Apparatus of manufacturing recycled material, and system of manufacturing regenerated material

Abstract

To provide an apparatus of manufacturing a recycled material, that removes a functional layer from a laminate film between a base film and the functional layer without deteriorating physical properties of the base film, and a system of manufacturing a regenerated material using the recycled material as a raw material.SOLUTION: An apparatus of manufacturing a recycled material has: a delivery section that delivers a laminate film in one direction from a roll on which the laminate film having a base film and a functional layer has been wound; a pretreatment section for performing a pretreatment that accelerates removal of the functional layer without using an organic solvent; a removal section for removing the functional layer; and a winding section for winding the laminate film from which the functional layer has been removed, into a roll shape. The removal section has: a cylindrical removal member that comes into contact with one surface of the laminate film to rotate; and a support member for supporting the laminate film from a surface on the side opposite to the one surface. The removal member is swingable in the axial direction of the removal member. The support member has a wear resistant layer for at least protecting both end portions of the support member in the width direction of the laminate film.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to a manufacturing device for recycled materials and a manufacturing system for recycled materials. [Background technology]

[0002] In response to the recent increase in environmental awareness, the reduction and reuse of waste plastics has been actively studied as a response to a recycling-oriented society. For example, a technology is known in which a laminated film in which a functional layer such as a hard coat layer or an adhesive layer is provided on the surface of a polyester film (resin film), the functional layer is removed to obtain a polyester film, and the obtained polyester film is reused (see, for example, Patent Document 1). In detail, Patent Document 1 discloses a method of removing functional layers such as a hard coat layer and an adhesive layer by treating them with a chemical containing an alkalizing agent and a compound having a hydroxyl group such as benzyl alcohol. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2021-160350 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the method described in Patent Document 1, the polyester constituting the polyester film may swell and deteriorate due to the benzyl alcohol used to remove the functional layer. In addition, the polyester constituting the polyester film may be hydrolyzed by the alkalizing agent used to remove the functional layer. Therefore, in the method described in Patent Document 1, the physical properties of the polyester film obtained as a recycled material may deteriorate from the polyester film constituting the original laminated film, and the use of the recycled material may be limited.

[0005] Furthermore, when a functional layer is removed from a laminate film using a resin film made of a material other than a polyester film to reuse the resin film, a method for suppressing deterioration of the resin film is also required.

[0006] The present invention has been made in view of the above circumstances, and aims to provide a manufacturing device for recycled materials that can remove a functional layer from a laminate film of a base film and a functional layer without deteriorating the physical properties of the base film, and a manufacturing system for recycled materials that uses the obtained recycled material as a raw material to manufacture a molded product. [Means for solving the problem]

[0007] In order to solve the above problems, one aspect of the present invention includes the following aspects.

[0008] [1] A manufacturing device for recycled materials comprising: a roll of a laminated film having a long base film extending in one direction and at least one functional layer formed on one side of the base film; a payout unit that pays out the laminated film in one direction from the roll; a pre-treatment unit that performs pre-treatment to promote removal of the functional layer without using an organic solvent; a removal unit that removes the functional layer; and a winding unit that winds up the laminated film from which the functional layer has been removed into a roll, wherein the removal unit has a cylindrical removal member that rotates in contact with one side of the laminated film, and a support member that supports the laminated film from the side opposite to the one side, wherein the removal member is capable of swinging in the axial direction of the removal member, and the support member is a portion that faces the removal member and has an abrasion-resistant layer that protects at least both ends of the support member in the width direction of the laminated film.

[0009] [2] The apparatus for producing recycled materials according to [1], wherein the wear-resistant layer is a chromium oxide layer.

[0010] [3] The recycling material manufacturing apparatus according to [1] or [2], wherein the support member is a backup roll.

[0011] [4] The apparatus for manufacturing recycled materials described in any one of [1] to [3], wherein the removal member is a buff roll, the removal section has a plurality of the buff rolls arranged in a conveying direction of the laminated film, and the number of the buff roll arranged most downstream among the plurality of buff rolls is larger than the number of the other buff rolls.

[0012] [5] The recycling material manufacturing apparatus according to any one of [1] to [4], wherein the pre-treatment section is a heating section that heats the laminated film.

[0013] [6] The recycling material manufacturing apparatus according to [5], wherein the heating section heats the laminated film in a gas phase.

[0014] [7] A recycled material manufacturing system comprising: a recycled material manufacturing apparatus according to any one of [1] to [6]; and a molding apparatus that melts and molds the recycled material produced by the recycled material manufacturing apparatus. Effect of the Invention

