step, by extending the immersion time of winding roller 1, the temperature or concentration of the alkaline aqueous solution can be kept at a mild level.

[0101] After the take-up roll treatment process is carried out, the alkaline aqueous solution used as treatment water is neutralized in a way that allows it to be discarded.

[0102] (The shape of the take-up roller)

[0103] In the winding roller processing step, the winding roller 1 can be immersed in the processing water in its original state, or it can be immersed in the processing water with the winding roller 1 housed in a holding container. Alternatively, the winding roller 1 can be immersed in the processing water while being fixed in place using a clamp (such as a clip). As a holding container, examples include containers with multiple holes (such as cages, sieves, and metal mesh).

[0104] Specific examples 1 and 2 are provided to illustrate the winding roll processing procedure. However, the winding roll processing procedure is not limited to specific examples 1 and 2.

[0105] (Concrete example 1)

[0106] The winding roller processing step in specific example 1 uses... Figure 6 The impregnation is carried out using container 20 as shown.

[0107] Figure 6 The image shows the state where the take-up roller 1 is directly immersed in the treatment water TW (take-up roller treatment process). The laminated film 90 is wound onto the spindle 80 in a reciprocating winding manner with a swing width α.

[0108] exist Figure 6 In this case, the treated water TW is stored in the immersion container 20. The treated water TW can be water, warm water, or an alkaline aqueous solution.

[0109] By directly immersing the take-up roller 1 in the treatment water TW, the treatment water TW penetrates the recess 94 within the laminated film 90 via a corner 94A (a communication portion with the outside) formed on at least one side of the first end E1 and the second end E2. As a result, the treatment water TW easily wets the interface between the substrate film 91 and the release agent layer 92, thus enabling easy separation of the substrate film 91 from the laminated film 90 in subsequent separation processes.

[0110] (Concrete example 2)

[0111] In Specific Example 2, the winding roller processing step is carried out using a pressure vessel (not shown). In this case, superheated water is used as the processing water. A known pressure vessel can be used.

[0112] In the case of specific example 2, the take-up roller processing procedure is carried out as follows.

[0113] The take-up roller 1 and water are placed in a pressure vessel. The water is heated, and the pressure inside the pressure vessel is increased to a pressure higher than 1 bar. Once the pressure inside the pressure vessel reaches the target water temperature, it is maintained at that temperature for a specified time (take-up roller processing step). Then, the pressure inside the pressure vessel is restored to normal atmospheric pressure, the pressure cap is opened, and the take-up roller 1 is removed from the treated water.

[0114] <Release Process>

[0115] The release process is performed by releasing the laminated film 90 from the winding roller 1 after the winding roller processing process.

[0116] In the unwinding process, it is preferable that the surface of the unwound laminated film 90 is not dry. That is, the unwinding process is preferably performed while maintaining the wet state of the take-up roller 1. As a result, the substrate film 91 can be efficiently separated from the laminated film 90.

[0117] <Separation Process>

[0118] The separation process is the process of separating the substrate film 91 from the released laminated film 90.

[0119] The separation process is preferably carried out while the released laminated membrane 90 is passed through washing water. This washes away the release agent layer with the green sheet, so that the release agent layer 92 and ceramic green sheet 93 separated from the laminated membrane 90 will not re-adhere to the substrate membrane 91.

[0120] The cleaning water used in the separation process can be the same type of water as the "normal water" described in the take-up roller treatment process of the second embodiment. The cleaning water may contain additives required for cleaning.

[0121] The temperature of the cleaning water is not particularly limited; it can be room temperature or warm water. From an energy efficiency perspective, room temperature is preferred. When using warm water for cleaning, the temperature is preferably 40°C or higher, more preferably 60°C or higher. Furthermore, it is preferably below 100°C, more preferably below 98°C.

[0122] If the cleaning water is warm, even if the bonding between the substrate film and the release agent layer or the intermediate layer described later is insufficient during the winding roller processing, the bonding between the aforementioned interfaces can be weakened during the separation process, thus easily separating the ceramic green sheet and the release agent layer.

[0123] The separation method of this embodiment preferably includes a step of winding up the substrate film 91 separated from the laminated film 90 after the separation step, and the process from the unwinding step to the winding step is performed in a roll-to-roll manner.

[0124] The separation process is preferably the following: while passing the laminated film 90 released from the take-up roller 1 through cleaning water, the ceramic green sheet and the release agent layer are scraped off from the substrate film 91.

[0125] Examples of scraping mechanisms include scrapers and wire brushes. Both scrapers and wire brushes can use known components. There are no particular limitations on the number or placement of the scraping mechanisms. Alternatively, high-pressure water jets can be used as another scraping method.

[0126] Hereinafter, the containers used in the separation process will sometimes be referred to as cleaning containers. Cleaning containers are, for example, water tanks.

[0127] In the separation process, it is preferable to wind the laminated film released from the take-up roller 1 onto the guide roller while passing it through the cleaning water contained in the cleaning container.

[0128] The purpose of the separation method in this embodiment is to prevent the separated ceramic green sheet and release agent layer from re-adhering to the substrate film 91, thus achieving this goal with a shorter transit time. The transit time in the cleaning water is typically 0.01 seconds or more and 10 minutes or less, preferably 0.1 seconds or more and 5 minutes or less.

[0129] The immersion container used in the winding roller processing step can be the same as or different from the cleaning container used in the separation step.

[0130] When cleaning water is used in the separation process, the separation process is preferably a process in which the substrate membrane 91 separated from the laminated membrane 90 is submerged in water, while the separated ceramic green sheet or release agent layer floats in the water. After the separation process, the substrate membrane 91 separated from the ceramic green sheet and release agent layer is removed from the cleaning water and recycled.

