Apparatus for manufacturing polymeric resin-impregnated film

Abstract

To provide a manufacturing apparatus for continuously and stably manufacturing a polymeric resin-impregnated film in which a porous sheet is impregnated with a functional polymer.SOLUTION: An apparatus for manufacturing a polymeric resin-impregnated film for continuously manufacturing a polymeric resin-impregnated film includes a base material conveyance mechanism for conveying a continuously traveling sheet-like base material, a coating mechanism for coating a polymeric resin-containing solution onto the base material, and forming a coating film, and a porous sheet lamination mechanism for laminating the continuously traveling porous sheet on a liquid surface of the coating film, and forming a laminate in which the base material, the polymeric resin-containing solution and the porous sheet are laminated in this order, wherein the porous sheet lamination mechanism includes two or more roller-shaped supporting means for supporting a surface on a side opposite to a surface contacting the polymeric resin-containing solution of the porous sheet, just before a liquid contact part where the porous sheet and the polymeric resin-containing solution are brought into contact with each other.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to an apparatus and method for producing a polymer resin-impregnated film in which a porous film is impregnated with a functional polymer resin. [Background technology]

[0002] In recent years, interest in environmental issues has increased, and technological developments have been active in devices and equipment that utilize hydrogen, such as fuel cells and water electrolysis. In particular, interest has been growing in functional membranes made of functional polymer materials, such as electrolyte membranes that allow the permeation of cationic ions such as hydrogen ions or anionic ions such as hydroxide ions, as important components that affect the performance of devices and equipment. However, there are issues with the durability and mechanical strength of functional membranes, and the introduction of reinforcing materials into functional membranes has been considered, and many reports have been published on methods for manufacturing functional membranes using such reinforcing materials.

[0003] For example, the following manufacturing method has been reported (see, for example, Patent Document 1). Fig. 4 is a schematic diagram showing the configuration of a manufacturing apparatus according to Patent Document 1. The manufacturing method of Patent Document 1 will be described with reference to Fig. 4.

[0004] In the manufacturing method of Patent Document 1, a polymer electrolyte solution is applied onto a continuously supplied substrate 71 using coating means 72, a porous material 73 is laminated onto the coated surface, and the coated surface is dried using a heating roller 74. Further, the polymer electrolyte solution is applied onto the porous material 73 using coating means 75, and the porous material 73 is dried in a drying oven 76, thereby producing a laminated sheet 78 in which a polymer electrolyte membrane 77 reinforced with the porous material 73 is formed on the substrate 71. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2011-222499 A Summary of the Invention [Problem to be solved by the invention]

[0006] In the configuration of Patent Document 1, as shown in Fig. 4, a polymer electrolyte solution is applied onto a substrate 71 to form a coating film (not shown) of the polymer electrolyte solution. Next, a porous material 73 is attached to the coated surface to impregnate the porous material 73 with the polymer electrolyte solution, and after drying, the polymer electrolyte solution is again applied onto the upper surface of the porous material 73 and dried. However, the configuration of Patent Document 1 has the following problem: In other words, in the impregnation step in which the porous material 73 is bonded, the influence of the surface state of the porous material 73, the void size, and the density variation, etc., causes non-uniformity in the impregnation state of the polymer electrolyte solution, and it is easy for some parts of the voids in the porous material 73 to be left unfilled with the polymer electrolyte solution.

[0007] In addition, the supplied porous material 73 has its transport direction changed to approximately parallel to the transport direction of the substrate 71 via the support roll 80, and then comes into contact with the coating film of the polymer electrolyte solution, leading to the impregnation process in which the porous material 73 is impregnated with the polymer electrolyte solution.

[0008] Here, the following problem occurs in the portion where the porous material 73 comes into contact with the electrolyte solution in the impregnation step (hereinafter referred to as the liquid-contacting portion). A schematic diagram of the vicinity of the contacting portion between the porous material 73 and the electrolyte solution in Fig. 4 is shown in Fig. 5, and will be described with reference to Fig. 5. Fig. 5 shows a portion (liquid-contacting portion 82) where the porous material 73 transported via a support roll 80 comes into contact with a coating film 81 of the polymer electrolyte solution formed on a substrate 71.

