Laminated film manufacturing method and manufacturing device

Abstract

To form a laminate film having a uniform coating layer without defects.SOLUTION: A method for manufacturing a laminate film includes the steps of: discharging a coating liquid onto a transfer roll 301 which comes in contact with a base material layer 101 and rotates using an inkjet discharge device 30, and forming a coating liquid layer; and bringing the transfer layer 301 into contact with the base material layer 101, and transferring the coating liquid layer formed on the transfer roll 301 onto the base material layer 101.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a technique for producing a laminated film. [Background technology]

[0002] It is known that a coating liquid that realizes a specific function is applied to the surface of a resin film to form a coating layer, and then the coating layer is dried to form a laminated film having various functions on the surface.

[0003] A known method for applying a coating liquid to a resin film is, for example, a roll coater, which supplies the liquid to an application roller and rotates the application roller in contact with the film in accordance with the transport of the film, thereby applying the liquid to the resin film.

[0004] A known example of a roll coater is the reverse gravure coater, which applies a coating liquid to an engraved roll (gravure roll), scrapes the surface of the gravure roll mainly with a blade, and transfers the coating liquid that has accumulated in the engraved recesses onto a film to form a coating layer.

[0005] It is also known that in the above-mentioned roll coater, regions where the coating liquid is not applied (dry edges) are formed along both edges of the film to prevent the coating liquid from running to the back.

[0006] Dry edge formation in a reverse gravure coater is carried out by attaching films to both ends of the gravure roll to prevent transfer to the sheet material.

[0007] In recent years, it has also become known to print on films using inkjet coating devices. The inkjet method involves discharging minute droplets of liquid onto the film to coat it, and is used as a method for achieving particularly fine coating patterns. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-346534 [Non-patent literature]

[0009] [Non-Patent Document 1] Katsuhiro Omori, “Roll to Roll Wet Coating Equipment”, [online], March 26, 2006, Surface Technology, [Retrieved April 12, 2022], Internet<URL:https: / / www.jstage.jst.go.jp / article / sfj / 60 / 7 / 60_7_435 / _pdf / -char / ja> [Non-patent document 2] "Various Coater Heads and Their Products," by Tadashi Sasa, Journal of the Japan Paper and Pulp Technology Association, Vol. 55, No. 12, December 2001 Summary of the Invention [Problem to be solved by the invention]

[0010] When applying a coating liquid to a film using an inkjet coating device, if nozzle clogging occurs in the inkjet head, ink will not be ejected from the un-ejected portion, which may result in streaky coating defects on the film.

[0011] One object of the present invention is to form a laminated film having a uniform, defect-free coating layer. [Means for solving the problem]

[0012] Therefore, this method for manufacturing a laminated film is a method for manufacturing a laminated film in which a coating layer is formed on a base layer, and includes the steps of: ejecting a coating liquid using an inkjet ejection device onto a transfer roll that rotates in contact with the base layer to form a coating liquid layer; and abutting the transfer roll against the base layer to transfer the coating liquid layer formed on the transfer roll to the base layer. [Effects of the Invention]

[0013] According to one embodiment, the quality of the laminated film can be improved. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a diagram illustrating a configuration of a laminated film manufacturing system as an example of an embodiment; [Figure 2] 1 is a diagram schematically illustrating an example of the configuration of a longitudinal stretching device of a laminated film manufacturing system as an example of an embodiment. [Figure 3] 1 is a diagram schematically illustrating a configuration example of a transverse stretching device of a laminated film manufacturing system as an example of an embodiment. [Figure 4] 1 is a diagram illustrating a transfer device of a laminated film manufacturing system as an example of an embodiment. [Figure 5] 1 is a diagram illustrating an example of a nozzle row of an inkjet head of an inkjet ejection device of a laminated film manufacturing system as an example of an embodiment. FIG. [Figure 6] 1 is a diagram illustrating an example of the arrangement of inkjet heads of an inkjet ejection device in a laminated film manufacturing system as an example of an embodiment. [Figure 7] 1 is a diagram illustrating an example of the arrangement of inkjet heads of an inkjet ejection device in a laminated film manufacturing system as an example of an embodiment. [Figure 8] 1 is a diagram illustrating an example of the arrangement of inkjet heads of an inkjet ejection device in a laminated film manufacturing system as an example of an embodiment. [Figure 9] FIG. 10 is a diagram illustrating a modified example of a transfer device of a laminated film manufacturing system as an example of an embodiment. [Figure 10] 10A and 10B are diagrams illustrating a modified example of an inkjet ejection device of a laminated film manufacturing system as an example of an embodiment. [Figure 11] 10A and 10B are diagrams illustrating a modified example of an inkjet ejection device of a laminated film manufacturing system as an example of an embodiment. [Figure 12] 10A and 10B are diagrams illustrating a modified example of an inkjet ejection device of a laminated film manufacturing system as an example of an embodiment. [Figure 13] 10A and 10B are diagrams illustrating a modified example of a transfer device of a laminated film manufacturing system as an example of an embodiment. [Figure 14] 10A and 10B are diagrams illustrating another modified example of the transfer device of the laminated film manufacturing system as one example of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, embodiments of the manufacturing method and manufacturing apparatus for the present laminated film will be described with reference to the drawings. However, the embodiments shown below are merely examples, and are not intended to exclude the application of various modifications and techniques not explicitly stated in the embodiments. In other words, the present embodiment can be implemented with various modifications within the scope of its purpose. Furthermore, each figure does not intend to include only the components shown in the figure, but can also include other functions, etc.