[0015] According to the present invention, it is possible to provide a manufacturing device for recycled materials that can remove a functional layer from a laminate film of a base film and a functional layer without deteriorating the physical properties of the base film, and a manufacturing system for recycled materials that uses the obtained recycled material as a raw material to manufacture a molded product. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a schematic cross-sectional view showing a laminated film 5 to be processed in a recycling material production apparatus according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic explanatory diagram of a manufacturing apparatus for recycled materials according to an embodiment. [Diagram 3] FIG. 3 is an explanatory diagram showing a modified example of the heating unit. [Figure 4] FIG. 4 is an explanatory diagram showing a modified example of the heating unit. [Diagram 5]FIG. 5 is a cross-sectional view of the backup roll 331. [Figure 6] FIG. 6 is a plan view of the backup roll 331 viewed from the +x direction. [Figure 7] FIG. 7 is an enlarged photograph of the recycled material 1 obtained by the manufacturing apparatus 100. [Figure 8] FIG. 8 is a schematic diagram showing a recycled material manufacturing system 1000 according to an embodiment. [Figure 9] FIG. 9 is a schematic explanatory diagram showing a modified example of the recycling material manufacturing apparatus. [Figure 10] FIG. 10 is a schematic explanatory diagram of a modified example of a manufacturing apparatus for recycled materials. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Hereinafter, the manufacturing device for recycled materials according to the present embodiment will be described with reference to Figures 1 to 10. In addition, in all the following drawings, the dimensions and ratios of each component are appropriately changed in order to make the drawings easier to understand.

[0018] 1 is a schematic cross-sectional view showing a laminated film 5 to be processed in the recycling material manufacturing apparatus of this embodiment. The laminated film 5 has a base film 2 and a functional layer 3 provided on one surface 2a of the base film 2. As will be described in detail later, the functional layer 3 is a layer to be removed in the recycling material manufacturing apparatus of this embodiment.

[0019] 1 has the functional layer 3 only on one surface 2a of the base film 2, but is not limited thereto. The laminate film 5 may have the functional layer 3 on both surfaces of the base film 2.

[0020] Furthermore, the layer (functional layer 3) to be removed from the laminate film 5 may be arranged discretely, such as dirt or partially printed paint. In other words, the dirt or partially printed paint is included in the "functional layer 3" that is the target of treatment in the recycling material manufacturing device.

[0021] The base film 2 is a long resin film extending in one direction. Polyester can be used as the material of the resin film. Examples of polyester that can be used include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). In addition to these, any polyester that can be used as a film material can be appropriately used. These polyesters may be used alone or in combination of two or more types (polymer blend).

[0022] Examples of materials for the resin film include polyolefins such as polyethylene and polypropylene, and polyamides. Any other resins known as materials for resin films may be used as appropriate.

[0023] The functional layer 3 is provided on one surface 2a of the base film 2, and provides various functions to the base film 2. There are no particular limitations on the functional layer 3, and examples of the functional layer 3 include a peeling layer, a release layer, an antistatic layer, a printing layer, and an adhesive layer. One layer of the functional layer 3 may be provided on the one surface 2a, or two or more layers may be laminated.

[0024] For example, when the functional layer 3 is a release layer, a silicone-based release agent may be used as the material for the release layer, and the functional layer 3 may be formed on one surface 2a of the base film 2. A laminate film 5 having such a functional layer 3 is used as a release film to be attached to the adhesive surface of a surface protection film of various industrial products. The laminate film 5 is also used as a carrier film when manufacturing ceramic chip capacitors.

[0025] Conventionally, the laminated films used for these purposes have been collected and disposed of by the manufacturers after their use for each purpose. Even if these laminated films are subjected to material recycling or chemical recycling, the value of the laminated films as recycled raw materials is reduced due to contamination with the material of the functional layer 3 (for example, a silicone-based release agent if the functional layer 3 is a release layer).

[0026] Furthermore, a method of using an alkali treatment is known as a method for removing the functional layer 3 from the laminate film 5 (see Patent Document 1 mentioned above). However, when the base film 2 is made of polyester, the polyester is hydrolyzed by the alkali treatment. Therefore, the polyester in the base film 2 obtained by removing the functional layer 3 has a low molecular weight, which may reduce the value of the base film 2 as a material.

[0027] Although the conventional problems have been explained using the example of a case in which functional layer 3 is a release layer, similar problems can occur even when recycling a laminated film in which functional layer 3 has other functions, namely, contamination with materials from the functional layer and a decrease in the value of the base film due to the process of removing the functional layer.

[0028] In the recycling material manufacturing apparatus of the present embodiment, the above-mentioned problems are solved, the functional layer 3 can be easily removed from the laminated film 5, and a recycling material made of the base film 2 can be obtained.

[0029] Fig. 2 is a schematic explanatory diagram of a manufacturing apparatus for a recycled material according to this embodiment. The manufacturing apparatus 100 for a recycled material (hereinafter, manufacturing apparatus 100) shown in Fig. 2 includes a payout section 10, a heating section 20, a removal section 30, a cleaning section 40, a drying section 50, a winding section 60, and a control section 90. The manufacturing apparatus 100 is an apparatus that manufactures a recycled material made of a base film 2 by removing the functional layer during the conveyance process while conveying a long laminated film 5 in the longitudinal direction.

[0030] In FIG. 2, the relative positions may be described with the horizontal direction, which is the conveying direction of the laminated film 5, being referred to as the x direction, and the vertical direction being referred to as the y direction.

[0031] 2 shows that the laminated film 5 is transported in the x direction while each treatment is performed within the transport path, but this is not limited to this. For example, a location may be provided within the transport path where the laminated film 5 is transported in the y direction, and each treatment may be performed at that location. With this configuration, it is possible to shorten the overall length of the recycling material manufacturing device and reduce the installation area of ​​the device. The following explains each in order.