[0131] Regarding the separation process, a specific example 3 is provided for illustration. However, the separation process is not limited to specific example 3.

[0132] (Concrete example 3)

[0133] Specifically, the separation process in Example 3 uses... Figure 7 The removal device 100 shown is used to implement this.

[0134] Figure 7 The removal device 100 shown includes a release mechanism 10, a separation mechanism 30, a take-up mechanism 40, and multiple guide rollers GR1, GR2, and GR3. The release mechanism 10 releases the laminated film 90 from the take-up roller 1 and includes a support member 10A that rotatably supports the shaft core 80 of the take-up roller 1. In the take-up roller 1, the laminated film 90 is wound onto the shaft core 80 (see reference 1) in a reciprocating winding manner having a swing width α. Figure 4 ).

[0135] The separation mechanism 30 includes a guide roller GR2 and a wire brush 34 (an example of a scraping mechanism) that scrapes ceramic green sheets and a release agent layer from the substrate film 91. Figure 7 In this case, the separation mechanism 30 includes a cleaning container 32. The cleaning container 32 contains cleaning water W2.

[0136] The wire brush 34 is positioned opposite to the guide roller GR2, and is positioned to abut against the ceramic green sheet side of the laminated film 90.

[0137] The winding mechanism 40 is a mechanism for winding the substrate film 91 after the ceramic green sheet and the release agent layer are separated into a roll shape, and includes a support member 40A that supports the rolled substrate film 91 so that it can rotate freely. The winding shape of the substrate film 91 can be a reciprocating winding while maintaining the shape of the winding roller 1, or a normal winding in which the oscillation width α is adjusted to eliminate the oscillation.

[0138] For example, after the take-up roller processing step is performed using the method of Example 1 or Example 2, the laminated film 90 can be released from the take-up roller 1 by mounting the shaft core 80 of the take-up roller 1 to the support member 10A of the release mechanism 10.

[0139] The laminated film 90, released from the take-up roller 1 by the release mechanism 10, passes through the cleaning water W2 in the cleaning container 32 after being wound around the guide roller GR1. Then, as the laminated film 90 is wound around the guide roller GR2 which is placed in the cleaning water W2, the ceramic green sheet and the release agent layer are scraped off from the substrate film 91 by the wire brush 34 which is placed opposite the guide roller GR2 (separation process, scraping process).

[0140] After the separation process, the substrate film 91 is removed from the cleaning container 32 and isolated from the ceramic green sheet and release agent layer separated in the cleaning water W2. Then, the substrate film 91 is wound on the guide roller GR3 and wound onto the shaft core 6A by the winding mechanism 40 for recycling.

[0141] [Third Implementation Method]

[0142] (Separation method of substrate membrane)

[0143] The separation method of the third embodiment is the same as that of the second embodiment, except that the take-up roller processing step is changed to a method of exposing the take-up roller to water vapor.

[0144] The method for separating the substrate film according to the third embodiment includes: a step of preparing the take-up roller of the first embodiment; a take-up roller treatment step of treating the take-up roller by exposing the take-up roller to water vapor; a step of releasing the laminated film from the take-up roller after the take-up roller treatment step; and a step of separating the substrate film from the released laminated film.

[0145] Hereinafter, the description will focus on the differences from the second embodiment, and the same reference numerals will be used to describe the same items, thereby omitting or simplifying the description.

[0146] <Creator Roll Processing>

[0147] The take-up roll treatment process is a process of treating the take-up roll by exposing it to water vapor. Preferably, the take-up roll is exposed to water vapor in a container (preferably a pressure vessel) during the take-up roll treatment process.

[0148] In the third embodiment, the container in which the take-up roller 1 is exposed to water vapor is sometimes referred to as a container for water vapor.

[0149] The steam container preferably has a structure that allows steam to be supplied into the steam container when the take-up roller 1 is housed, or a structure that generates steam within the steam container. Examples of steam containers include containers with lids and pressure vessels.

[0150] In the third embodiment, the steam contained in the steam container is preferably either steam generated outside the steam container or steam generated from steam introduced into the steam container or water introduced into the steam container (hereinafter also referred to as steam source water).

[0151] In one embodiment, the take-up roller 1 and the steam are contained in a pressure vessel that serves as a container for the steam.

[0152] The water source water stored in the steam container can be water of the same quality as the "ordinary water" described in the winding roller processing step of the second embodiment. The water source water is heated to change from a liquid state to a gas (water vapor).

[0153] As a means of containing water vapor in a container for water vapor, examples include: (1) a means of introducing water vapor generated externally into a container for water vapor; (2) a means of introducing water from a water vapor source into a container for water vapor, heating the water from the water vapor source to generate water vapor in the container for water vapor, etc.

[0154] As a means of (1) above, for example, a known steam generator (e.g., a boiler) and a steam inlet path for introducing steam generated by the steam generator into a steam container. As a means of (2) above, for example, a known heating means (e.g., a heater) for heating steam source water introduced into the steam container and the steam source water.

[0155] Methods for exposing the take-up roller 1 to water vapor include: placing the take-up roller 1 into a water vapor container filled with water vapor; supplying water vapor into the water vapor container while the take-up roller 1 is contained in the water vapor container; and heating the water vapor source after containing the take-up roller 1 and the water vapor source in the water vapor container.

[0156] In the winding roll processing step, the air pressure and temperature inside the steam container are preferably within the following ranges.

[0157] In the winding roller processing step, the pressure inside the steam container is preferably 1.2 atmospheres or higher, more preferably 1.4 atmospheres or higher. The pressure inside the steam container is preferably 9.9 atmospheres or lower, more preferably 4.7 atmospheres or lower.

[0158] In the winding roller processing step, the temperature inside the steam container is preferably 105°C or higher, more preferably 110°C or higher. The temperature inside the steam container is preferably 180°C or lower, more preferably 150°C or lower.