[0016] (A) Configuration Fig. 1 is a diagram illustrating the configuration of a laminated film manufacturing system 1 as one example of an embodiment. Note that Fig. 1 shows an example in which a base layer is manufactured by a sequential biaxial stretching method, but the method for manufacturing the base layer is not limited to this, and may be, for example, a uniaxial stretching method, a non-stretching method, or any other known method.

[0017] The laminated film manufacturing system 1 of the present invention produces a laminated film 100. The laminated film 100 has a laminated structure in which a coating layer 102 is formed on a base layer 101. The base layer 101 corresponds to a cast film layer (hereinafter sometimes simply referred to as a "cast film layer") formed by extruding a resin composition until the longitudinal stretching step is completed, corresponds to a first stretched layer after the longitudinal stretching step until the transverse stretching step is completed, and corresponds to a substrate layer after the transverse stretching step is completed.

[0018] The base layer 101, that is, the material for forming the substrate layer, may be a resin composition containing a thermoplastic resin.

[0019] Examples of thermoplastic resins include olefin polymers, polyamides, polyesters, polycarbonates, polystyrenes, poly(meth)acrylates, polyvinyl chloride, and mixed resins thereof. Among these, olefin polymers are preferred from the viewpoint of water resistance and solvent resistance.

[0020] As the olefin polymer, propylene polymers such as polypropylene, ethylene polymers such as polyethylene, etc. can be preferably used.

[0021] The resin composition may further contain a filler, which may be either an inorganic filler or an organic filler.

[0022] The base layer 101 may further contain stabilizers, light stabilizers, dispersants, lubricants, fluorescent whitening agents, colorants, etc., as required.

[0023] The base layer 101 may have a single layer structure or a multi-layer structure of two or more layers.

[0024] The laminated film production system 1 illustrated in FIG. 1 includes raw material silos 10a and 10b, a granulator 11, a pellet silo 12, an extruder 13, a longitudinal stretching device 14, a transverse stretching device 16, a transfer device 350, and a dryer 18.

[0025] Each of the raw material silos 10a, 10b, granulator 11, pellet silo 12, extruder 13, longitudinal stretching device 14, transverse stretching device 16, transfer device 350 and dryer 18 that make up the laminated film manufacturing system 1 realizes the manufacturing process for producing the laminated film 100.

[0026] The raw material silos 10a and 10b store raw materials for the laminated film 100. The raw materials for the laminated film 100 include, for example, thermoplastic resin, filler, and optional additives. Although the number of raw material silos in Fig. 1 is two, any number of silos may be provided.

[0027] The raw materials of the laminated film 100 may include recycled materials produced by processing scraps generated during the cutting process or the like when the laminated film 100 is formed.

[0028] The raw materials stored in the raw material silos 10a and 10b are fed into a granulator 11.

[0029] The granulator 11 adds fillers and various additives to the thermoplastic resin raw material as required to produce pellets of the resin composition.

[0030] The pellet silo 12 stores the pellets produced by the granulator 11. The pellet silo 12 supplies the pellets stored therein to the extruder 13.

[0031] The extruder 13 extrudes the molten resin composition in the form of a sheet from an extruder die (not shown) to produce the base layer 101, which is a cast film layer.

[0032] The extruder 13 forms a base layer 101, which is a cast film layer, by extruding a molten resin composition in the form of a sheet from an extruder die (not shown). The base layer 101 extruded from the extruder 13, i.e., the cast film layer, is transported by transport rollers (not shown) and supplied to a longitudinal stretching device 14 (described later).

[0033] The longitudinal stretching device 14 is disposed downstream of the base layer 101 extruded from the extruder 13, that is, the cast film layer, in the flow direction (transport direction).

[0034] The longitudinal stretching device 14 stretches the base layer 101 extruded from the extruder 13, i.e., the cast film layer, in the flow direction of the base layer 101. Hereinafter, the flow direction (conveyance direction) of the base layer 101 may be referred to as the longitudinal direction. The longitudinal direction corresponds to the first direction.

[0035] The longitudinal stretching device 14 corresponds to a first stretching device that stretches the base layer 101 (cast film layer) in the longitudinal direction (first direction). The longitudinal stretching device 14 also performs a first stretching step that stretches the base layer 101 (cast film layer) in the longitudinal direction (first direction).

