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 first coating mechanism for coating a polymeric resin-containing solution onto the base material, and forming a first coating film; a porous sheet lamination mechanism for laminating the continuously traveling porous sheet on a liquid surface of the first 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; a monitoring mechanism for observing an impregnation state of the polymeric resin solution from the surface of the laminate; and a second coating mechanism for coating the polymeric resin-containing solution onto the laminate, and forming a second coating film.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a method and an apparatus 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 addition, as an important component that determines the performance of devices and equipment, 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. However, there are issues with the reliability of functional membranes, such as durability and mechanical strength, 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 Patent Document 1). Fig. 6 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. 6.

[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.

[0005] As a similar method, a polymer electrolyte solution may be applied onto a substrate 71 using application means 72, a porous material 73 is laminated onto the coated surface, and without drying, the polymer electrolyte solution is further applied onto the porous material 73 using application 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]

[0006] [Patent Document 1] JP 2011-222499 A Summary of the Invention [Problem to be solved by the invention]

[0007] However, the configuration of Patent Document 1 has the following problems. In the configuration of Patent Document 1, as shown in Fig. 6, 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, and an impregnation process is performed in which the porous material 73 is impregnated with the polymer electrolyte solution. After the porous material 73 is dried in a preliminary drying process, the polymer electrolyte solution is again applied onto the upper surface of the porous material 73 and dried. A method that does not require the preliminary drying process can also be considered, but the following problems arise in either case.

[0008] Here, in the impregnation step in which the porous material 73 is bonded, non-uniformity in the impregnation state of the polymer electrolyte solution is likely to occur due to the influence of variations in the surface state, pore size, and density of the porous material 73. Therefore, if the impregnation step time is short, there will be some places in the pores of the porous material 73 that are not filled with the polymer electrolyte solution, and if the impregnation step time is long, the impregnated polymer electrolyte solution will seep out onto the surface of the porous material 73 and begin to dry, resulting in variations in film thickness.

[0009] This phenomenon will be explained with reference to Fig. 7. Fig. 7 is a diagram showing the impregnation process when a porous material 73 is laminated on a coating film 81 of a polymer electrolyte solution formed on a substrate 71.

[0010] 7(a) shows an initial state in which a coating film 81 and a porous material 73 are laminated on a substrate 71. Then, the polymer electrolyte solution forming the coating film 81 permeates into the porous material 73. 7(b) shows the initial stage of the impregnation process, where the impregnation is insufficient and part of the porous material 73 is not impregnated, that is, there is an unimpregnated portion 74. If the process proceeds to the next step in this state, the unimpregnated portion 74 will cause air bubbles and cissing.

[0011] As the impregnation process progresses further, most of the polymer electrolyte solution in the coating film 81 is impregnated into the porous material 73, as shown in FIG. 7(c). However, at this stage, the polymer electrolyte material that has seeped onto the surface of the porous material 73 begins to dry, and a concentrated portion or dry film of the polymer electrolyte material (hereinafter referred to as an overdried portion 75) may be formed on the surface of the porous material 73. As the impregnation process progresses further, the area and thickness of the overdried portion 75 increase, resulting in an overdried state. As a result, the portion where the overdried portion 75 is formed will ultimately form a thick film of the polymer electrolyte material, causing thickness variations.

[0012] In this way, due to the causes described above, the impregnation state of the polymer electrolyte material in the porous material 73 varies, and as a result, air bubbles remain in the polymer electrolyte membrane or the thickness varies partially, which leads to deterioration of membrane performance such as a decrease in ion conductivity and the occurrence of variations in the ion conductivity of the polymer electrolyte membrane, and is a factor that causes deterioration of the performance of devices and equipment in, for example, fuel cells and water electrolysis apparatus.

[0013] The present disclosure is intended to solve the above-mentioned problems of the conventional art, and aims 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, a polymer electrolyte, and a porous sheet, such as a porous membrane and a porous material. [Means for solving the problem]

[0014] 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 first coating mechanism that applies a polymer resin-containing solution onto the substrate to form a first coating film, a porous sheet laminating mechanism that laminates a continuously running porous sheet onto the liquid surface of the first coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in that order, a monitoring mechanism that observes the impregnation state of the polymer resin solution from the surface of the laminate, and a second coating mechanism that applies the polymer resin-containing solution onto the laminate to form a second coating film.