[0032] (Feed-out section) The unwinding unit 10 unwinds the laminate film 5 in the longitudinal direction of the laminate film 5 from the roll 5R on which the laminate film 5 is wound. The operation performed in the unwinding unit 10 corresponds to the "unwinding step" in the present invention. Examples of the roll 5R include a used release film or a carrier film wound into a roll.

[0033] These laminate films are usually wound into a roll after use and collected from the place where they were used. The roll-shaped laminate film thus collected may be used as it is as the roll 5R. In addition, when the width (length in the short direction) of the laminate film 5 constituting the roll 5R is wider than the width that can be processed by the manufacturing apparatus 100, the laminate film 5 may be slit in advance to adjust the width of the roll 5R.

[0034] The laminated film 5 is transported in a position in which the functional layer 3 faces upward (+y side). The transport speed of the laminated film 5 is, for example, 1 m / min to 10 m / min.

[0035] (heating part) The heating section 20 is provided downstream (+x side) of the feeding section 10 in the transport direction of the laminated film 5, and heats the transported laminated film 5. The treatment performed in the heating section 20 corresponds to the "heating process" in the present invention. Heating the laminated film 5 in the heating section 20 is expected to promote the removal of the functional layer 3 in the removal section 30 described below. The heating section 20 performs a pretreatment that promotes the removal of the functional layer 3 without using an organic solvent. For this reason, the heating section 20 corresponds to the "pretreatment section" in the present invention.

[0036] The heating unit 20 has a treatment tank 21 in which hot water HW is stored. The treatment tank 21 may have a heater (not shown) for adjusting the temperature of the hot water HW, and a water supply pipe and a drain pipe connected to the treatment tank 21.

[0037] In the heating section 20, the laminated film 5 is transported using transport rolls 101, 102, and 103. Of these, the transport roll 102 is disposed in the hot water HW of the treatment tank 21. As a result, the transported laminated film 5 passes through the hot water HW and is heated.

[0038] The temperature of the hot water HW may be set according to the type of laminate film to be treated, based on the correspondence between the heating temperature of the laminate film 5 after passing through the heating section 20 and the effect of removing the functional layer 3 in the removal section 30, which will be described later. The correspondence between the temperature of the hot water HW and the effect of removing the functional layer 3 may be determined in advance by a preliminary experiment.

[0039] The heating temperature of the laminate film 5 means "the temperature of the laminate film 5 at the outlet of the heating section 20." The heating temperature of the laminate film 5 can be measured by a known non-contact thermometer.

[0040] Furthermore, when the transport speed of the laminated film 5 is relatively fast within the settable speed range, the time for the hot water HW to pass through becomes relatively short. Therefore, when the transport speed is increased, it is advisable to increase the temperature of the hot water HW so that the desired heating can be performed in a short time.

[0041] As an example, the temperature of the hot water HW is 40° C. to 90° C. It is preferable to use a treatment tank 21 storing the hot water HW as the heating unit 20 and immerse the laminated film 5 in the hot water HW, since the laminated film 5 can be effectively heated in a short time.

[0042] The heating method in the heating section 20 is not limited to wet heating in which the laminated film 5 comes into direct contact with a heat medium, such as immersing the laminated film 5 in the hot water HW described above, but may also be "gas phase heating" in which the laminated film 5 is heated in the gas phase without direct contact with a heat medium.

[0043] 3 and 4 are explanatory diagrams showing modified examples of the heating unit. 3 heats the functional layer 3 by blowing hot air HA onto the laminated film 5 from above (the +y side) of the laminated film 5. As the heating unit 25, a known heat gun or hot air heater can be used.

[0044] 4 irradiates the laminated film 5 with infrared rays IR from above, thereby heating the functional layer 3. As the heating unit 26, a known heater such as a halogen lamp or an infrared heater can be used.

[0045] The heating sections 25 and 26 may be configured to heat the laminated film 5 from below (-y side) of the laminated film 5, or may be configured to heat the laminated film 5 from above and below.

[0046] When the heating parts 25 and 26 are employed, the heating temperature of the laminate film 5 means "the temperature of the laminate film 5 overlapping the downstream end of the heating part when viewed from the normal direction of the laminate film 5." The heating temperature of the laminate film 5 can be measured by a known non-contact thermometer.

[0047] Alternatively, the vapor phase heating may be performed by passing through a heated environment using the laminated film 5. An example of "passing through a heated environment" is passing through a chamber whose inside is heated.

[0048] Of the above-mentioned configurations, "vapor phase heating" is preferred as the heating section. Vapor phase heating has the advantage of consuming less energy to maintain the temperature of the heating section compared to wet heating. Among the vapor phase heating methods, a configuration in which the laminated film 5 is locally heated without using a chamber, such as the heating sections 25 and 26, is preferred. By employing the heating sections 25 and 26, it is easy to make the installation more compact.

[0049] When these methods are adopted for the heating section, it becomes possible to heat the laminated film 5 to a temperature higher than the boiling point of water.