[0036] In the longitudinal stretching device 14, for example, a plurality of conveying rollers are arranged parallel to one another in a direction perpendicular to the longitudinal stretching direction. Then, between these conveying rollers, for example, by varying the peripheral speed of the conveying rollers, tension in the longitudinal direction is applied to the cast film layer, thereby stretching the layer in the longitudinal direction. That is, the longitudinal stretching device 14 may perform inter-roll stretching utilizing the difference in peripheral speed between the rolls.

[0037] When the thermoplastic resin used is an amorphous resin, the stretching temperature is preferably in the range of the glass transition temperature of the thermoplastic resin or higher. When the thermoplastic resin is a crystalline resin, the stretching temperature is preferably in the range of the glass transition temperature of the amorphous part of the thermoplastic resin or higher and the melting point of the crystalline part of the thermoplastic resin or lower, and is preferably 2 to 60°C lower than the melting point of the thermoplastic resin. Specifically, for propylene homopolymer (melting point 155°C to 167°C), the stretching temperature is preferably 100°C to 164°C, and for high-density polyethylene resin (melting point 121°C to 134°C), the stretching temperature is preferably 70°C to 133°C.

[0038] The stretching speed is not particularly limited, but is preferably within the range of 20 m / min to 350 m / min from the viewpoint of stable stretching.

[0039] The stretching ratio can also be appropriately determined taking into consideration the properties of the thermoplastic resin used, etc. For example, when a propylene-based resin is used and biaxially stretched, the lower limit of the stretching ratio, in terms of area stretching ratio, is usually 1.5 times or more, preferably 4 times or more, and the upper limit is usually 60 times or less, preferably 50 times or less.

[0040] FIG. 2 is a diagram schematically illustrating an example of the configuration of the longitudinal stretching device 14 of the laminated film manufacturing system 1 as one example of the embodiment.

[0041] 2, four conveying rollers 141a, 141b, 141c, and 141d are arranged with their rotation axes parallel to one another and perpendicular to the vertical direction. The four conveying rollers 141a, 141b, 141c, and 141d are arranged in the flow direction of the base layer 101 in the following order: conveying roller 141a, conveying roller 141b, conveying roller 141c, and conveying roller 141d. Hereinafter, when there is no need to distinguish between the conveying rollers 141a, 141b, 141c, and 141d, they will be referred to as conveying rollers 141.

[0042] Each of these transport rollers 141 is configured to be rotatable around a rotation axis by a drive motor (not shown), and rotates in a direction following the flow of the base layer 101 while in contact with the base layer 101 .

[0043] Furthermore, the rotation speed of the drive motor of each conveying roller 141 is controlled so that the circumferential speed of the conveying roller 141 located downstream in the flow direction of the base layer 101 is increased. As a result, tension is generated in the base layer 101 between adjacent conveying rollers 141 along the flow direction of the base layer 101, and the base layer 101 is stretched in the longitudinal direction.

[0044] Further, other transport rollers (not shown) are also provided on the transport path of the base layer 101 to transport the base layer 101 downstream. These transport rollers correspond to a transport device that transports the base layer 101.

[0045] The transverse stretching device 16 is disposed downstream of the longitudinal stretching device 14 .

[0046] The transverse stretching device 16 stretches the base layer 101 (first stretched layer) stretched by the longitudinal stretching device 14 in a direction (transverse direction, width direction) perpendicular to the longitudinal direction. The transverse direction corresponds to the second direction.

[0047] The transverse stretching device 16 corresponds to a second stretching device that stretches the base layer 101 (first stretched layer) in a transverse direction (width direction, second direction) perpendicular to the longitudinal direction (first direction). The transverse stretching device 16 also performs a second stretching step in which the base layer 101 (first stretched layer) stretched by the longitudinal stretching device 14 is stretched in a transverse direction (width direction, second direction) perpendicular to the longitudinal direction (first direction).

[0048] In the second stretching step, as in the first stretching step, the base layer 101 is heated to a stretching temperature according to the type of thermoplastic resin used and stretched.

[0049] FIG. 3 is a diagram schematically illustrating an example of the configuration of the transverse stretching device 16 of the laminated film manufacturing system 1 as one example of the embodiment.

[0050] The transverse stretching device 16 is provided with a plurality of clips 161 (six in the example shown in FIG. 3) that grip the edges of the base layer 101, which is the first stretching layer. These clips 161 are arranged in pairs at positions that face each other across the base layer 101 on each of the two edges of the base layer 101. In the example shown in FIG. 3, three pairs of clips 161 are provided along the machine direction of the base layer 101.

[0051] Of these multiple clips 161, pairs of clips 161 are provided at opposing positions across the base layer 101, and while each grips an edge portion of the base layer 101, they move away from each other, thereby pulling and stretching the base layer 101, i.e., the first stretching layer, in the lateral direction (width direction).

[0052] The clips 161 gripping the base layer 101 stretch the base layer 101 in the width direction while moving in the flow direction following the transport of the base layer 101, and release the base layer 101 at a predetermined position. Thereafter, each clip 161 returns to an upstream position in the transport direction of the base layer 101 and grips the base layer 101 again. In this way, the transverse stretching device 16 uses a plurality of clips 161 to repeatedly grip, stretch, and release the base layer 101, thereby stretching the base layer 101 in the transverse direction. That is, the transverse stretching device 16 performs clip stretching using a tenter oven.