[0159] In the winding roll processing step, the winding roll 1 is exposed to water vapor for, for example, 5 minutes or more and 60 minutes or less, preferably 10 minutes or more and 40 minutes or less.

[0160] (The shape of take-up roller 1)

[0161] The shape of the take-up roller 1 in the take-up roller processing step of the third embodiment is preferably the same as that of the take-up roller 1 described in the second embodiment.

[0162] The take-up roller processing step in the third embodiment is performed without immersing the take-up roller 1 in liquid water.

[0163] Specific examples 4 to 6 are provided to illustrate the take-up roller processing steps of the third embodiment. However, the take-up roller processing steps of the third embodiment are not limited to specific examples 4 to 6.

[0164] (Concrete example 4)

[0165] The winding roller processing step in specific example 4 uses... Figure 8A The water vapor shown is generated using container 60.

[0166] Figure 8A The image shows the state in which the take-up roller 1 is stored in the steam container 60 in its original form. In the take-up roller 1, the laminated film 90 is wound onto the spindle 80 in a reciprocating winding manner with a swing width α.

[0167] The steam container 60 includes a container body 62 and a lid 61. A steam inlet passage 63 for introducing steam V1 and a pressure discharge pipe 64 are formed on the upper part of the lid 61. A pressure discharge valve 73 for controlling the pressure inside the steam container 60 is disposed on the pressure discharge pipe 64. In addition, an edge 601 is formed along the outer periphery of the lid 61.

[0168] The specific winding roller processing procedure in Example 4 is implemented as follows.

[0169] First, the take-up roller 1 is housed in the steam container 60. Steam V1 generated by the steam generator (not shown) is introduced into the steam container 60 through the steam inlet path 63.

[0170] The take-up roller 1 is exposed to water vapor V1 introduced from the water vapor inlet path 63 into the water vapor container 60.

[0171] In Example 4, by exposing the take-up roller 1 to water vapor V1, the water vapor V1 penetrates the recess 94 within the laminated film 90 via a corner 94A (a communication portion with the outside) formed on at least one side of the first end E1 and the second end E2. As a result, for the same reason as in Example 1, the substrate film 91 can be easily separated from the laminated film 90 during the separation process.

[0172] (Concrete example 5)

[0173] The winding roller processing step in specific example 5 uses... Figure 8B The pressure vessel 400 shown is used for implementation (an example of a steam vessel).

[0174] Figure 8B The text indicates that the take-up roller 1 is stored in the pressure vessel 400 in a cage 407 (an example of a holding container). A wheel 407A is provided at the bottom of the cage 407.

[0175] The pressure vessel 400 includes an outer frame 402, a pressure vessel body 401 disposed within the outer frame 402, and a cover 403 that seals the pressure vessel body 401 and the outer frame 402.

[0176] A steam inlet pipe 404 and a steam outlet pipe 405 are provided on the upper part of the pressure vessel 400. The steam inlet pipe 404 is connected to the boiler 420. Steam regulating valves 404A and 405A are respectively installed on the steam inlet pipe 404 and the steam outlet pipe 405.

[0177] A drain pipe 406 is provided at the bottom of the pressure vessel 400. The drain pipe 406 discharges the water W3 introduced into the pressure vessel body 401 through the drain port 406B. A drain regulating valve 406A is provided on the drain pipe 406.

[0178] Additionally, a heater 411 for heating the water W3 introduced into the pressure vessel body 401 is disposed at the bottom of the pressure vessel 400. The placement of the heater 411 is not limited to... Figure 8B For example, heater 411 can also be configured inside the outer frame 402 and outside the pressure vessel body 401.

[0179] The pressure vessel body 401 has a water-retaining wall 410 and a storage section 409 for storing water W3 at the bottom, and a mounting platform 408 at a position higher than the storage section 409. A cage 407 for holding the take-up roller 1 is arranged on the mounting platform 408.

[0180] The stage 408 has multiple openings 408A through which water vapor generated from water W3 in the storage section 409 diffuses into the pressure vessel body 401.

[0181] The specific winding roller processing procedure in Example 5 is implemented as follows.

[0182] In specific example 5, the water vapor used in the winding roll processing step is only used from the inside of the pressure vessel 400 (in Figure 8B In the case of water vapor generated by water W3 (water vapor source water) in storage section 409, the situation will be explained.

[0183] First, the winding roller 1 and water W3, which are held in the cage 407, are stored in the storage section 409 of the pressure vessel body 401. The water W3 is heated by the heater 411 to generate water vapor V3. The generated water vapor V3 diffuses from the opening 408A of the stage 408 into the pressure vessel body 401.

[0184] As a result, the pressure vessel body 401 is filled with water vapor V3, and the winding roller 1 is exposed to water vapor V3.

[0185] In Example 5, by exposing the take-up roller 1 to water vapor V3, water vapor V2 penetrates into the recess 94 within the laminated film 90 via a corner 94A (a communication portion with the outside) formed on at least one side of the first end E1 and the second end E2 of the laminated film 90. As a result, for the same reason as in Example 1, the substrate film 91 can be easily separated from the laminated film 90 during the separation process.

[0186] (Concrete example 6)

[0187] In specific example 6, it is explained that the water vapor used in the winding roll processing step is only water vapor generated outside the pressure vessel 400 (in... Figure 8B In the case of steam V2 generated in boiler 420. Figure 8B The text indicates that water W3, which can generate water vapor, is introduced into the storage section 409 of the pressure vessel body 401. However, in the case of Specific Example 6, water W3 may not be introduced.

[0188] First, the winding roller 1, which is held in the cage 407, is housed in the pressure vessel body 401. Steam V2 generated by the boiler 420 is introduced into the pressure vessel body 401 from the steam inlet 404B of the steam inlet pipe 404, exposing the winding roller 1 to the steam V2.