[0015] 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 first coating step of applying a polymer resin-containing solution onto the sheet-like substrate to form a first coating film, an impregnation step of laminating a porous sheet on the liquid surface of the first coating film and 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, a monitoring step of observing the impregnation state of the polymer resin solution from the surface of the laminate, and a second coating step of applying the polymer resin-containing solution onto the laminate to form a second coating film. Effect of the Invention

[0016] As described above, the apparatus and method for producing a polymer resin-impregnated film according to the present disclosure can stabilize the liquid contact portion of the coating film of the functional polymer solution on the porous sheet, and reduce the variation in the impregnation state of the functional polymer resin in the porous sheet. This makes it possible to produce a polymer resin-impregnated film with reduced air bubble contamination, fewer residual air bubbles, and less variation in thickness. [Brief description of the drawings]

[0017] [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] 3 is a schematic diagram showing an observation method in an impregnation state observation mechanism according to the first embodiment. FIG. [Figure 4] 10 is a schematic diagram showing an observation method of Modification 1 in the impregnation state observation mechanism according to the first embodiment. FIG. [Diagram 5] 4 is a schematic diagram showing the configuration of a modified example 2 of the polymer resin-impregnated film manufacturing apparatus according to the first embodiment. FIG. [Figure 6] FIG. 1 is a schematic diagram showing the configuration of a conventional polymer resin-impregnated film manufacturing apparatus described in Patent Document 1. [Figure 7] FIG. 2 is a schematic diagram showing an impregnation state in the impregnation process described in Patent Document 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] 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 first coating mechanism that applies a polymer resin-containing solution onto the substrate to form a first coating film, a porous sheet laminating mechanism that laminates a continuously running porous sheet onto the liquid surface of the first coating film to form a laminate in which the substrate, the polymer resin-containing solution, and the porous sheet are laminated in that order, a monitoring mechanism that observes the impregnation state of the polymer resin solution from the surface of the laminate, and a second coating mechanism that applies the polymer resin-containing solution onto the laminate to form a second coating film.

[0019] The second aspect of the polymer resin-impregnated film manufacturing apparatus is the same as the first aspect, and may further include a feedback processing unit in which the distance between the second coating mechanism and the first coating mechanism is variable and the second coating mechanism is adapted to change the position of the second coating mechanism based on the observation results by the monitoring mechanism.

[0020] The third aspect of the polymer resin-impregnated film manufacturing apparatus is the above-mentioned first or second aspect, and the substrate conveying mechanism may be capable of varying the substrate conveying speed, and may further include a feedback processing unit that changes the conveying speed of the conveying mechanism based on the observation results by the monitoring mechanism.

[0021] The apparatus for producing a polymer resin-impregnated film according to a fourth aspect is any one of the first to third aspects, wherein the monitoring mechanism detects a difference in reflectance on the surface of the porous sheet.

[0022] A fifth aspect of the polymer resin-impregnated film manufacturing apparatus is any one of the first to third aspects, wherein the monitoring mechanism detects a color information difference on the surface of the porous sheet.

[0023] The apparatus for producing a polymer resin-impregnated film according to a sixth aspect may be the same as the first aspect, and further include a feedback processing unit that controls the second coating mechanism or the transport mechanism based on the observation results by the monitoring mechanism.

[0024] A method for producing a polymer resin-impregnated film according to a seventh 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 first coating step of applying a polymer resin-containing solution onto the sheet-like substrate to form a first coating film, an impregnation step of laminating a porous sheet on the liquid surface of the first coating film and 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, a monitoring step of observing the impregnation state of the polymer resin solution from the surface of the laminate, and a second coating step of applying the polymer resin-containing solution onto the laminate to form a second coating film.

[0025] The method for producing a polymer resin-impregnated film according to an eighth embodiment may be the same as the seventh embodiment, except that the position of the second coating mechanism is changed based on the observation results in the monitoring step.

[0026] The above-mentioned monitoring process allows the impregnation state to be observed from the surface of the porous sheet in the impregnation process, the occurrence of unimpregnated areas and overdried areas to be monitored, and a determination is made as to whether or not there are more than a predetermined threshold amount of unimpregnated areas and overdried areas. Based on the results, the position of the second coating mechanism is changed, and feedback is given to the conditions in the second coating process to produce a polymer resin-impregnated film.