[0053] A transfer device 350 is provided downstream of the transverse stretching device 16. The transfer device 350 applies a coating liquid to the surface of the base layer 101 (substrate layer) that has been stretched by the transverse stretching device 16 and is being transported in the machine direction (flow direction), thereby forming a uniform coating layer 102 on the first surface (surface) of the base layer 101.

[0054] FIG. 4 is a diagram illustrating a transfer device 350 of the laminated film manufacturing system 1 as one example of an embodiment.

[0055] As shown in FIG. 4, the transfer device 350 includes an applicator roll 301, an inkjet ejection device 30, and a support roller 302.

[0056] The applicator roll 301 is disposed along the width direction of the base layer 101 with its rotation axis perpendicular to the longitudinal direction. The applicator roll 301 is configured to be rotatable about its rotation axis by a drive motor (not shown), and rotates in a direction along the flow of the base layer 101 (subordinate rotation) while in contact with the base layer 101. The applicator roll 301 also rotates so that its peripheral speed matches the transport speed of the base layer 101, and rotates while in contact with the surface of the base layer 101, following the movement of the base layer 101 transported in the flow direction.

[0057] A coating liquid layer is formed on the outer peripheral surface (cylindrical surface) of the applicator roll 301 by applying the coating liquid by an inkjet discharge device 30, which will be described later. The surface of the applicator roll 301 may be engraved to form irregularities on the surface, or may be made of a highly hydrophilic rubber material, so that the surface can retain the coating liquid and facilitate the formation of the coating liquid layer.

[0058] The applicator roll 301 rotates in contact with the surface of the base layer 101, following the movement of the base layer 101, so that the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred onto the surface of the base layer 101. The applicator roll 301 may also be called a transfer roll.

[0059] On the opposite side of the applicator roll 301 across the base layer 101, a support roller 302 is arranged parallel to the applicator roll 301 so as to abut against the back surface of the base layer 101. While abutting against the base layer 101, the support roller 302 rotates in a direction along the flow of the base layer 101 (subordinate rotation).

[0060] The applicator roll 301 may be biased to press against the base layer 101 using, for example, an elastic member (not shown). Alternatively, the base layer 101 may be biased to press against the applicator roll 301, or the support roller 302 may be biased to press against (press against) the applicator roll 301.

[0061] In this way, by pressing the base layer 101 against the applicator roll 301, the coating liquid layer formed on the surface of the applicator roll 301 is reliably transferred to the surface of the base layer 101. Furthermore, by pressing the base layer 101 against the applicator roll 301, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is pressed between the surface of the applicator roll 301 and the surface of the base layer 101 and leveled.

[0062] Here, if nozzle clogging occurs in the nozzles of the inkjet ejection device 30 (see FIG. 5), a streaky coating defect occurs in the coating liquid layer formed on the surface of the applicator roll 301.

[0063] In some cases, the coating liquid spreads over the surface of the applicator roll, suppressing the occurrence of streaky coating defects. However, when the coating liquid layer formed on the surface of the applicator roll 301 is transferred to the base layer 101, the applicator roll 301 is pressed against the base layer 101, and the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is pressed between the surface of the applicator roll 301 and the surface of the base layer 101. This causes the coating liquid to flow in the gap between the surface of the applicator roll 301 and the surface of the base layer 101, more reliably filling coating defects caused by nozzle clogging, resulting in a uniform coating liquid. Therefore, a uniform coating layer 102 without coating defects is formed on the surface of the base layer 101.

[0064] In addition to suppressing the occurrence of streak-like coating defects, when applying a coating liquid that does not wet or spread easily, the droplets ejected from the inkjet ejection device 30 are pressed and leveled between the surface of the applicator roll 301 and the surface of the base layer 101, thereby forming a uniform coating layer 102.

[0065] The base layer 101 extruded from the transverse stretching device 16 is sandwiched between the applicator roll 301 and the support roller 302 in the transfer device 350, and during the process of passing between the applicator roll 301 and the support roller 302, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the surface of the base layer 101.

[0066] In the transfer device 350, the applicator roll 301 and the support roller 302 function as a transfer section that contacts the applicator roll 301 (transfer roll) with the base layer 101 (substrate layer) and transfers the coating liquid layer formed on the applicator roll 301 to the base layer 101.

[0067] In addition, in the transfer device 350, the applicator roll 301 and the support roller 302 bring the applicator roll 301 (transfer roll) into contact with the base layer 101 (substrate layer) to realize a process of transferring the coating liquid layer formed on the applicator roll 301 to the base layer 101.

[0068] The inkjet discharge device 30 forms a coating liquid layer on the outer peripheral surface of an applicator roll 301 (transfer roll). That is, the inkjet discharge device 30 realizes the process of forming a coating liquid layer on the surface of the applicator roll 301 (transfer roll) that rotates in contact with the base layer 101 of the laminate film 100.