[0050] The heating temperature in the heating section is, for example, 20°C to 250°C. The lower limit of the heating temperature is set to a temperature higher than the environmental temperature in which the recycling material manufacturing device of this embodiment is installed. For example, when the recycling material manufacturing device is used in winter or in cold regions, heating to 20°C may be considered heating. The upper limit of the heating temperature is set to a temperature lower than the melting point of the base film constituting the laminated film to be treated.

[0051] (Removal part) The removal unit 30 is provided downstream of the heating unit 20 in the transport direction of the laminated film 5, and removes the functional layer 3 from the transported laminated film 5. The process performed in the heating unit 20 corresponds to the "removing step" in the present invention. (Removing step). The removal unit 30 has a first removal means 30A and a second removal means 30B.

[0052] The first removing means 30A has nip rolls 31 and 32, a buff roll (removing member) 33, a backup roll (supporting member) 331, and a water sprinkling means .

[0053] The nip roll 31 has rolls 311 and 312. The nip roll 31 conveys the laminated film 5 while sandwiching it between the rolls 311 and 312.

[0054] Further, the nip roll 32 has rolls 321 and 322. The nip roll 32 is provided downstream of the nip roll 31, and conveys the laminated film 5 while sandwiching it between the rolls 321 and 322.

[0055] The buff roll 33 is a cylindrical member provided between the nip rolls 31 and 32, and rotates around the axis of the cylinder. The axial length of the buff roll 33 is longer than the width direction length of the transported laminated film 5. The buff roll 33 is disposed so as to intersect with and straddle the laminated film 5, and in a rotated state, is pressed against the one surface 2a side of the laminated film 5 from above (+y side). In this way, the buff roll 33 polishes the functional layer 3 provided on the one surface 2a side, and physically peels it off.

[0056] The buff roll 33 oscillates in the axial direction of the cylinder, i.e., in the width direction of the laminated film 5. The buff roll 33 has a swinging part that swings the buff roll 33 in the width direction of the laminated film 5 while rotating. It is preferable that the swinging part be capable of appropriately setting the swing width and swing period of the buff roll 33.

[0057] The rotation direction of the buff roll 33 may be the same as the transport direction of the laminated film 5 (forward rotation) at the point of contact with the laminated film 5, or may be the opposite direction (reverse rotation) to the transport direction of the laminated film 5. When the buff roll 33 is set to rotate in the reverse direction, it is expected that the effect of removing the functional layer 3 will be improved.

[0058] Furthermore, when the buff roll 33 rotates in the forward direction, the laminated film 5 is sent out in the transport direction, and it is expected that the speed will be faster than the set film transport speed. Therefore, when the buff roll 33 rotates in the forward direction, it is advisable to adjust the film transport speed so that it does not exceed the winding speed of the winding section 60.

[0059] The buff roll 33 is a member formed by molding a nonwoven fabric containing an abrasive into a cylindrical shape. The material of the buff roll 33 may be natural fibers such as cotton or hemp, or synthetic fibers such as polyester or nylon. The material and grain size of the abrasive contained in the buff roll 33 may be appropriately selected depending on the configuration (material, thickness) of the functional layer 3 to be removed.

[0060] The rotation speed of the buff roll 33 may be set according to the type of laminated film to be treated, based on the relationship between the rotation speed and the effect of removing the functional layer 3. The relationship between the rotation speed and the effect of removing the functional layer 3 may be determined in advance by a preliminary experiment.

[0061] Fig. 5 is a cross-sectional view of the backup roll 331. As shown in Fig. 5, the backup roll 331 has a roll body 331a and an abrasion-resistant layer 331b provided on the surface (side surface) of the roll body 331a, which is a curved surface facing the buff roll 33.

[0062] The backup roll 331 is a cylindrical member that rotates freely around the axis of the cylinder. The axial length of the backup roll 331 is longer than the width direction length of the laminated film 5 being transported. The backup roll 331 is provided parallel to the buff roll 33 below the position where the buff roll 33 and the laminated film 5 come into contact (the opposite side of the buff roll 33 with respect to the laminated film 5; -y side). That is, the backup roll 331 is disposed across the laminated film 5, intersecting with the laminated film 5 (orthogonal in the figure), and straddling the laminated film 5, supporting the laminated film 5 from below. This allows the laminated film 5 to be prevented from bending due to the pressure from the buff roll 33, and the functional layer 3 can be removed efficiently.

[0063] There is no limitation on the material of the roll body 331a, and any material used in known backup rolls can be used.

[0064] The wear-resistant layer 331b is formed of a material harder than the material of the roll body 331a. For example, a thermal spray film made of chromium oxide can be used as the wear-resistant layer 331b. In addition, a material having a hardness equal to or higher than that of chromium oxide (for example, a Mohs hardness of 6 or more (Vickers hardness of HV650 or more)) can be used as the material of the wear-resistant layer 331b. In addition, it is more preferable that the material of the wear-resistant layer 331b has a Vickers hardness of HV900 or more.

[0065] Furthermore, when the material of the roll body 331a is iron or an alloy containing iron, the wear-resistant layer 331b may be a film of iron carbonitride formed on the surface of the roll body 331a by subjecting the roll body 331a to gas soft nitriding treatment.