[0027] A ninth aspect of the method for producing a polymer resin-impregnated film is the same as the seventh or eighth aspect, in which the substrate is transported by changing the transport speed in the transport step based on the observation results in the monitoring step.

[0028] The above-mentioned monitoring process allows the impregnation state to be observed from the surface of the porous sheet in the impregnation process, the occurrence of unimpregnated areas and overdried areas to be monitored, and a determination is made as to whether or not there are unimpregnated areas and overdried areas at or above a predetermined threshold value. Based on the results, the conveying speed in the conveying process is changed to convey the substrate, and feedback is given to the conditions in the second coating process to produce a polymer resin-impregnated film.

[0029] 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.

[0030] (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.

[0031] (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.

[0032] (2) Next, a polymer resin solution is applied to a predetermined area on the surface of the substrate 1 to form a first coating film 2 (coating step) (FIG. 1(b)).

[0033] (3) Furthermore, a porous sheet 3 is laminated onto the surface of the first coating film 2 while applying a certain tension (lamination process). At this time, the polymer resin solution forming the first coating film 2 gradually penetrates into the voids in the porous sheet 3 (arrow 4 in the figure) (impregnation process). In this state, the substrate 1-first coating film 2-porous sheet 3 are in a laminated state, which is called a laminate 5 (Fig. 1c).

[0034] <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.

[0035] <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.

[0036] 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.

[0037] (4) A polymer resin solution is applied to the porous sheet 3 side of the laminate 5 in an overlapping manner to form a second 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)).

[0038] (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)).

[0039] (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.

[0040] <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 transport mechanism, a first coating mechanism 23 , a porous sheet laminating mechanism 25 , an impregnation state observation mechanism 43 , a second coating mechanism 29 , and a drying mechanism 30 .

[0041] Each component of the polymer resin-impregnated film manufacturing apparatus will be described below.

[0042] <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.

[0043] Next, between the unwinding roll 20 and the winding roll 31, the following mechanisms are configured in this order.

[0044] <First Coating Mechanism> A first coating mechanism 23 that forms a first 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.

[0045] <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 first 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. The transported porous sheet 3 constitutes a porous sheet lamination mechanism 25 that is laminated on the first coating film.

[0046] <Impregnation state observation mechanism> Next, a section (impregnation step) is provided in which the polymer resin solution constituting the first coating film is permeated into the porous sheet 3 laminated on the coating film, and the impregnation state is observed from the surface of the porous sheet 3. An impregnation state observation mechanism 43 is configured by a detection means 40 and a calculation means 42 that processes the results of the detection means 40 using a predetermined calculation method. In addition, the processing results of the calculation means 42 are fed back to the setting conditions (conveyance speed, temporary stop of conveyance, etc.) of the base material conveying mechanism such as the winding roll 31 or the unwinding roll 2, or are fed to the setting conditions (change of coating position, etc.) of the second coating mechanism described later. The purpose of this is to determine the impregnation state of the porous sheet 3 using the impregnation state observation mechanism, determine whether it is an insufficient impregnation state with many unimpregnated areas, or an over-dried state with many over-dried areas, and adjust the time it takes to reach the second coating mechanism, i.e., the time of the impregnation process.

[0047] <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 second coating film. The second coating mechanism 29 is a mechanism that is movable in its position in response to the results of the calculation means 42 of the impregnation state observation mechanism 43. The second coating mechanism 29 is movable by providing a working area in which a support section (not shown) that fixes the support roll 27 and the coating nozzle 28 can move in the sheet transport direction.

[0048] <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.

[0049] 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.

[0050] By using the manufacturing apparatus for polymer resin-impregnated film according to the first embodiment, the impregnation of the polymer resin solution into the porous sheet laminated on the first coating film of the polymer resin solution is stabilized. This can be expected to improve performance and yield by reducing residual air bubbles in the finally formed polymer resin-impregnated film and reducing film thickness variations.

[0051] <Details of the impregnation state observation mechanism> Further, the impregnation state observation mechanism 43 will be described in detail. The impregnation state will be determined by using the calculation means 42 based on the results detected by the detection means 40 in FIG.