[0069] The inkjet ejection device 30 is disposed in a position facing the outer circumferential surface of the applicator roll 301 along the direction of the rotation axis of the applicator roll 301 .

[0070] The inkjet ejection device 30 includes a plurality of inkjet heads 310-1 to 310-6 (six in the example shown in FIG. 4). These inkjet heads 310-1 to 310-6 are arranged side by side along the rotation axis of the applicator roll 301, at positions facing the outer circumferential surface of the applicator roll 301. Hereinafter, when there is no need to distinguish between the inkjet heads 310-1 to 310-6, they will be referred to as inkjet heads 310.

[0071] A plurality of inkjet nozzles (discharge ports) that discharge the coating liquid in the form of particles are formed in each inkjet head 310. In the inkjet head 310, a plurality of inkjet nozzles may be formed in a row.

[0072] The inkjet nozzle may simply be referred to as a nozzle. Alternatively, a row of multiple nozzles formed in the inkjet head 310 may be referred to as a nozzle row. The inkjet head 310 may be formed with one or more nozzle rows.

[0073] FIG. 5 is a diagram illustrating an example of a nozzle row of an inkjet head 310 of an inkjet ejection device 30 of a laminated film manufacturing system 1 as one example of an embodiment.

[0074] Inkjet head 310 has a plurality of nozzles (inkjet nozzles) formed at positions facing base layer 101.

[0075] 5, black circles represent nozzles formed in the inkjet head 310. In Fig. 5, symbol (A) indicates an example in which one nozzle row is formed in the inkjet head 310, and symbol (B) indicates an example in which two nozzle rows are formed in the inkjet head 310.

[0076] The ejection of the coating liquid from each nozzle in the inkjet head 310 is controlled by a coating control unit 400 (see FIG. 1). The coating control unit 400 controls the ejection of the coating liquid from each nozzle in each inkjet head 310. For example, the coating control unit 400 can precisely control the amount of coating liquid ejected by controlling the on / off switching of the ejection from each inkjet nozzle.

[0077] The function of the coating control unit 400 is realized by the processor of a computer (not shown) executing driver software.

[0078] The coating control unit 400 controls the on / off of ejection for any of the multiple nozzles formed in each inkjet head 310, thereby controlling the ejection of coating fluid from a specific nozzle in the inkjet head 310 or preventing ejection from a nozzle. Driver software that controls the ejection of the inkjet head 310 is known, and a detailed description thereof will be omitted.

[0079] In the inkjet head 310, the nozzles that eject the coating liquid may be referred to as ejection nozzles, and the region including the ejection nozzles may be referred to as the ejection nozzle region.

[0080] In addition, in the inkjet head 310, the nozzles from which the ejection of the coating liquid is suppressed may be referred to as ejection suppression nozzles, and the region including the ejection suppression nozzles may be referred to as ejection suppression nozzle region.

[0081] The nozzle row formed in the inkjet head 310 provided in the inkjet ejection device 30 corresponds to the first nozzle row.

[0082] The inkjet heads 310 are arranged in a position facing the outer peripheral surface of the applicator roll 301 along the rotation axis of the applicator roll 301 with their nozzle rows facing the outer peripheral surface of the applicator roll 301.

[0083] As described above, the applicator roll 301 is disposed in a position facing the surface of the base layer 101 along the width direction of the base layer 101. Therefore, it can be said that the inkjet heads 310 are indirectly arranged side by side at corresponding positions in the width direction of the base layer 101 via the applicator roll 301.

[0084] 6 to 8 are diagrams showing examples of the arrangement of inkjet heads 310 relative to the base layer 101 in the inkjet ejection device 30 of the laminated film manufacturing system 1 as one example of the embodiment.

[0085] In the first example shown in FIG. 6, in the inkjet ejection device 30, a plurality of inkjet heads 310-1 to 310-5 (five in the example shown in FIG. 6) are arranged in a row across the entire width direction (left-right direction in the figure) of the base layer 101.

[0086] When there is no need to distinguish between the inkjet heads 310-1 to 310-5, they will be referred to as inkjet heads 310.

[0087] A plurality of inkjet heads 310 arranged in a line may be referred to as an inkjet head array. In the example shown in Figure 6, the inkjet head array is denoted by reference numeral 300.

[0088] In the example shown in FIG. 6, the length of the five inkjet heads 310-1 to 310-5 arranged in series is approximately equal to the length of the base layer 101 in the width direction.

[0089] 6, in the inkjet head array 300, the inkjet heads 310-1 and 310-5 arranged at both ends have ejection suppression nozzle regions corresponding to predetermined ranges from the edges of the base layer 101. In Fig. 6, the ejection suppression nozzle region of the inkjet head 310 is indicated by the reference symbol 310b, and the ejection nozzle region is indicated by the reference symbol 310a.

[0090] The coating control unit 400 controls the inkjet heads 310-1 to 310-5 to discharge the coating liquid from the discharge nozzle region 310a onto the applicator roll 301. As a result, the coating liquid is discharged in the form of particles from each nozzle in the discharge nozzle region 310a of each inkjet head 310.