[0066] 6 is a plan view of the backup roll 331 viewed from the +x direction. As described above, the buff roll 33 oscillates in the width direction (the direction of the symbol X) of the laminated film 5, and therefore the portion α of the backup roll 331 that does not overlap with the laminated film 5 in a plan view comes into contact with the buff roll 33 and is polished. At this time, since the backup roll 331 has an abrasion-resistant layer 331b provided on its surface, it is not easily deteriorated by polishing by the buff roll 33 and has a long life.

[0067] In addition, the backup roll 331 does not need to have the wear-resistant layer 331b on the entire side surface thereof as long as the wear-resistant layer 331b is provided on at least the portion α and protects at least both axial ends of the roll body 331a.

[0068] The pressure applied from the buff roll 33 to the laminated film 5 can be adjusted by the height position of the central axis of the buff roll 33. That is, the height position of the central axis of the buff roll 33 that contacts the laminated film 5 without pressing it when supported without slack by the nip rolls 31 and 32 is set as a reference position, and the pressure can be adjusted by the movement distance of the central axis when the buff roll 33 is lowered. The pressure can be set according to the type of laminated film to be treated, based on the correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3. The correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3 can be obtained in advance by a preliminary experiment.

[0069] When the baffle roll 33 presses down on the laminate film 5, strong pressure is applied to the laminate film 5 from the baffle roll 33, and a force that corresponds to the rotation direction of the baffle roll 33 is easily applied. When the baffle roll 33 rotates forward, a force is applied that pushes the laminate film 5, which is located downstream of the baffle roll 33, further downstream. This can cause the laminate film 5 to sag on the downstream side, resulting in uneven processing and difficulty in winding in the winding section 60, which will be described later.

[0070] Furthermore, when the baffle roll 33 rotates in the reverse direction, a force is applied that pulls the laminate film 5, which is located downstream of the baffle roll 33, back upstream. If the pressure applied to the laminate film 5 from the baffle roll 33 is increased, the resulting "pull-back force" becomes stronger than the force that is applied to the laminate film 5 by the winding section 60, which will be described later, causing the laminate film 5 to run in the reverse direction, which may prevent processing from proceeding.

[0071] In such cases, by adjusting the holding force of the laminated film 5 by the nip rolls 31, 32, the laminated film 5 can be held tightly between the nip rolls 31, 32, and reverse running of the laminated film 5 can be prevented even if high pressure is applied from the buff roll 33.

[0072] The nip rolls 31 and 32 feed the laminate film 5 downstream at the same speed as the winding speed of the winding unit 60. Since the laminate film 5 is fed downstream using the winding unit 60 and the nip rolls 31 and 32, a difference in conveying speed occurs between the winding unit 60 and the nip rolls 31 and 32, and slack may occur in the laminate film 5 downstream of the nip roll 32. For this reason, a dancer roll may be provided downstream of the nip roll 32 to make the tension of the laminate film 5 adjustable.

[0073] The support member may be the backup roll described above, or a support plate that supports the laminated film 5 from below the laminated film 5. In this case, the support member is a portion that faces the buff roll (removal member) and has an abrasion-resistant layer that protects at least both ends of the support plate in the width direction of the laminated film 5. Even with such a configuration, the effects of the invention can be achieved.

[0074] The water sprinkling means 34 sprinkles water onto the upper surface (+x side surface) of the laminated film 5 from the upstream side (-x side) of the contact point between the buff roll 33 and the laminated film 5. The buff roll 33 polishes the surface of the laminated film 5 while the surface is wet. The water sprinkling means 34 suppresses frictional heat at the contact point between the buff roll 33 and the laminated film 5, and also washes away fine shavings (polishing debris) generated by polishing.

[0075] The configuration of the water spray means 34 is not particularly limited, and for example, a known shower head capable of spraying water in the width direction of the laminated film 5 can be used.

[0076] The water W to be sprayed may be at room temperature or may be hot water. The temperature of the hot water is, for example, 30°C to 40°C.

[0077] Second removing means 30B has nip rolls 35, 36, a buff roll (removing member) 37, a backup roll 371, and water sprinkling means 38. Nip roll 35 has rolls 351, 352. Nip roll 36 has rolls 361, 362. Nip rolls 35, 36, backup roll 371, and water sprinkling means 38 can have the same configuration as those of first removing means 30A.

[0078] The buff roll 37 is arranged in the transport direction of the laminated film 5 together with the above-mentioned buff roll 33. The buff roll 37 may be the same as or different from the buff roll 33 of the first removing means 30A. The operating conditions of the buff roll 37 may be the same as or different from those of the buff roll 33.

[0079] 2, the removal section 30 has the first removal means 30A and the second removal means 30B, but is not limited thereto. The removal section 30 can have one or more removal means with a set of removal means having the same configuration as the first removal means 30A (nip roll, buff roll, water sprinkling means). The removal section 30 is preferably configured to have 2 to 4 removal means.

[0080] When the removal unit 30 has a plurality of buff rolls, it is preferable that the number of the buff roll arranged on the most downstream side among the plurality of buff rolls is larger than the number of the other buff rolls. This allows the functional layer 3 to be removed efficiently. For example, it is preferable that the number of the upstream buff roll is 240 and the number of the most downstream buff roll is 600.