[0009] In this liquid contact portion 82, the polymer electrolyte solution forming the coating film 81 gradually permeates the porous material 73. However, as described above, the surface condition of the porous material 73, the pore size, and the density of the porous material 73 affect the ease of permeation of the polymer electrolyte solution. Therefore, in the liquid contact portion 82 during the permeation, the shape of the interface between the porous material 73, the polymer electrolyte solution, and the outside air (gas-liquid interface 83), which is maintained between the porous material 73 and the coating film 81 by the surface tension of the polymer electrolyte solution, changes due to the variation in the permeation state. As a result, in the liquid contact portion 82, the force that attracts the porous material to the coating film 81 (the surface tension of the polymer electrolyte solution) changes, causing the porous material 73 to vibrate (arrow in the figure).

[0010] In addition, the porous material 73, whose conveying direction is changed via the support roll 80 while maintaining a certain tension, is likely to be subjected to compressive stress and tensile stress by the support roll 80 at the contact portion 84 with the support roll 80. Therefore, the compressive stress and tensile stress become factors that cause the porosity of the porous material 73 to vary, and further cause the above-mentioned problem. In particular, the closer the liquid contact portion 82 and the contact portion 84 are to each other, the more likely this problem is to occur. However, on the other hand, the farther the liquid contact portion 82 and the contact portion 84 are from each other, the more likely the above-mentioned vibration of the porous material 73 is to occur.

[0011] In this way, due to the above-mentioned causes, there is variation in the impregnation state of the polymer electrolyte material in the porous material 73. As a result, air bubbles remain in the polymer electrolyte membrane, which leads to deterioration of membrane performance such as a decrease in ion conductivity and occurrence of variation in the polymer electrolyte membrane, and is a factor that causes deterioration of device or equipment performance in, for example, fuel cells or water electrolysis equipment.

[0012] The present disclosure is intended to solve the above-mentioned problems of the conventional art, and has an object to provide a manufacturing apparatus for continuously and stably manufacturing a composite film (hereinafter referred to as a polymer resin-impregnated film) in which a porous sheet is impregnated with a functional polymer, for example, using a functional polymer such as a polymer electrolyte and a porous sheet such as a porous membrane and a porous material. [Means for solving the problem]

[0013] In order to achieve the above object, the polymer resin-impregnated film manufacturing apparatus according to the present disclosure is a polymer resin-impregnated film manufacturing apparatus that continuously produces a polymer resin-impregnated film, and includes a substrate conveying mechanism that conveys a continuously running sheet-like substrate, a coating mechanism that applies a polymer resin-containing solution onto the substrate to form a coating film, and a porous sheet laminating mechanism that laminates a continuously running porous sheet on the liquid surface of the coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in that order, and the porous sheet laminating mechanism includes two or more roller-shaped support means that support the surface of the porous sheet opposite to the surface that comes into contact with the polymer resin-containing solution, immediately before the liquid contact portion where the porous sheet comes into contact with the polymer resin-containing solution.

[0014] The method for producing a polymer resin-impregnated film according to the present disclosure is a method for producing a polymer resin-impregnated film having a laminated structure of a sheet-like substrate and a polymer resin-containing porous sheet, and includes a coating step of applying a polymer resin-containing solution onto a sheet-like substrate to form a coating film, and an impregnation step of laminating a porous sheet on the liquid surface of the coating film, impregnating the porous sheet with the polymer resin-containing solution to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in this order, and impregnating the porous sheet with the polymer resin-containing solution. In the impregnation step, the porous sheet is transported via a means for changing the transport direction of the porous sheet and a means for adjusting the angle between the porous sheet and the coating film at a liquid contact portion where the porous sheet and the polymer resin-containing solution come into contact with each other, and the porous sheet is laminated on the liquid surface of the coating film. Effect of the Invention

[0015] As described above, the apparatus and method for producing a polymer resin-impregnated film according to the present disclosure can stabilize the liquid contact area between the porous sheet and the functional polymer coating film, and reduce the variation in the impregnation state of the functional polymer resin into the porous sheet. This makes it possible to produce a polymer resin-impregnated film with fewer residual bubbles by reducing the inclusion of air bubbles. [Brief description of the drawings]