[0091] When the coating liquid is discharged from each nozzle in the discharge nozzle region 310a onto the rotating applicator roll 301, a uniform coating liquid layer is formed on the outer peripheral surface of the applicator roll 301 at a position facing the discharge nozzle region 310a.

[0092] Then, when the base layer 101 abuts against the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed in this manner, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101.

[0093] That is, the coating layer 102 is formed at a position in contact with a position facing the discharge nozzle region 310a of the applicator roll 301 in the width direction of the base layer 101. Hereinafter, the position in contact with a position facing the discharge nozzle region 310a of the applicator roll 301 in the width direction of the base layer 101 may be simply referred to as the position corresponding to the discharge nozzle region 310a in the width direction of the base layer 101.

[0094] The coating layer 102 is formed at a position corresponding to the discharge nozzle region 310a in the width direction of the base layer 101. In Figure 6, the region of the base layer 101 where the coating layer 102 is formed (coating layer region) is indicated by the reference symbol 100b.

[0095] In the inkjet head array 300, the width of the nozzle array formed by arranging the inkjet heads 310-1 to 310-5 in the horizontal direction (orthogonal direction) is greater than the width of the coating layer 102 (coating layer region 100b).

[0096] Furthermore, the coating control unit 400 inhibits the inkjet heads 310-1 and 310-5 provided at both ends of the inkjet head array 300 from ejecting the coating liquid from the ejection inhibiting nozzle regions 310b.

[0097] In the width direction of the base layer 101, the coating liquid layer is not transferred to a position that contacts a position facing the discharge suppression nozzle region 310b on the applicator roll 301, and therefore the coating layer 102 is not formed. Hereinafter, the position that contacts a position facing the discharge suppression nozzle region 310b on the applicator roll 301 in the width direction of the base layer 101 may simply be referred to as the position corresponding to the discharge suppression nozzle region 310b in the width direction of the base layer 101.

[0098] Dry edges, which are areas where no coating liquid is applied, are formed at positions corresponding to the discharge suppression nozzle areas 310b on both ends (both edges) in the width direction of the base layer 101. In Fig. 6, the dry edges are indicated by the reference symbol 100a.

[0099] In the second example shown in FIG. 7, the width of the base layer 101 is wider than that of the example shown in FIG.

[0100] 7, the length of the five inkjet heads 310-1 to 310-5 arranged in series (the length of the inkjet head array 300) is approximately the same as the width of the coating layer region 100b of the base layer 101. That is, in the inkjet head array 300, the width in the lateral direction (orthogonal direction) of the nozzle array formed by arranging the multiple inkjet heads 310-1 to 310-5 is approximately the same as the width of the coating layer 102 (coating layer region 100b).

[0101] The coating control unit 400 uses all the inkjet heads 310 constituting the inkjet head array 300 as ejection nozzle areas 310a in the inkjet heads 310-1, 310-5 arranged at both ends of the inkjet head array 300 without providing ejection suppression nozzle areas 310b, and causes them to eject coating liquid onto the applicator roll 301.

[0102] As a result, a uniform coating liquid layer is formed at a position facing the discharge nozzle region 310a on the outer peripheral surface of the applicator roll 301. Then, when the base layer 101 comes into contact with the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101. That is, the coating layer 102 is formed at a position in the width direction of the base layer 101 that corresponds to the discharge nozzle region 310a.

[0103] Furthermore, in the width direction of the base layer 101, the coating liquid layer is not transferred to the position facing the discharge suppression nozzle region 310b on the applicator roll 301 and in contact with the position, and thus the coating layer 102 is not formed. As a result, the coating liquid layer is not applied (transferred) to the positions where the inkjet heads 310 are not present at both ends (both edges) in the rotational axis direction of the applicator roll 301, and dry edges 100a are formed, respectively.

[0104] In the third example shown in FIG. 8, the width of the base layer 101 is narrower than in the example shown in FIG.

[0105] In the example shown in FIG. 8, the length of three inkjet heads 310-2 to 310-4, out of five inkjet heads 310-1 to 310-5, arranged in series is greater than the width of the coating layer region 100b of the base layer 101.

[0106] In addition, the inkjet heads 310-1 and 310-5 arranged at both ends of the inkjet head row 300 are configured as the ejection suppression nozzle regions 310b. Furthermore, in the inkjet heads 310-2 and 310-4, the portions corresponding to a predetermined range (dry edge 100a) from the edge of the base layer 101 are configured as the ejection suppression nozzle regions 310b.

[0107] The coating control unit 400 controls the inkjet heads 310-2 to 310-4 in the inkjet head row 300 to discharge the coating liquid onto the applicator roll 301 from the discharge nozzle region 310a.

[0108] As a result, a uniform coating liquid layer is formed at a position facing the discharge nozzle region 310a on the outer peripheral surface of the applicator roll 301. Then, when the base layer 101 comes into contact with the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101. That is, the coating layer 102 is formed at a position in the width direction of the base layer 101 that corresponds to the discharge nozzle region 310a.