[0189] (Concrete example 7)

[0190] The winding roller processing step in specific example 7 uses... Figure 8C The pressure vessel 60A shown is implemented in place of the pressure vessel 400 used in Specific Example 5.

[0191] exist Figure 8C The diagram shows the state in which the take-up roller 1 and water W1 (water source for steam) are housed together in the pressure vessel 60A.

[0192] A mounting platform 66 with a height greater than the depth of water W1 is provided inside the pressure vessel 60A, and a winding roller 1 is arranged on the mounting platform 66.

[0193] Pressure vessel 60A includes a pressure vessel body 62A and a pressure cover 61A. An edge 601A is formed along the outer periphery of the pressure cover 61A. A pressure control unit 70 is disposed on the upper part of the pressure cover 61A. The pressure control unit 70 controls the internal pressure of the pressure vessel 60A to a first pressure higher than one atmosphere. The pressure control unit 70 can be, for example, a pressure regulating valve (e.g., a safety valve), a pressure regulating valve (e.g., a pressure relief valve), or a pressure regulating valve commonly used in pressure cookers (e.g., counterweight type and spring type).

[0194] exist Figure 8C In this case, the pressure control unit 70 includes a safety valve 71 and a pressure sensor 72. The safety valve 71 regulates the internal pressure of the pressure vessel 60A to a predetermined pressure by controlling the opening area of ​​the steam outlet 71A formed on the pressure cover 61A. The control of the opening area of ​​the steam outlet 71A is controlled by the computer control unit based on the pressure value obtained by the pressure sensor 72. The control of the internal pressure of the pressure vessel 60A is not limited to this.

[0195] A heater 68 for heating water W1 is disposed at the lower part of the pressure vessel body 62A.

[0196] The specific winding roller processing procedure in Example 7 is implemented as follows.

[0197] First, the take-up roller 1 is housed on the mounting platform 66 located within the pressure vessel 60A, and water W1 is housed at the bottom of the pressure vessel 60A. The water W1 within the pressure vessel 60A is heated by the heater 68, and the internal pressure of the pressure vessel 60A is increased to a pressure higher than one atmosphere, thereby generating water vapor within the pressure vessel 60A, filling the pressure vessel 60A with water vapor. The take-up roller 1, positioned on the mounting platform 66, is not immersed in the water W1 but is exposed to the water vapor (not shown).

[0198] In Example 7, by exposing the take-up roller 1 to water vapor, the water vapor penetrates the recess 94 within the laminated film 90 via a corner 94A (a connection to the outside) formed on at least one side of the first end E1 and the second end E2. As a result, for the same reason as in Example 1, the substrate film 91 can be easily separated from the laminated film 90 during the separation process.

[0199] <Discharge process and separation process>

[0200] The discharge and separation processes of the third embodiment can be implemented using the same methods as the discharge and separation processes described in the second embodiment.

[0201] [Variations on the implementation method]

[0202] In the first embodiment, an example of a laminated film 90 wound on the take-up roller 1 was described, but it is also possible to wind the film instead of the laminated film 90. Figure 3 The laminated film 90B shown is an example.

[0203] Figure 3 This is a cross-sectional view of a laminated film 90B according to one embodiment.

[0204] Compared to Figure 2 The laminated film 90 shown, and the laminated film 90B further include an intermediate layer 921 disposed between the substrate film 91 and the release agent layer 92. Apart from this, the laminated film 90B is for use with... Figure 2 The laminated film 90 shown has the same structure.

[0205] The laminated film 90B is sequentially configured with a substrate film 91, an intermediate layer 921, a release agent layer 92, and a ceramic green sheet 93. The release film 95A includes a substrate film 91, an intermediate layer 921, and a release agent layer 92.

[0206] Figure 3 In the diagram, 'a' represents the substrate film side surface of intermediate layer 921, 'b' represents the release agent layer side surface of intermediate layer 921, 'd' represents the ceramic green sheet side surface of release agent layer 92, and 'c' represents the intermediate layer side surface of release agent layer 92.

[0207] Preferably, the substrate film 91 of the laminated film 90B is in direct contact with the intermediate layer 921. Figure 3 In this case, the substrate film 91 is in direct contact with the intermediate layer 921, and the intermediate layer 921 is in direct contact with the release agent layer 92. In addition, the release agent layer 92 is in direct contact with the green sheet portions 931, 932, and 933.

[0208] In specific example 3, regarding the use Figure 7 The separation process is described using the removal device 100 shown, but it can also be used instead of the removal device 100. Figure 9 The removal device 100A shown is used to perform the separation process.

[0209] Figure 9 The removal device 100A shown is relative to Figure 7 The removal device 100 shown has the same structure as the removal device 100, except that it has a circulation mechanism 300. The circulation mechanism 300 is a mechanism that returns the cleaning water W2 to the cleaning container 32 after filtering it with a filter 35.

[0210] The circulation mechanism 300 includes: a drain outlet 32A disposed in a cleaning container 32; a filter 35 for filtering the cleaning water W2; a storage section 36 for storing the filtered cleaning water W2; an inlet 38 disposed in the opening of the cleaning container 32; and a circulation path 37 connecting the drain outlet 36A and the inlet 38 at the bottom of the storage section 36.

[0211] Figure 9 In this case, the stripping agent layer containing the green sheet separated from the laminated membrane 90, together with the cleaning water W2, is discharged from the drain port 32A of the cleaning container 32 and filtered by the filter 35. The cleaning water W2 filtered by the filter 35 is stored in the storage section 36 and then discharged from the bottom drain port 36A of the storage section 36. It circulates in the circulation path 37 and is then supplied back into the cleaning container 32 from the inlet port 38.