[0052] FIG. 3 is a schematic diagram showing a state in which a polymer resin solution 2 is applied onto a substrate 1, and a porous sheet 3 is laminated thereon and transported in the direction of the arrow, as observed from the upper surface side of the porous sheet 3. As shown in the lower part of FIG. 3, the polymer resin solution 2 is impregnated into the porous sheet 3, and there are unimpregnated parts 50 where the impregnation is insufficient. Then, as shown in the upper part of FIG. 3, the unimpregnated parts 50 decrease as the sheet is conveyed, and the polymer resin solution that has seeped out onto the surface of the porous sheet 3 dries and is concentrated, or an overdried part 51 where the surface is solidified is generated. In addition, the other parts show a state where the polymer resin solution has seeped out onto the surface of the porous sheet 3 and remains in solution (hereinafter referred to as an impregnated part 52). Here, in the unimpregnated part 50, the color of the porous sheet 3 itself is observed, while in the impregnated part 52, the color of the polymer resin solution is observed, so that they are easily distinguished by the difference in color or the difference in light and dark contrast. In addition, in the overdried part 51, the polymer resin solution dries out, a film or concentrated layer of the polymer resin is formed on the surface, and the surface roughness increases. On the other hand, since the impregnated portion 52 is in a solution state, the surface is a liquid surface maintained by surface tension, so the surface roughness is small and the light reflectance is high. Therefore, by irradiating light at a specific angle and observing the state of light reflection on the surface of the porous sheet, it is possible to distinguish between the overdried portion 51 and the impregnated portion 52 by, for example, color difference or reflectance.

[0053] Here, an example of observing the impregnated state will be described. For example, a predetermined range is observed from the upper surface side of the porous sheet. Here, the area of ​​the range 53 is observed as an image using a camera as the detection means 40, and the image is divided into a predetermined range and number by the calculation means 42, and image processing is performed for each divided image. This image processing method may be performed by setting a threshold value that can distinguish between the unimpregnated part 50 and the impregnated part 52 in advance based on the brightness difference due to light and dark, and when the divided image has a certain area or more, such as when the area is equal to or greater than the threshold, it may be determined that the impregnation is insufficient. Also, a threshold value that can distinguish the difference in reflectance between the overdried part 51 and the impregnated part 52 may be set in advance, and when the area of ​​the divided image having a reflectance equal to or less than the threshold is equal to or less than a certain value, it may be determined that the divided image has an overdried state.

[0054] Based on the result of this determination, the result may be fed back to the setting conditions (conveying speed, temporary stop of conveying, etc.) of the base material conveying mechanism such as the winding roll 31 or the unwinding roll 2. Alternatively, the result may be fed back to the setting conditions (change of coating position, etc.) of the second coating mechanism.

[0055] (Variation 1) Next, the impregnation state observation method of another modified example 1 will be described with reference to FIG. 4. FIG. 4 is a diagram showing the difference in detection locations from FIG. 3. For example, in order to distinguish the unimpregnated portion 50, the overdried portion 51, and the impregnated portion 52, it is also possible to observe the change in color information of the surface by using a color difference meter as the detection means 40 at multiple points in a line in a direction perpendicular to the sheet conveying direction. In general, by using a color difference meter, for example, in the L*a*b* color system, L* indicating the brightness of light and dark, a* indicating the color tone of red or green, and b* indicating the color tone of yellow or blue may be detected. A threshold value that can distinguish the unimpregnated portion 50, the overdried portion 51, and the impregnated portion 52 described above may be set in advance, and if there are more than a predetermined number of unimpregnated portions 50 at the measurement points, it may be determined that there is an insufficient impregnation state, and feedback may be provided as described above. Also, if there are more than a predetermined number of overdried portions 51 at the measurement points, it may be determined that there is an overdried state, and feedback may be provided as described above.

[0056] The above is just an example, and the detection means 40 and the calculation means 42 are not limited to those described above, and other means are also possible. For example, the detection means 40 can be a means for capturing an image and detecting predetermined information by processing the image obtained, and can be a means for detecting the surface shape or internal information in the thickness direction of an object using light of different wavelengths, such as a laser, a hyperspectral camera, or an X-ray detector. Alternatively, a means for detecting surface properties such as the color or reflectance of the surface is also effective. Furthermore, it is also possible to use a plurality of detection means in combination.