[0109] The inkjet discharge device 30 discharges a coating liquid onto an applicator roll 301 (transfer roll) that rotates in contact with the base layer 101 (substrate layer) to form a coating liquid layer. The inkjet discharge device 30 also realizes a process of discharging the coating liquid onto the applicator roll 301 (transfer roll) that rotates in contact with the base layer 101 (substrate layer) using the inkjet discharge device 30 to form a coating liquid layer.

[0110] Furthermore, the coating control unit 400 controls the inkjet heads 310-1, 310-2, 310-4, and 310-5 in the inkjet head row 300 to suppress the ejection of the coating liquid from the ejection suppression nozzle region 310b.

[0111] The coating liquid is not transferred to a position corresponding to the discharge suppression nozzle region 310b in the width direction of the base layer 101, and no coating layer 102 is formed. That is, dry edges 100a, which are regions where no coating liquid is applied, are formed on both ends (both edges) of the base layer 101 in the width direction.

[0112] As described above, in the present laminated film manufacturing system 1, the inkjet head array 300 has inkjet heads 310 arranged at positions corresponding to at least the widthwise edges of the coating layer region 100b, i.e., the widthwise edges of the coating layer 102. By applying and forming both ends of the coating liquid layer using inkjet nozzles, the edges of the layer can be formed precisely linearly, and the edge of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be formed precisely linearly, allowing the dry edge 100a to be formed with high precision.

[0113] For example, inkjet heads 310-1 and 310-5 in the first example shown in Figure 6, inkjet heads 310-1 and 310-5 in the second example shown in Figure 7, and inkjet heads 310-2 and 310-4 in the third example shown in Figure 8 correspond to inkjet heads 310 arranged at positions corresponding to the widthwise edges of the coating layer area 100b (coating layer 102).

[0114] A dryer 18 is provided downstream of the transfer device 350. The dryer 18 dries the coating layer 102 formed on the surface of the base layer 101. The dryer 18 may dry the coating layer 102, for example, by blowing hot air onto the surface of the base layer 101 being transported in the vertical direction. The dryer 18 performs a drying step to dry the coating layer 102.

[0115] Downstream of the dryer 18, the laminate film 100 may be processed, such as by cutting both edges of the laminate film 100, using a cutting device (not shown). Also, the thickness of the laminate film 100 may be measured using a measuring device (not shown). Thereafter, the laminate film 100 is wound up by a winder (not shown) and sent to the subsequent finishing process.

[0116] (B) Operation In the laminated film manufacturing system 1 configured as described above, the raw materials stored in the raw material silos 10a and 10b are fed into the granulator 11.

[0117] The pelletizer 11 adds fillers and various additives to the raw thermoplastic resin as needed to produce pellets of the resin composition. The produced pellets are stored in a pellet silo 12.

[0118] The pellet silo 12 supplies the pellets stored therein to the extruder 13 .

[0119] The extruder 13 produces a base layer 101 (cast film layer). The base layer 101 produced by the extruder 13 is fed into a longitudinal stretching device .

[0120] The longitudinal stretching device 14 stretches in the longitudinal direction the base layer 101 extruded from the extruder 13. The base layer 101 (first stretched layer) stretched in the longitudinal direction by the longitudinal stretching device 14 is then fed into a transverse stretching device 16.

[0121] The transverse stretching device 16 stretches the base layer 101, which has been stretched in the longitudinal direction by the longitudinal stretching device 14, in the transverse direction (width direction).

[0122] In the transfer device 350, the inkjet ejection device 30 ejects a coating liquid onto the surface of an applicator roll 301 that rotates in accordance with (synchronization with) the transport of the base layer 101, forming a coating liquid layer of uniform thickness on the outer peripheral surface thereof.

[0123] The applicator roll 301 rotates following the movement of the base layer 101 with its outer circumferential surface in contact with the surface of the base layer 101, thereby transferring the coating liquid layer formed on its outer circumferential surface to the surface of the base layer 101 (substrate layer). As a result, a coating layer 102 with a uniform thickness is formed on the surface of the base layer 101 (substrate layer).

[0124] The coating liquid layer 102 formed on the surface of the base layer 101 is dried by a dryer 18. This produces a laminated film 100. Thereafter, the laminated film 100 is subjected to processing such as cutting of both edges and thickness measurement. The laminated film 100 is wound up by a winder (not shown) and sent to the subsequent finishing process.

[0125] (C) Effects As described above, in the laminated film manufacturing system 1 as an example of the embodiment, the inkjet discharge device 30 applies a coating liquid to the outer peripheral surface (cylindrical surface) of the applicator roll 301 to form a uniform coating liquid layer. The applicator roll 301 rotates following the movement of the base layer 101 with its outer peripheral surface in contact with the surface of the base layer 101, whereby the coating liquid layer formed on the outer peripheral surface is transferred to the surface of the base layer 101, forming a coating layer 102 of uniform thickness on the surface of the base layer 101. This allows the formation of a laminated film 100 having a uniform, defect-free coating layer.