[0212] exist Figure 7 and Figure 9 In the removal apparatus described herein, a foreign matter removal mechanism may be provided at any location between the downstream side of the cleaning container 32 (the part where the substrate film 91 is removed from the cleaning water W2 after the separation process) and the winding mechanism 40. The foreign matter removal mechanism removes foreign matter adhering to the substrate film 91. Examples of foreign matter include ceramic flakes and release agent layers remaining on the substrate film 91, as well as water droplets adhering to the substrate film 91. There are no particular limitations on the foreign matter removal mechanism; for example, an air knife and a dryer can be used.

[0213] exist Figure 7 and Figure 9 The number of guide rollers in the removal device described herein is not particularly limited.

[0214] The structure of the laminated film used in the above embodiments will be described.

[0215] [Laminated film]

[0216] The laminated film used in the embodiments includes: a release film having a substrate film and a release agent layer; and a ceramic green sheet.

[0217] In the substrate film separation method of the described embodiment, the substrate film is separated from the laminated film. That is, the laminated film is separated into the substrate film and layers other than the substrate film.

[0218] Hereinafter, the "layers other than the substrate film" will sometimes be referred to as coating layers.

[0219] For example, in the case where the laminated film consists of a substrate film, a release agent layer and a ceramic green sheet, the coating layer (the layer other than the substrate film) is the release agent layer and the ceramic green sheet.

[0220] The release agent layer can be a single layer or a multilayer consisting of two or more release agent layers of the same or different types. The ceramic green sheet can be disposed on at least a portion of the release agent layer or on the entire surface of the release agent layer.

[0221] The coating layer may also include layers other than the release agent layer and the ceramic green sheet.

[0222] For example, the coating layer may include an intermediate layer, a release agent layer, and a ceramic green sheet, with the intermediate layer disposed between the substrate film and the release agent layer. The intermediate layer may be a single layer or a multilayer consisting of two or more intermediate layers of the same or different types.

[0223] One method of laminating a film is to directly laminate a substrate film, a release agent layer, and a ceramic green sheet in sequence. Another method is to directly laminate a substrate film, an intermediate layer, a release agent layer, and a ceramic green sheet in sequence.

[0224] <Substrate Film>

[0225] The substrate film is a resin film made by forming a film from a predetermined recycled resin component. As the resin film, polyester films such as polyethylene terephthalate film, polybutylene terephthalate, and polyethylene naphthalate; polyolefin films such as polyethylene film and polypropylene film; polyimide film; polyamide film; polycarbonate film; polyacetate film; ethylene-vinyl acetate copolymer (EVA) film; ethylene-(meth)acrylate copolymer film; ethylene-(meth)acrylate copolymer film; cyclic olefin polymer film; polyurethane film; polyphenylene sulfide film; cellophane, etc. Among these, polyester film is preferred from the viewpoint of heat resistance and strength. In this specification, the main component or principal component refers to a component that accounts for 50% or more of the total mass of the material.

[0226] From the viewpoint of ease of resin recycling and regeneration, polyester films with any one of polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate as the main component are preferred as the polyester film. Furthermore, the resin film may contain known fillers, colorants, antistatic agents, antioxidants, organic lubricants, and catalysts. Additionally, the resin film may be transparent or colored as needed. Furthermore, at least one surface of the substrate film may be pre-treated with etching processes such as sputtering, corona discharge, flame etching, ultraviolet irradiation, electron beam irradiation, and oxidation, as required.

[0227] There is no particular limitation on the thickness of the substrate film, but from the viewpoint of strength and rigidity, it is preferably 10 μm or more and 500 μm or less, more preferably 15 μm or more and 300 μm or less, and even more preferably 20 μm or more and 200 μm or less.

[0228] <Resistant Layer>

[0229] The release agent layer is preferably formed from a release agent composition. There are no particular limitations on the release agent composition used to form the release agent layer, as long as it possesses release properties. For example, release agent compositions mainly composed of organosilicon compounds, fluorine compounds, compounds containing long-chain alkyl groups, olefin resins, diene resins, and other thermoplastic resin materials can be used. Furthermore, release agent compositions mainly composed of energy-curable or thermosetting resins are preferred. These release agent compositions can be used alone or in combination of two or more.

[0230] In a release agent composition with an organosilicon compound as the main component, examples of such organosilicon compounds include those having an organopolysiloxane as the basic framework. Other examples of such organosilicon compounds include thermosetting organosilicon compounds such as addition reaction type and condensation reaction type; and energy-curing organosilicon compounds such as ultraviolet curable type and electron beam curable type.

[0231] In stripper compositions with fluorinated compounds as the main component, examples of fluorinated compounds include fluorosilicone compounds, fluoroboron compounds, and compounds containing poly(perfluoroalkylene ether) chains.

[0232] In stripping agent compositions with long-chain alkyl compounds as the main component, examples of such long-chain alkyl compounds include: polyvinyl urethane obtained by reacting a polyvinyl alcohol polymer with a long-chain alkyl isocyanate; alkyl urea derivatives obtained by reacting polyethyleneimine with a long-chain alkyl isocyanate; and copolymers of long-chain alkyl esters of (meth)acrylate. Furthermore, in alkyd resins obtained by the condensation reaction of polyols and polyacids, long-chain alkyl-modified alkyd resins using long-chain fatty acids as modifiers can be used.

[0233] As a release agent composition primarily composed of an energy-curable resin, it preferably includes, for example, an energy-curable compound having reactive functional groups selected from (meth)acryloyl, alkenyl, and maleimide groups, and a polyorganosiloxane. In the release agent layer formed from this release agent composition, since the energy-curable compound and the polyorganosiloxane have different molecular structures, polarities, and molecular weights, the components from the polyorganosiloxane are segregated near the outer surface of the release agent layer before curing, and then immobilized by energy-curing. This improves the release properties of the release agent layer. The release agent composition primarily composed of an energy-curable resin may further contain a photopolymerization initiator.