[0081] In this embodiment, a buff roll is used as the removing member, but other configurations can be used as long as they can peel off the functional layer. For example, a cylindrical rotating brush, a rubber roll, or a grindstone can also be used as the removing member.

[0082] The removal member is preferably configured to rotate while contacting the functional layer, thereby applying friction to the contact point and removing the functional layer. The rotation axis of the removal member is preferably set in a direction intersecting the conveying direction of the laminated film 5. In the manufacturing apparatus 100 of Fig. 2, the buff rolls 33 and 37 as the removal members are both set in a direction perpendicular to the conveying direction of the laminated film 5, but the angles of the rotation axes of the multiple buff rolls (removal members) with respect to the conveying direction of the laminated film may be the same or different.

[0083] (Washing section, drying section) The laminated film 5 (i.e., base film 2) from which the functional layer 3 has been removed in the removal unit 30 is transported downstream using transport rolls 104, 105, 106, and 107. The manufacturing apparatus 100 has a cleaning unit 40 and a drying unit 50, in this order, downstream of the removal unit 30.

[0084] The cleaning section 40 has water spraying means 41 provided above the transported base film 2, and washes the upper surface (one surface 2a side) of the laminated film 5 after the functional layer 3 has been removed with water. The water spraying means 41 sprays water onto the upper surface of the laminated film 5. There are no particular limitations on the configuration of the water spraying means 41, and for example, a known shower head capable of spraying water in the width direction of the laminated film 5 can be used.

[0085] The drying section 50 includes a squeegee (dewatering section) 51 and a hot air blower 52 in this order from the upstream side. The squeegee 51 comes into contact with one surface 2a of the base film 2 and drains water from the one surface 2a. The squeegee 51 is preferably longer than the width of the base film 2. In addition, the squeegee 51 is preferably arranged to diagonally intersect with the base film 2 in a plan view.

[0086] An air knife may be used as the dewatering section. The air knife blows compressed air toward one surface 2a of the base film 2 to remove water from the one surface 2a. The blowing direction of the compressed air is preferably inclined toward the upstream side with respect to the one surface 2a.

[0087] The hot air blower 52 blows hot air H toward the one surface 2a of the base film 2 to dry the one surface 2a. The temperature of the hot air H is, for example, 50°C to 70°C.

[0088] (Winding section) The winding section 60 winds up the transported base film 2 (i.e., the recycled material 1) into a roll. The roll 1R wound up by the winding section 60 is used as a raw material for material recycling or chemical recycling.

[0089] In addition, in the case where the laminated film to be processed has functional layers formed on both sides of the base film, the laminated film can be passed through the manufacturing apparatus 100 twice and the functional layers can be removed from both sides of the base film to obtain recycled material.

[0090] (Control unit) The control unit 90 controls the operating conditions of each component of the manufacturing apparatus 100. The control unit 90 may store a correspondence between the type of laminated film 5 to be processed and the operating conditions of each component, so that the control unit 90 can retrieve appropriate operating conditions and change the conditions each time the type of laminated film 5 to be processed is changed.

[0091] For example, when the functional layer of the laminated film 5 is a release layer, a silicone-based release agent is applied to the entire surface of the laminated film 5. In this case, the buff roll pressed against the functional layer may slip on the surface of the functional layer (release layer), preventing removal. In this case, it is necessary to press the buff roll firmly against the laminated film.

[0092] Furthermore, when the functional layer is a printed layer, the ease of removal of the functional layer varies depending on the printing conditions, such as whether it is monochromatic or multicolor printing, whether there is a base coat (overcoat), and the type of ink used.

[0093] Therefore, it is necessary to set appropriate operating conditions according to the type of laminated film 5 to be treated, i.e., the type of functional layer. On the other hand, when recycling laminated films, it is expected that laminated films of the same configuration will be repeatedly treated. Therefore, by storing in the control unit 90 the correspondence between the type of laminated film 5 and the operating conditions of each unit, it becomes easy to switch the object to be treated.

[0094] As described above, in the manufacturing apparatus 100, the functional layer 3 is physically peeled off using the buff rolls 33, 37. That is, in the above-mentioned manufacturing apparatus 100, the laminated film 5 is not brought into contact with an organic solvent from the unwinding section 10 to the winding section 60, i.e., from the unwinding process to the winding process. This makes it possible to suppress deterioration and swelling of the recycled material 1, and to produce the recycled material 1 by removing the functional layer 3 from the laminated film 5 without degrading the physical properties of the base film 2. In addition, the environmental impact of producing the recycled material 1 can be reduced.

[0095] In the manufacturing apparatus 100, the removal unit has the backup rolls 331, 371, and the buff rolls 33, 37 are oscillated to facilitate removal of the functional layer 3. At this time, an abrasion-resistant layer is provided on the surface of the backup rolls 331, 371, which prevents the surface of the backup roll from being polished by the buff roll and thereby prevents the backup roll from being deteriorated.

[0096] Moreover, in the manufacturing apparatus 100, the laminated film 5 is not brought into contact with an alkaline solution. As a result, when the material of the base film 2 is polyester, hydrolysis of the base film 2 can be suppressed, and the functional layer 3 can be removed from the laminated film 5 without deteriorating the physical properties of the base film 2 to produce the recycled material 1.