[0016] [Figure 1] 1(a) to 1(g) are schematic cross-sectional views showing cross-sectional configurations in each step of the method for producing a polymer resin-impregnated film according to the first embodiment. [Diagram 2] 1 is a schematic diagram showing a configuration of a manufacturing apparatus for a polymer resin-impregnated film according to a first embodiment. [Diagram 3] 1 is a partially enlarged view showing a configuration in the vicinity of a liquid-contacting portion where a porous sheet comes into contact with a polymer resin-containing solution in a manufacturing apparatus for a polymer resin-impregnated film according to a first embodiment. [Figure 4] FIG. 1 is a schematic diagram showing the configuration of a conventional polymer resin-impregnated film manufacturing apparatus described in Patent Document 1. [Diagram 5] FIG. 2 is a partially enlarged view showing a configuration in the vicinity of a liquid-contacting portion where a porous sheet comes into contact with a polymer resin-containing solution in a conventional polymer resin-impregnated film manufacturing apparatus described in Patent Document 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The polymer resin-impregnated film manufacturing apparatus according to the first embodiment is a polymer resin-impregnated film manufacturing apparatus that continuously produces a polymer resin-impregnated film, and includes a substrate conveying mechanism that conveys a continuously running sheet-like substrate, a coating mechanism that applies a polymer resin-containing solution onto the substrate to form a coating film, and a porous sheet laminating mechanism that laminates a continuously running porous sheet on the liquid surface of the coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in that order. The porous sheet laminating mechanism includes two or more roller-shaped support means that support the surface of the porous sheet opposite to the surface that comes into contact with the polymer resin-containing solution, immediately before the liquid contact portion where the porous sheet comes into contact with the polymer resin-containing solution.

[0018] The second aspect of the present invention relates to an apparatus for manufacturing a polymer resin-impregnated film, which is the same as the first aspect, and the support means includes a first support means provided on the rear side of the porous sheet in the transport direction, and a second support means provided on the front side of the porous sheet in the transport direction and located closer to the liquid contact portion than the first support means, and the first support means and the second support means may each have a mechanism for adjusting the distance from the substrate.

[0019] The polymer resin-impregnated film manufacturing apparatus according to a third aspect of the present invention is the same as the second aspect, except that the distance between the second supporting means and the substrate is shorter than the distance between the first supporting means and the substrate.

[0020] The polymer resin-impregnated film manufacturing apparatus according to a fourth aspect is the above-mentioned second or third aspect, wherein the roller diameter of the second supporting means may be smaller than the roller diameter of the first supporting means.

[0021] The polymer resin-impregnated film manufacturing apparatus according to the fifth aspect is any one of the second to fourth aspects, wherein the contact area between the second support means and the porous sheet is smaller than the contact area between the first support means and the porous sheet.

[0022] The sixth aspect of the polymer resin-impregnated film manufacturing apparatus may be such that, in any one of the second to fifth aspects, the amount of change in the conveying angle of the porous sheet caused by the second support means is smaller than the amount of change in the conveying angle of the porous sheet caused by the first support means.

[0023] The seventh aspect of the polymer resin-impregnated film manufacturing apparatus is any one of the first to sixth aspects, wherein the support means changes the transport direction of the porous sheet so that the continuously running porous sheet is aligned along the liquid surface of the coating film.

[0024] The method for producing a polymer resin-impregnated film according to an eighth aspect is a method for producing a polymer resin-impregnated film having a laminated structure of a sheet-like substrate and a polymer resin-containing porous sheet, and includes a coating step of applying a polymer resin-containing solution onto a sheet-like substrate to form a coating film, and an impregnation step of laminating a porous sheet on the liquid surface of the coating film, impregnating the porous sheet with the polymer resin-containing solution to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in this order, and impregnating the porous sheet with the polymer resin-containing solution. In the impregnation step, the porous sheet is transported via a means for changing the transport direction of the porous sheet and a means for adjusting the angle between the porous sheet and the coating film at a liquid contact portion where the porous sheet and the polymer resin-containing solution come into contact with each other, and the porous sheet is laminated on the liquid surface of the coating film.

[0025] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method and an apparatus for producing a polymer resin-impregnated film according to an embodiment will be described with reference to the accompanying drawings.

[0026] (Embodiment 1) <Method of manufacturing polymer resin-impregnated film> FIG. 1 is a schematic cross-sectional view showing a cross-sectional configuration in each step of the method for producing a polymer resin-impregnated film according to the first embodiment. A method for producing a polymer resin-impregnated film according to the first embodiment will be described with reference to FIG.