[0234] Examples of release agent compositions primarily composed of thermosetting resins include those primarily composed of melamine resin and those primarily composed of epoxy resin. A melamine resin-based release agent composition may include a composition comprising melamine resin as the main component, an acid catalyst for thermosetting the melamine resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Similarly, an epoxy resin-based release agent composition may include an epoxy resin as the main component, an acidic or alkaline thermosetting catalyst for thermosetting the epoxy resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Before curing, the polyorganosiloxane component is segregated near the outer surface of the release agent layer; after curing, the segregation is fixed. This improves the release properties of the release agent layer.

[0235] In addition to the resin component, the release agent layer may also contain other additives. Examples of such additives include anti-aging agents, light stabilizers, flame retardants, conductive agents, antistatic agents, and plasticizers.

[0236] The thickness of the release agent layer can be appropriately selected without particular limitation. For example, it is preferably 0.02 μm or more and 5 μm or less, more preferably 0.03 μm or more and 2 μm or less, and even more preferably 0.05 μm or more and 1.5 μm or less.

[0237] <Intermediate Layer>

[0238] Examples of intermediate layers include water-soluble intermediate layers, alkali-degradable intermediate layers, and layers that are hydrophilic but not water-soluble.

[0239] (Water-soluble intermediate layer)

[0240] When the intermediate layer is a water-soluble intermediate layer, examples of water-soluble resins contained in the intermediate layer include water-soluble polyvinyl alcohol resin, water-soluble acrylic resin, water-soluble polyester resin, water-soluble polyester polyurethane resin, water-soluble ethylene ionomer resin, water-soluble polyvinylpyrrolidone resin, water-soluble poly-N-vinylacetamide resin, water-soluble polyamide resin, water-soluble ethylene-vinyl alcohol resin, and water-soluble starch.

[0241] The content of water-soluble resin in the intermediate layer is preferably 30% by mass and 90% by mass or less relative to the total mass of the intermediate layer, more preferably 40% by mass and 80% by mass or less. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.

[0242] (Alkali-decomposing intermediate layer)

[0243] When the intermediate layer is an alkali-degradable intermediate layer, the alkali-degradable resin contained in the intermediate layer can be, for example, phenolic resin, polyacrylic acid, polyamide resin, polyester resin, and polylactic acid.

[0244] The content of alkali-degradable resin in the intermediate layer is preferably 30% by mass or more and 90% by mass or less relative to the total mass of the intermediate layer, more preferably 40% by mass or more and 80% by mass or less. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.

[0245] (The layer shown is hydrophilic and water-insoluble)

[0246] When the intermediate layer is a hydrophilic and water-insoluble layer, from the viewpoint that it is easier to separate the coating layer from the substrate film side surface of the intermediate layer, the intermediate layer is preferably a layer composed of a silane-based compound that exhibits condensation properties through hydrolysis.

[0247] The following is based on Figure 3 Taking the laminated membrane 90B as an example, we will explain whether the intermediate layer 921 is hydrophilic and whether the intermediate layer 921 is insoluble in water.

[0248] In this specification, regarding whether the intermediate layer 921 is "hydrophilic", if the contact angle of water on the substrate film side surface of the intermediate layer 921 is less than 55 degrees, the intermediate layer 921 is determined to be hydrophilic.

[0249] Figure 3In the case of the laminated film 90B shown, the substrate film side surface of the intermediate layer 921 ( Figure 3 In the middle, when the water contact angle of symbol a) is below 55 degrees, the intermediate layer 921 is hydrophilic.

[0250] Furthermore, from the viewpoint of promoting the separability of the substrate film 91, the contact angle is preferably 50 degrees or less, more preferably 45 degrees or less. This contact angle is obtained by measuring the water contact angle of the surface of the intermediate layer 921 that is in contact with the substrate film 91 (the peeled surface) after the substrate film 91 has been separated from the laminated film 90B, that is, after the intermediate layer 921 has been brought into contact with water and the interface between the intermediate layer 921 and the substrate film 91 has been peeled off. Pure water is used as the water in contact with the intermediate layer when measuring the water contact angle.

[0251] Specifically, the intermediate layer 921 is separated from the substrate film 91 by the following method, and the water contact angle of the substrate film side surface of the intermediate layer 921 is measured. The obtained value is taken as the water contact angle of the substrate film side surface of the intermediate layer 921.

[0252] A 50mm wide adhesive tape (manufactured by Nitto Denko Corporation, product name "Polyester Adhesive Tape No. 31B") was attached to the surface of the release agent layer of the laminated film, and then cut into 50mm×50mm sizes to make test pieces.

[0253] Next, 300 mL of 90°C purified water was filled into a 500 mL glass beaker as treatment water, and the entire test piece was immersed in the purified water for 3 hours. Then, it was confirmed that the test piece separated into a laminate and a substrate film. The laminate, in which the release agent layer and intermediate layer are integrally mounted on an adhesive tape, was removed from the purified water and dried at room temperature for 24 hours. Then, the contact angle of the surface of the intermediate layer mounted on the adhesive tape (the surface of the intermediate layer in contact with the substrate film surface) was measured. The contact angle was measured using a contact angle meter (manufactured by Kyowa Interface Science Co., Ltd., product name "DM-701") via the static drop method based on JIS R3257:1999. Distilled water was used for the droplet.