[0097] In this embodiment, the term "alkaline solution" refers to a solution having a pH of more than 8. Weakly basic solutions having a pH of 7 to 8 are not included in the alkaline solution in this embodiment. In this respect, for example, the water W sprayed from the spraying means in the above-mentioned removal unit 30 may contain a small amount of surfactant to the extent that the effect of the invention is not impaired.

[0098] (Recycled materials) 7 is an enlarged photograph of the recycled material 1 obtained by the manufacturing apparatus 100. The recycled material 1 is made of a polyester base film 2 from which the functional layer 3 has been removed.

[0099] In the figure, the direction indicated by the symbol A is the width direction of the laminate film, and the direction indicated by the symbol B is the longitudinal direction of the laminate film. As shown in Fig. 7, one surface 2a of the base film 2 has a plurality of grooves extending in the longitudinal direction. In Fig. 7, the grooves can be confirmed as white streaks. The grooves are scratches formed by the buff roll described above.

[0100] In addition, when the recycled material 1 is made of polyester, the intrinsic viscosity (IV value) of the polyester constituting the recycled material 1 (base film 2) is 0.5 dL / g or more. The intrinsic viscosity of the polyester constituting the base film 2 is preferably 0.55 dL / g or more, and more preferably 0.6 dL / g or more.

[0101] The intrinsic viscosity of the film (substrate film, recycled material) can be measured by a method in accordance with JIS K 7390.

[0102] Generally, in a laminate film 5 used as a release film or a carrier film, the intrinsic viscosity of the base film 2 is about 0.6 dL / g. If an alkaline solution (basic substance) is used to remove the functional layer 3 from such a laminate film 5, the base film 2 may be hydrolyzed, resulting in a decrease in the intrinsic viscosity.

[0103] For example, when molding a film, the intrinsic viscosity of the polyester material is approximately 0.6 dL / g, and when spinning fibers, the intrinsic viscosity is approximately 0.5 dL / g. Therefore, when using recycled materials obtained from laminated films as materials for chemical recycling or material recycling, the recycled materials must have the intrinsic viscosity of each of the above molded products.

[0104] In contrast, in the manufacturing apparatus for recycled materials of the present embodiment, as described above, the alkaline solution does not come into contact with the laminated film 5. Therefore, the intrinsic viscosity of the polyester is not reduced in the obtained recycled material 1, and the recycled material 1 can be suitably used as a material for chemical recycling or material recycling.

[0105] The term "without decreasing" means that a decrease in intrinsic viscosity within the range of measurement error is permitted.

[0106] Furthermore, the recycled material 1 may be made of a resin other than polyester, which is given as an example of the material of the resin film.

[0107] The resulting recycled material can be melted and molded to produce a regenerated material. 8 is a schematic diagram showing a recycled material manufacturing system 1000 of this embodiment. The recycled material manufacturing system 1000 has the above-mentioned recycled material manufacturing apparatus 100 and a molding apparatus 500 that melts and molds the above-mentioned recycled material (substrate film 2). The recycled material manufacturing system 1000 may have, as the molding apparatus 500, a re-pelletizing section that re-pellets the recycled material and a molding section that molds the target object. Examples of recycled materials include the above-mentioned films and fibers.

[0108] According to the recycled material manufacturing apparatus configured as described above, the functional layer can be removed from a laminated film consisting of a base film and a functional layer without reducing the physical properties of the base film, and a recycled material that can be suitably used as a material for chemical recycling or material recycling can be produced.

[0109] Furthermore, in the recycled material manufacturing system configured as described above, since the recycled materials described above are used as raw materials, the environmental impact is low and it is possible to contribute to a recycling-oriented society.

[0110] 9 to 11 are schematic explanatory diagrams showing modified examples of the recycling material manufacturing apparatus.

[0111] 9, in a manufacturing apparatus 150 for recycled materials (hereinafter, manufacturing apparatus 150), a payout section 10 pays out laminated film 5 from two rolls 5R in the longitudinal direction of laminated film 5. For example, payout section 10 pays out laminated film 5 from roll 5RA, and immediately after payout from roll 5RA is completed, payout from roll 5RB is started.

[0112] In the manufacturing apparatus 150, the roll 5RA is replaced with a new roll while the roll 5RB is being unwound. The roll replacement may be performed manually by an operator or a manager of the manufacturing apparatus 150, or may be performed automatically by the manufacturing apparatus 150.

[0113] The manufacturing apparatus 150 has a connection section 80 between the unwinding section 10 and the heating section 20, which connects the laminated film 5A unwound from the roll 5RA and the laminated film 5B unwound from the roll 5RB within the transport path. The connection section 80 connects the rear end of one laminated film (e.g., laminated film 5A) to the front end of the other laminated film (e.g., laminated film 5B), and has the function of combining the two laminated films 5 unwound from the two rolls 5R into one.

[0114] Furthermore, the manufacturing apparatus 150 has a dividing section 85 that divides the transported recycled material 1 into two recycled materials 1A and 1B in the longitudinal direction between the hot air blower 52 (drying section 50) and the winding section 60. The dividing section 85 may divide the recycled material 1 into two recycled materials 1A and 1B at a position corresponding to the position where the laminated film 5A and the laminated film 5B are connected, or may divide the recycled material 1 at any position.