[0027] (1) First, a sheet-like substrate 1 that can be continuously conveyed is prepared (FIG. 1(a)). The substrate may be made of, for example, a commonly used polymer resin. Here, the surface of the substrate 1 may be subjected to a surface treatment such as surface coating or surface cleaning so that the polymer resin solution used in the subsequent process is compatible with the substrate. Specifically, if the substrate has poor wettability with the polymer resin solution, repellency or omissions may occur on the coated surface when the substrate is coated. On the other hand, if the substrate has too good wettability, a problem may occur in which the polymer resin-impregnated film formed in the end cannot be peeled off stably when peeling it off from the substrate. Therefore, a surface treatment may be performed appropriately according to the polymer resin solution and substrate to be used.

[0028] (2) Next, a polymer resin solution is applied to a predetermined area on the surface of the substrate 1 to form a coating film 2 (coating step) (FIG. 1(b)).

[0029] (3) Furthermore, a porous sheet 3 is attached to the surface of the coated surface 2 while applying a certain tension (impregnation step). At this time, the polymer resin solution forming the coating film 2 gradually impregnates the voids in the porous sheet 3 (arrow 4 in the figure). In this state, the substrate 1-coating film 2-porous sheet 3 are laminated together, forming a laminate 5 (Figure 1c).

[0030] <Porous sheet> Examples of the porous sheet include a polymer film made of a porous polymer resin and having minute continuous pores therein, and a fiber film made of a laminate of polymer resin fibers. Examples of the polymer resin composition include, but are not limited to, methacrylate resins such as polymethyl methacrylate, styrene resins such as polystyrene, polyester resins such as polyethylene terephthalate, fluorine resins such as polyvinylidene fluoride and polytetrafluoroethylene, polyolefin resins such as polyethylene and polypropylene, polyamide, polyimide, and polycarbonate.

[0031] <Polymer resin solution> The polymer resin solution is, for example, a solution in which an ionic group-containing polymer material, such as a polymer electrolyte, which is a functional polymer, is dissolved in a solvent. Examples of the ionic group-containing polymer include fluorine-containing polymers and non-fluorine-containing polymers. Examples of the fluorine-containing polymers that can be used include sulfonic acid-type perfluorocarbon polymers and perfluorocarbon polymers having phosphonic acid groups and / or carboxy groups. Examples of the non-fluorine-containing polymers include polysulfone resins, but are not limited to these.

[0032] An example of the solvent is a volatile solvent. Here, the solvent is preferably one that dissolves the ionic group-containing polymer material, does not dissolve the substrate and the porous sheet, does not cause deterioration, and can be removed in a drying process. Examples of the solvent include, but are not limited to, alcohol, dimethylacetamide, N-methyl-2-pyrrolidone, and dimethylsulfoxide.

[0033] (4) A polymer resin solution is applied to the porous sheet 3 side of the laminate 5 in an overlapping manner to form a coating film 7, and a three-layer structure 8 consisting of the porous sheet 3 sandwiched between the polymer resin solutions 2 and 7 is formed on the substrate 1 (Figure 1(d)).

[0034] (5) Furthermore, the substrate 1 is heated and dried while maintaining the shape of the three-layer structure 8. When the substrate 1 is heated and dried, the solvent in the polymer resin solution is vaporized (arrow 9 in the figure), and the vaporized solvent is exhausted while drying. The drying speed is also important here. If the drying speed is fast, the polymer resin solution 7 on the upper surface side forming the three-layer structure will dry and solidify faster than the polymer resin solution 2 on the substrate side, which will hinder the drying of the polymer resin solution 2 on the substrate side. Therefore, it is necessary to appropriately adjust the drying speed, i.e., the speed of solvent evaporation 9, to match the speed at which the solvent in the polymer resin solution 2 on the substrate side diffuses to the polymer resin solution 7 side through the porous sheet 3 (Figure 1(e)).

[0035] (6) After drying, a polymer resin-impregnated film 12 is formed on the substrate 1, which is composed of a polymer resin layer 10 formed by solidifying the polymer resin solution 2 on the substrate side, a polymer resin layer 11 formed by solidifying the polymer resin solution 7 on the upper surface side, and a porous sheet 3 sandwiched between them and having an internal void permeated and filled with polymer resin (FIG. 1(f)). Finally, the polymer resin-impregnated film 12 is peeled off from the substrate 1, and it is possible to use it after removing the residual solvent as necessary.