[0057] (Variation 2) Next, in order to produce a polymer resin-impregnated film more stably, the following measures are also possible. The following will be described with reference to Fig. 5. Fig. 5 is a schematic diagram showing the configuration of Modified Example 2 of the polymer resin-impregnated film manufacturing apparatus according to Embodiment 1. In Fig. 5, a second post-coating observation mechanism 47 is further provided between the second coating mechanism 29 and the drying mechanism 30 in the apparatus configuration of Fig. 2.

[0058] <Second post-coating observation mechanism> 5, the second post-coating observation mechanism 47 is composed of a detection means 45 and a calculation means 46 that processes the detection results of the detection means 45. The second post-coating observation mechanism 47 observes the state of the object (here, the three-layer structure 8 formed on the substrate 1 described in FIG. 1) having the second coating film formed on its uppermost surface, which is transported from the second coating mechanism, immediately before being transported to the drying mechanism 30, and provides feedback to the calculation means 42.

[0059] For example, the results of the detection means 45, which detects the surface condition of the object being transported to the drying mechanism 30, are processed by the calculation means 46 using a predetermined calculation method, and are used to determine the feedback to the setting conditions of the substrate transport mechanism or the setting conditions of the second coating mechanism determined by the calculation means 42.

[0060] As a specific example, immediately before being transported to the drying mechanism 30, the detection means 45 detects the surface condition of the second coating film applied by the second coating mechanism 29, and if the surface of the second coating film is wavy and has a predetermined uneven shape or more, leveling is required. The result of the detection means 45 may be judged by the calculation means 46. Then, if the calculation means 42 judges that the need cannot be met by feedback only to the setting conditions of the second coating mechanism, it may be judged to give priority to feedback to the setting conditions of the substrate transport mechanism.

[0061] Here, the detection means 45 may be the same as or different from the detection means 40, and may be any means capable of detecting the leveling state of the surface of the second coating film. The detection means 45 may be, for example, a means for detecting height information of the surface of the second coating film using a laser or the like. The calculation means 46 may be integrated with the calculation means 42 and installed as a single calculation means. [Industrial Applicability]

[0062] 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]

[0063] 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 29 Second Coating Mechanism 30 Drying mechanism 31 Substrate winding roll 40 Detection Methods 42 Calculation means 43 Impregnation state observation mechanism 45 Detection Methods 46 Calculation means 47 Second post-coating observation mechanism

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 first coating mechanism that applies a polymer resin-containing solution onto the substrate to form a first 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; a monitoring mechanism for observing a state of impregnation of the polymer resin solution from the surface of the laminate; a second coating mechanism for applying a polymer resin-containing solution onto the laminate to form a second coating film; An apparatus for producing a polymer resin-impregnated film comprising:

2. The second coating mechanism is capable of varying a distance from the first coating mechanism, The apparatus further includes a feedback processing unit that changes a position of the second coating mechanism based on an observation result by the monitoring mechanism.

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

3. the substrate conveying mechanism is capable of varying a conveying speed of the substrate, a feedback processing unit that changes a conveying speed of the conveying mechanism based on an observation result by the monitoring mechanism.

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

4. The monitoring mechanism detects a difference in reflectance of the surface of the porous sheet. An apparatus for producing the polymer resin-impregnated film according to any one of claims 1 to 3.

5. The monitoring mechanism detects a color information difference on the surface of the porous sheet. An apparatus for producing the polymer resin-impregnated film according to any one of claims 1 to 3.

6. Further comprising a feedback processing unit that controls the second coating mechanism or the conveying mechanism based on an observation result by the monitoring mechanism.

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

7. 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 first coating step of coating a polymer resin-containing solution onto a sheet-like substrate to form a first coating film; an impregnation step of laminating a porous sheet on the liquid surface of the first 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; a monitoring step of observing an impregnation state of the polymer resin solution from the surface of the laminate; a second coating step of coating a polymer resin-containing solution onto the laminate to form a second coating film; A method for producing a polymeric resin-impregnated film, comprising:

8. and changing the position of the second coating mechanism based on the observation results of the monitoring step. A method for producing the polymer resin-impregnated film according to claim 7.

9. Based on the observation results in the monitoring step, a conveying speed in the conveying step is changed to convey the base material. A method for producing the polymer resin-impregnated film according to claim 7.

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