[0254] In this specification, regarding whether the intermediate layer 921 is "non-water soluble," the surface of the release agent layer was measured using the following method ( Figure 3 In the middle, the water contact angle (symbol d) is relative to the substrate film side surface of the intermediate layer 921 ( Figure 3 In the case where the difference in contact angle between the intermediate layer 921 and the water (symbol a) is 30 degrees or more, the intermediate layer 921 is determined to be non-water-soluble. This difference in contact angle is preferably 40 degrees or more, and more preferably 50 degrees or more. If this difference is small, it means that the components constituting the intermediate layer 921 have dissolved into the water, and the exposed stripping agent layer 92 is measured.

[0255] Furthermore, there is no particular limitation on the contact angle of water on the surface of the stripper layer, which is typically 80 degrees or more, preferably 85 degrees or more, and more preferably 90 degrees or more. Additionally, the upper limit of the contact angle of water on the surface of the stripper layer is typically 150 degrees, preferably 140 degrees, and more preferably 130 degrees.

[0256] The contact angle of water on the surface of the stripper layer was measured using a contact angle meter (manufactured by Kyowa Interface Science Co., Ltd., product name "DM-701") via the static drop method based on JIS R3257:1999. Distilled water was used for the droplets.

[0257] When the intermediate layer is a hydrophilic and water-insoluble layer, tetraalkoxysilane is preferred as the silane compound. More preferred examples of tetraalkoxysilane include tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, and tetrabutoxysilane. From the viewpoint of ease of acquisition and reactivity of hydrolysis reaction, at least one of tetramethoxysilane and tetraethoxysilane, or a mixture of tetramethoxysilane and tetraethoxysilane, is preferred.

[0258] Commercially available products can also be used as hydrolytic condensates of the silane compounds.

[0259] The laminated films used in each embodiment are preferably laminated films for specific applications. For example, to improve the tight adhesion between the substrate film and the coating layers (intermediate layer, release agent layer, and ceramic green sheet) during use, the laminated film, which includes an intermediate layer, a release agent layer, and a ceramic green sheet, and is used for a specific application (in practical application), may be composed of an intermediate layer incorporating a non-water-soluble resin component together with the silane-based compound. The intermediate layer may be composed of a composition incorporating a non-water-soluble resin component coated and cured.

[0260] Examples of water-insoluble resin components include energy-curable resins, epoxy resins, and melamine resins. Preferably, the water-insoluble resin component maintains its water-insoluble nature even after curing.

[0261] As a "non-water-soluble resin component", energy-curable resins are preferred, such as dipentaerythritol tri(meth)acrylate, dipentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, pentaerythritol tri(meth)acrylate, and pentaerythritol tetra(meth)acrylate and other polyfunctional (meth)acrylates.

[0262] When the intermediate layer contains a hydrophilic and water-insoluble resin (preferably the silane-based compound), the content of the hydrophilic and water-insoluble resin relative to the total mass of the intermediate layer is preferably 30% by mass or more and 90% by mass or less, more preferably 40% by mass or more and 80% by mass or less. The upper limit of the content of the hydrophilic and water-insoluble resin in the intermediate layer is 100% by mass.

[0263] When the intermediate layer contains a hydrophilic and water-insoluble resin (preferably the aforementioned silane compound) and a "water-insoluble resin component," the content of the hydrophilic and water-insoluble resin relative to the total mass of the intermediate layer is preferably 30% by mass or more and 90% by mass or less, more preferably 40% by mass or more and 80% by mass or less. The content of the "water-insoluble resin component" relative to the total mass of the intermediate layer is preferably 10% by mass or more and 70% by mass or less, more preferably 20% by mass or more and 60% by mass or less. The maximum value of the total content of the hydrophilic and water-insoluble resin and the "water-insoluble resin component" in the intermediate layer is 100% by mass.

[0264] Furthermore, when an energy-curable resin is incorporated into the intermediate layer, the intermediate layer preferably further comprises a photopolymerization initiator. Examples of photopolymerization initiators preferably include 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropane-1-one, 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-1-butanone, or 2-(dimethylamino)-2-[(4-methylphenyl)methyl]-1-[4-(4-morpholino)phenyl]-1-butanone.

[0265] When the intermediate layer contains a photopolymerization initiator, and the "non-water-soluble resin component" is set to 100 parts by mass, the content of the photopolymerization initiator is preferably 20 parts by mass or less, more preferably 10% by mass or less.

[0266] From the viewpoint that water can easily seep into the intermediate layer when it comes into contact with water, the thickness of the intermediate layer is preferably 0.01 μm or more and 1 μm or less, more preferably 0.03 μm or more and 0.5 μm or less, and even more preferably 0.05 μm or more and 0.3 μm or less.

[0267] <Ceramic raw shards>

[0268] Ceramic green sheets are obtained by coating a ceramic slurry onto the surface of a release agent layer opposite to the substrate film, followed by drying the slurry. Coating can be performed using methods such as slot die coating or blade coating.

[0269] Ceramic slurry contains ceramic powder, binder components, and solvents.

[0270] Examples of ceramic powders include barium titanate, titanium dioxide, aluminum oxide, zirconium oxide, zinc oxide, aluminum silicate, and silicon nitride, which are dielectric powders.

[0271] Examples of adhesive components include butyraldehyde resins and acrylic resins. Examples of solvents include organic solvents and aqueous solvents.

[0272] In the laminated films used in the aforementioned embodiments, the ceramic green sheets are not attached to the entire surface of the release agent layer. Therefore, in the residue of the coating layer with green sheets after the separation process, the green sheets partially remain attached to or not attached to the surface of the release agent layer. Consequently, the properties of the residue of the coating layer with green sheets are substantially the same as the properties of the residue of the coating layer without attached ceramic green sheets.