[0036] <Production equipment for polymer resin-impregnated films> 2 is a schematic diagram showing the configuration of a polymer resin-impregnated film manufacturing apparatus according to embodiment 1. The apparatus will be described as an example of a polymer resin-impregnated film manufacturing apparatus that embodies the polymer resin-impregnated film manufacturing method described in FIG. The polymer resin-impregnated film manufacturing apparatus includes a substrate conveying mechanism, a first coating mechanism 23 , a porous sheet laminating mechanism 25 , a second coating mechanism 29 , and a drying mechanism 30 .

[0037] Each component of the polymer resin-impregnated film manufacturing apparatus will be described below.

[0038] <Substrate material transport mechanism> First, the substrate 1 is pulled out from the substrate unwinding roll 20 and wound up by the winding roll 31. The substrate unwinding roll 20 and the winding roll 31 constitute a substrate transport mechanism that enables continuous transport of the substrate 1. This mechanism makes it possible to adjust the transport speed and tension of the substrate 1.

[0039] Next, between the unwinding roll 20 and the winding roll 31, the following mechanisms are configured in this order.

[0040] <First coating mechanism> A first coating mechanism 23 for forming a coating film on the substrate 1 is constituted by a support roll 21 that maintains the back surface of the substrate 1 and a coating nozzle 22 that applies a polymer resin solution to the front surface of the substrate 1.

[0041] <Porous sheet stacking mechanism> The porous sheet 3 is unwound from the porous sheet unwinding roll 24 and laminated on the liquid surface of the coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in this order. The porous sheet 3 is transported to the vicinity of the substrate 1 by the porous sheet unwinding roll 24 and a plurality of rollers that transport the porous sheet 3. This transported porous sheet 3 constitutes a porous sheet laminating mechanism 25 in which the porous sheet 3 is laminated on the coating film near the substrate 1 via porous sheet support means 40, 41. Here, the support means 40, 41 is composed of at least two roller-shaped supports 40, 41 that support the surface of the porous sheet opposite to the surface that contacts the coating film, just before the liquid contact section 42 where the coating film and the porous sheet 3 come into contact.

[0042] <Second Coating Mechanism> A second coating mechanism 29 is constituted by a support roll 27 that supports the substrate side of the laminate, and a coating nozzle 28 that applies a polymer resin solution from the upper surface side of the porous sheet 3 to form a coating film.

[0043] <Drying mechanism> The solvent in the polymer resin solution is removed by drying the substrate together with the drying mechanism 30, and a polymer resin-impregnated film 12 made of the polymer resin and the porous sheet is formed on the substrate 1.

[0044] Here, the coating nozzles 22 and 28 are intended to apply a polymer resin solution, and any coating means used in various coating methods can be used. For example, there are a die head in a die coating method, a knife blade in a knife coating method, a coating roll in a roll coating method, a spray nozzle in a spray coating method, etc., and are not particularly limited and should be appropriately selected depending on the polymer resin solution used.

[0045] The second coating mechanism 29 may be installed or omitted as necessary. For example, when the permeability of the polymer resin solution into the porous sheet is very high, the polymer resin solution sufficiently impregnates the porous sheet, and the polymer resin solution seeps out onto the surface of the porous sheet, the second coating mechanism can be omitted.

[0046] By using the polymer resin-impregnated film manufacturing apparatus according to the first embodiment, the impregnation of the polymer resin solution into the porous sheet laminated on the coating film of the polymer resin solution is stabilized. This makes it possible to reduce air bubbles remaining in the polymer resin-impregnated film that is finally formed, and is expected to have the effect of improving performance and yield.

[0047] <Details of the porous sheet stacking mechanism> Further details regarding the porous sheet stacking mechanism will be described. FIG. 3 is a partially enlarged view showing the positional relationship of the porous sheet 3, substrate 1, polymer resin solution 2, and two roller-shaped supports (hereinafter referred to as the first roller and the second roller) 40, 41 that support the porous sheet 3 in the porous sheet lamination mechanism. The support for supporting the porous sheet 3 is composed of at least two rollers that support the surface of the porous sheet 3 opposite to the surface that contacts the coating film 2, immediately before the liquid contact portion where the coating film 2 made of a polymer resin solution contacts the porous sheet 3. Specifically, as shown in Fig. 3, a first roller 40 and a second roller 41 are installed in this order immediately before the liquid contact portion 42 in the conveying directions D1, D2, and D3 of the porous sheet.