[0115] The unwinding section 10 and the connecting section 80 may be implemented by, for example, a known turret unwinder.

[0116] The winding section 60 and the dividing section 85 may be implemented by, for example, a known turret winding machine.

[0117] The winding section 60 alternately winds the recycled material 1 onto two rolls 1RA and 1RB. In the winding section 60, for example, the recycled material 1A is wound onto the roll 1RA, and when the amount of the recycled material wound onto the roll 1RA reaches a set value, the winding section 60 switches to winding onto the roll 1RB.

[0118] The roll replacement may be performed manually by an operator or a manager of the manufacturing apparatus 150, or may be performed automatically by the manufacturing apparatus 150.

[0119] The control unit 90 controls the connection unit 80 and the division unit 85 to continuously pay out the laminated film 5 and take up the recycled material 1. This allows the production apparatus 150 to operate continuously.

[0120] As shown in FIG. 10, in the removal section 30 of the production apparatus 150, the water spraying means 34 may include a waste water tank 341, a filter 342, a pipe 343, a pump 344, and a shower head 345.

[0121] The waste water tank 341 is disposed below the baffle roll 33 and receives and stores the waste water WW generated from the contact point between the baffle roll 33 and the laminated film 5 .

[0122] The filter 342 removes solid matter (polished debris) contained in the wastewater WW.

[0123] The pipe 343 connects the wastewater tank 341, the filter 342, and the shower head 345. The wastewater WW from which solids have been removed is supplied to the shower head 345 via the pipe 343 by a pump 344 disposed in the path of the pipe 343.

[0124] The shower head 345 sprays water W obtained by removing solid matter from waste water WW onto the buff roll 33 .

[0125] Similarly, in removal unit 30, sprinkling means 38 may have a wastewater tank 381, a filter 382, ​​piping 383, a pump 384, and a shower head 385. Each component of sprinkling means 38 may be similar to each component of sprinkling means 34.

[0126] Furthermore, the water sprinkling means 34, 38 may be provided with a heating device for heating the water flowing inside the piping.

[0127] By providing the above-mentioned water sprinkling means to the manufacturing apparatus 150, it becomes possible to recycle the water sprinkled on the buff roll, thereby reducing the amount of wastewater and the environmental load.

[0128] By using the recycling material manufacturing device of this embodiment, for example, it is possible to recover used release films and remove the functional layer from the recovered release films to produce recycled materials. Furthermore, the obtained recycled materials can be melt-processed to produce a base film as a recycled material, and a release layer (functional layer) can be formed on one side to regenerate and use the release film. In this way, the present invention can contribute to a recycling-oriented society.

[0129] Although the preferred embodiment of the present invention has been described above with reference to the accompanying drawings, the present invention is not limited to the above embodiment. The shapes and combinations of the components shown in the above embodiment are merely examples, and various modifications can be made based on design requirements, etc., without departing from the spirit of the present invention. [Explanation of symbols]

[0130] 1, 1A, 1B... recycled material, 2... base film, 2a... one side, 3... functional layer, 5, 5A, 5B... laminated film, 10... unwinding section, 20, 25, 26... heating section, 30... removal section, 33, 37... buff roll (removal member), 60... winding section, 100, 150... recycled material manufacturing device, 331, 371... backup roll (support member), 331b... wear-resistant layer, 500... molding device, 1000... recycled material manufacturing system, α... part

Claims

1. a roll of a laminated film including a long base film extending in one direction and at least one functional layer formed on one surface of the base film; and a payout unit that pays out the laminated film in the one direction from a roll of the laminated film. a pretreatment section for performing a pretreatment to promote removal of the functional layer without using an organic solvent; A removal unit that removes the functional layer; a winding section that winds up the laminated film from which the functional layer has been removed into a roll, The removal unit includes a cylindrical removal member that rotates in contact with the one surface of the laminate film; a support member that supports the laminated film from a surface opposite to the one surface, The removal member is oscillating in an axial direction of the removal member, The supporting member is a portion facing the removing member, and has an abrasion-resistant layer that protects at least both ends of the supporting member in the width direction of the laminated film.

2. 2. The recycling material manufacturing apparatus according to claim 1, wherein the wear-resistant layer is a chromium oxide layer.

3. 3. The recycling material manufacturing apparatus according to claim 1, wherein the supporting member is a backup roll.

4. the removing member is a buff roll; The removal unit has a plurality of the buff rolls, The plurality of buff rolls are arranged in a conveying direction of the laminated film, 3. The recycling material manufacturing apparatus according to claim 1, wherein the number of the baffle roll arranged on the most downstream side among the plurality of baffle rolls is greater than the number of the other baffle rolls.

5. 3. The recycling material manufacturing apparatus according to claim 1, wherein the pre-treatment section is a heating section for heating the laminated film.

6. The recycling material manufacturing device according to claim 5 , wherein the heating section heats the laminated film in a gas phase.

7. The recycling material manufacturing apparatus according to claim 1 or 2, A molding device that melts and molds the recycled material produced by the recycled material manufacturing device.

Images