[0273] In the cases where the laminated film used in the above embodiments has a hydrophilic and water-insoluble intermediate layer, the residue of the separated coating layer with green flakes forms a structure having a release agent layer surface and a hydrophilic intermediate layer surface. When this residue is immersed in water, due to surface tension, the release agent layer surface faces the air, and the intermediate layer surface faces the water, thus stabilizing it. That is, the residue of this structure is more likely to exist at the water-air boundary than in water. Here, since the residue with the coating layer with green flakes is an extremely thin film, even if the density is slightly high, the buoyancy generated by surface tension will be greater, and since the intermediate layer is water-insoluble, it is considered that it can continuously float on the surface of water.

[0274] The laminated films used in these embodiments are typically used to protect the surfaces of other functional sheets and components during manufacturing, handling, and storage for specific purposes. In practice, after fulfilling their protective function, they are mostly peeled off from the surface and discarded. Therefore, by using the laminated film, the coating layer and substrate film of the raw sheet can be easily separated from the laminated film, making it a highly valuable application from the perspectives of resource conservation and environmental protection.

[0275] Explanation of reference numerals in the attached figures

[0276] 1: Take-up roller

[0277] 10: Releasing agency

[0278] 10A: Support component

[0279] 20: Containers for impregnation

[0280] 30: Separation mechanism

[0281] 32: Containers for cleaning

[0282] 32A: Drain outlet

[0283] 34: Wire brush

[0284] 35: Filter

[0285] 36: Storage Department

[0286] 36A: Bottom drain

[0287] 37: Circular route

[0288] 38: Injection port

[0289] 40: Winding mechanism

[0290] 40A: Support component

[0291] 60: Containers for steam

[0292] 60A: Pressure Vessel

[0293] 61: Cover

[0294] 61A: Pressure Cover

[0295] 62: Container body

[0296] 62A: Pressure vessel body

[0297] 63: Water vapor inlet path

[0298] 64: Pressure relief pipe

[0299] 66: Platform

[0300] 68: Heater

[0301] 70: Pressure Control Department

[0302] 71: Safety valve

[0303] 71A: Steam exhaust port

[0304] 72: Pressure sensor

[0305] 73: Pressure relief valve

[0306] 80: Shaft core

[0307] 82: Through hole

[0308] 90, 90A, 90B: Laminated films

[0309] 91: Substrate film

[0310] 92: Release agent layer

[0311] 93: Ceramic raw shards

[0312] 94: Concave

[0313] 94A: Corner

[0314] 94B: Gap width

[0315] 95, 95A: Release film

[0316] 100, 100A: Removal device

[0317] 300: Circulation mechanism

[0318] 400: Pressure Vessel

[0319] 401: Pressure vessel body

[0320] 402: External frame

[0321] 403: Cover

[0322] 404: Steam inlet pipe

[0323] 404A, 405A: Steam regulating valve

[0324] 404B: Steam inlet

[0325] 405: Steam exhaust pipe

[0326] 406: Drain pipe

[0327] 406A: Drain regulating valve

[0328] 406B: Drainage outlet

[0329] 407: Cage

[0330] 407A: Wheels

[0331] 408: Platform

[0332] 408A: Opening

[0333] 409: Storage Department

[0334] 410: Water retaining wall

[0335] 411: Heater

[0336] 420: Boiler

[0337] 601, 601A: Edge

[0338] 921: Intermediate Layer

[0339] 931, 932, 933: Raw Film Department

Claims

1. A take-up roller comprising a shaft and an elongated laminated film wound around the outer peripheral surface of the shaft, characterized in that, The laminated film comprises: a release film having a substrate film and a release agent layer; and a ceramic green sheet, wherein the substrate film, the release agent layer, and the ceramic green sheet are arranged sequentially. The ceramic green sheet has at least a first green sheet portion attached to a first end side in the width direction of the laminated film and a second green sheet portion attached to a second end side opposite to the first end side. The first green sheet portion and the second green sheet portion are respectively arranged along the length direction of the laminated film. A recess formed on the release agent layer, sandwiched between the first green sheet portion and the second green sheet portion, The laminated film is wound onto the shaft core in a reciprocating winding manner with a swing width α. When viewed in a cross section orthogonal to the length direction of the laminated film, the swing width α is a dimension larger than the width β1 from the edge of the laminated film on the first end side to the inner edge of the first green sheet portion, or a dimension larger than the width β2 from the edge of the laminated film on the second end side to the inner edge of the second green sheet portion, or a dimension larger than both the width β1 and the width β2.

2. The take-up roller according to claim 1, characterized in that, The ceramic green sheet has a plurality of third green sheet portions attached to the release agent layer along the width direction of the laminated film. One end of the third green sheet portion along its length is connected to the first green sheet portion. The other end of the third green sheet portion along its length is connected to the second green sheet portion. A recess is formed on the release agent layer, which is surrounded by the first green sheet portion, the second green sheet portion and the two third green sheet portions.

3. The take-up roller according to claim 2, characterized in that, At least one of the multiple corners of the recess is connected to the outside.

4. The take-up roller according to any one of claims 1 to 3, characterized in that, The laminated film further includes an intermediate layer disposed between the substrate film and the release agent layer.

5. A method for separating a substrate membrane, characterized in that, have: The process of preparing the take-up roller as described in claim 1; The take-up roll treatment process involves immersing the take-up roll in treatment water or exposing it to water vapor to treat the take-up roll; The process of releasing the laminated film from the take-up roller after the take-up roller processing step; The process of separating the substrate film from the released laminated film.

6. The method for separating the substrate membrane according to claim 5, characterized in that, In the take-up roller processing step, the processing water used when immersing the take-up roller is water or an alkaline aqueous solution.

7. The method for separating the substrate film according to claim 5 or 6, characterized in that, Following the separation process, there is also a process of winding up the substrate film separated from the laminated film. The release process and the winding process are performed in a roll-to-roll manner.

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