[0048] First, the conveying direction D1 of the porous sheet 3 is changed by the first roller 40. Specifically, the conveying direction D1 of the porous sheet 3 is changed so that the porous sheet 3 is aligned with the liquid surface of the coating film 2 provided on the substrate 1. In the case of FIG. 3, the conveying direction D1 of the porous sheet 3 intersects with the conveying direction D0 of the substrate 1 immediately before the first roller 40. Meanwhile, the conveying direction D2 of the porous sheet 3 is changed by the first roller 40 to be substantially parallel to the conveying direction D0 of the substrate 1. Next, the angle between the porous sheet 3 and the coating film 2 provided on the substrate 1 can be adjusted by the second roller 41. In other words, by providing the second roller 41, it is possible to reduce changes in the porosity of the porous sheet 3, which was difficult to achieve with only the first roller 40, and to suppress the occurrence of variations in the impregnation state of the polymer resin solution.

[0049] Here, the relationship between the first roller 40 and the second roller 41 will be further described with reference to FIG. First, the first roller 40 and the second roller 41 each have a mechanism (not shown) capable of individually adjusting the distance from the substrate 1. The mechanism is not particularly limited, and the member for fixing the rollers 40 and 41 can be movable or fixed at a plurality of positions. The distance T2 between the second roller 41 and the substrate 1 is shorter than the distance T1 between the first roller 40 and the substrate 1. This makes it possible to adjust the contact angle between the porous sheet 3 and the polymer resin solution 2 at the liquid contact portion 42. In addition, it is easier to adjust in the vicinity of the liquid contact portion 42 than in the past, and it is possible to make the impregnation state of the polymer resin solution into the porous sheet 3 more stable, and there is an effect of suppressing the inclusion of air bubbles, etc., and it is possible to manufacture continuously and stably.

[0050] In addition, it is possible to appropriately adjust the settings in accordance with changes in wettability and porosity due to changes in the type of porous sheet, changes in the solvent due to changes in the type of polymer resin solution, etc. Therefore, it is easy to change the settings in accordance with changes in the materials used due to changes in the product type. Furthermore, the distance T3 between the center of rotation of the second roller 41 and the liquid contacting portion 42 is preferably 0.25 to 3 times the roller diameter R2 of the second roller 41. If it is 0.25 times or less, the polymer resin solution that has permeated from the liquid contacting portion 42 will seep out onto the upper surface of the porous sheet 3 and come into contact with the second roller 41, which is likely to cause a problem of staining the roller. If it is 3 times or more, it will be difficult to achieve the above-mentioned effect. Furthermore, in order to further suppress the occurrence of the above-mentioned problems, it is preferable to set the distance to 0.5 to 2 times.

[0051] Next, it is desirable that the contact area between the second roller 41 and the porous sheet 3 is smaller than the contact area between the first roller 40 and the porous sheet 3. If the contact area between the second roller 41 and the porous sheet 3 is large, compressive stress or tensile stress is likely to be applied to the porous sheet 3 itself, which may change the porosity of the porous sheet 3 and result in variation in the impregnation state of the polymer resin solution. Therefore, it is desirable that the contact area between the second roller 41, which is located immediately before the liquid contact portion 42 where the porous sheet 3 and the polymer resin solution 2 come into contact with each other, and the porous sheet 3 is small.

[0052] In order to realize this relationship, it is desirable to make the roll diameter R2 of the second roller 41 smaller than the roll diameter R1 of the first roller 40. In addition, it is desirable to adjust the arrangement of each roller and the transport path of the porous sheet 3 so that the inner angle (θ2 in the figure) at which the porous sheet 3 contacts in a cross section perpendicular to the rotation axis of the second roller 41 is smaller than the inner angle (θ1 in the figure) at which the porous sheet 3 contacts in a cross section perpendicular to the rotation axis of the first roller 40. This reduces the effects of compressive stress and tensile stress on the porous sheet 3 by the second roller 41, and reduces the above-mentioned variation in the impregnation state.

[0053] Next, it is desirable to make the angle at which the conveying direction D1 of the porous sheet is changed by the first roller 40 (the difference in angle from the conveying direction D2 of the porous sheet 3 to the conveying direction D3 before and after the roller 41) smaller than the angle at which the conveying direction D1 of the porous sheet is changed by the first roller 40 (the difference in angle from the conveying direction D1 of the porous sheet 3 to the conveying direction D2 before and after the roller 40). If the angle change in the conveying direction is large, the roller applies a strong compressive stress or tensile stress to the porous sheet. For this reason, here, by reducing the angle at which the conveying direction (D2 → D3) of the porous sheet is changed by the second roller 41, the stress on the porous sheet 3 in the second roller 41 close to the liquid contact portion 42 can be reduced as much as possible. As a result, the change in porosity of the porous sheet 3 caused by the above-mentioned stress is reduced, and there is an effect of suppressing the occurrence of variations in the impregnation state of the polymer resin solution. [Industrial Applicability]

[0054] The manufacturing method and manufacturing apparatus for a polymer resin-impregnated film according to the present disclosure can form a polymer resin-impregnated film that is both functional and strong by, for example, using a polymeric porous film as a reinforcing material and impregnating the porous film with a polymer resin that has been given functionality such as ion conductivity. [Explanation of symbols]

[0055] 1 Base material 2, 7 Polymer resin solution 3. Porous sheet 5. Laminate 12 Polymer resin impregnated film 20 Substrate unwinding roll 22, 28 Coating nozzle 23 First Coating Mechanism 24 Porous film unwinding roll 27 Support Roll 29 Second Coating Mechanism 30 Drying mechanism 31 Substrate winding roll 40 First Roller 41 Second Roller 42 Liquid contact part

Claims

1. An apparatus for continuously producing a polymer resin-impregnated film, comprising: A substrate conveying mechanism that conveys a continuously running sheet-like substrate; a coating mechanism for applying a polymer resin-containing solution onto the substrate to form a coating film; a porous sheet laminating mechanism for laminating a continuously running porous sheet on the liquid surface of the coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in this order; Equipped with The porous sheet lamination mechanism includes two or more roller-shaped support means for supporting a surface of the porous sheet opposite to a surface that contacts the polymer resin-containing solution, the surface being immediately before a liquid contact portion where the porous sheet contacts the polymer resin-containing solution. Equipment for manufacturing polymer resin-impregnated films.

2. The support means includes a first support means provided on the rear side in the transport direction of the porous sheet, and a second support means provided on the front side in the transport direction of the porous sheet and located closer to the liquid contact portion than the first support means, The first supporting means and the second supporting means each have a mechanism for adjusting a distance from the base material.

2. An apparatus for producing the polymer resin-impregnated film according to claim 1.

3. the distance between the second supporting means and the substrate is shorter than the distance between the first supporting means and the substrate; 3. An apparatus for producing a polymer resin-impregnated film according to claim 2.

4. a roller diameter of the second supporting means is smaller than a roller diameter of the first supporting means; 4. An apparatus for producing a polymer resin-impregnated film according to claim 2 or 3.

5. a contact area between the second support means and the porous sheet is smaller than a contact area between the first support means and the porous sheet; 4. An apparatus for producing a polymer resin-impregnated film according to claim 2 or 3.

6. a change in a conveying angle of the porous sheet caused by the second supporting means is smaller than a change in a conveying angle of the porous sheet caused by the first supporting means; 4. An apparatus for producing a polymer resin-impregnated film according to claim 2 or 3.

7. 2. The apparatus for producing a polymer resin-impregnated film according to claim 1, wherein the supporting means changes a transport direction of the porous sheet so that the continuously running porous sheet is aligned along the liquid surface of the coating film.

8. A method for producing a polymer resin-impregnated film having a laminated structure of a sheet-like substrate and a polymer resin-containing porous sheet, comprising: A coating step of applying a polymer resin-containing solution onto a sheet-like substrate to form a coating film; an impregnation step of laminating a porous sheet on the liquid surface of the coating film, permeating the porous sheet with the polymer resin-containing solution to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in this order, and impregnating the porous sheet with the polymer resin-containing solution; Including, In the impregnation step, the porous sheet is transported via a means for changing the transport direction of the porous sheet and a means for adjusting an angle between the porous sheet and the coating film at a liquid contact portion where the porous sheet and the polymer resin-containing solution come into contact with each other, and the porous sheet is laminated on the liquid surface of the coating film. A method for producing a polymer resin-impregnated film.

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