[0126] By pressing the base layer 101 against the applicator roll 301, the coating liquid layer formed on the surface of the applicator roll 301 is reliably transferred to the surface of the base layer 101. Furthermore, by pressing the base layer 101 against the applicator roll 301, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is pressed between the surface of the applicator roll 301 and the surface of the base layer 101 and leveled.

[0127] Furthermore, even if nozzle clogging occurs in the nozzles of the inkjet discharge device 30, causing streaky coating defects in the coating liquid layer formed on the surface of the applicator roll 301, the base layer 101 is pressed against the applicator roll 301, and the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is pressed between the surface of the applicator roll 301 and the surface of the base layer 101. This causes the coating liquid to flow in the gap between the surface of the applicator roll 301 and the surface of the base layer 101, filling in the coating defect caused by the nozzle clogging and making the coating liquid uniform. Therefore, a uniform coating layer 102 without coating defects is formed on the surface of the base layer 101.

[0128] In other words, even if a nozzle clog occurs in the inkjet head 310, the coating liquid around the undischarged portion on the applicator roll 301 flows into the undischarged portion, filling in the coating defect, thereby suppressing a decrease in the coating quality of the base layer 101.

[0129] The coating control unit 400 controls the inkjet head array 300 of the inkjet ejection device 30 to eject the coating liquid onto the applicator roll 301 only from the nozzles included in the ejection nozzle region 310a provided at a position corresponding to the coated layer region 100b of the base layer 101. The coating control unit 400 inhibits the ejection of the coating liquid from the nozzles included in the ejection inhibiting nozzle region 310b provided at a position corresponding to the dry edge 100a of the base layer 101.

[0130] This facilitates the formation of dry edges 100a at both widthwise ends (edges) of the base layer 101, preventing the coating liquid from running to the back of the base layer 101. The coating liquid ejected from the nozzles of the inkjet head 310 is small, and the coating control unit 400 can precisely control the coating amount. This allows the edge of the coating liquid layer on the surface of the applicator roll 301 to be precisely linear, and the edge of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be precisely linear. As a result, the dry edge 100a can be formed with high precision. Consequently, the coating liquid can be prevented from running to the back of the base layer 101 at the edge.

[0131] For example, in the first example shown in Figure 6, the coating control unit 400 suppresses the ejection of coating liquid from the ejection suppression nozzle area 310b for the inkjet heads 310-1, 310-5 arranged corresponding to the widthwise edge portion of the base layer 101 in the inkjet head row 300 of the inkjet ejection device 30.

[0132] This makes it possible to easily and accurately form dry edges 100a at positions corresponding to the discharge suppression nozzle regions 310b at both ends (both edges) of the base layer 101 in the width direction, thereby preventing the coating liquid from running to the back at both ends of the base layer 101.

[0133] 7, the length of the inkjet head array 300 is set to be approximately the same as the width direction length of the coating layer region 100b of the base layer 101. The coating control unit 400 uses all of the inkjet heads 310 constituting the inkjet head array 300 as discharge nozzle regions 310a to discharge the coating liquid onto the applicator roll 301.

[0134] This also allows the coating liquid layer to be precisely linearly formed at both ends (edges) in the width direction of the coating liquid layer on the surface of the applicator roll 301 by ejecting the coating liquid as minute particles from the inkjet nozzles, and also allows the end of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) to be precisely linearly formed. As a result, the dry edge 100a can be formed easily and with high precision, and the coating liquid can be prevented from running to the back at both ends of the base layer 101.

[0135] 8, the coating control unit 400 controls the inkjet heads 310-2 to 310-4, which are provided at positions corresponding to the coated layer region 100b of the base layer 101, to eject the coating liquid onto the applicator roll 301 only from the nozzles included in the ejection nozzle region 310a. The coating control unit 400 inhibits the ejection of the coating liquid from the nozzles included in the ejection inhibiting nozzle region 310b of the inkjet heads 310-2 and 310-4, which are provided at positions corresponding to the dry edge 100a of the base layer 101. The coating control unit 400 also inhibits the ejection of the coating liquid from the inkjet heads 310-1 and 310-5, which do not correspond to the base layer 101.

[0136] This also makes it possible to easily and accurately form dry edges 100a at positions corresponding to the discharge suppression nozzle regions 310b at both ends (both edges) of the base layer 101 in the width direction, thereby preventing the coating liquid from running to the back at both ends of the base layer 101.

[0137] In the inkjet head row 300, inkjet heads 310 are arranged at least at positions corresponding to the widthwise edges of the coating layer region 100b (coating layer 102). For example, inkjet heads 310-1 and 310-5 in the first example shown in Fig. 6, inkjet heads 310-1 and 310-5 in the second example shown in Fig. 7, and inkjet heads 310-2 and 310-4 in the third example shown in Fig. 8 correspond to inkjet heads 310 arranged at positions corresponding to the widthwise edges of the coating layer region 100b (coating layer 102).

[0138] Inkjet heads 310 are arranged at positions corresponding to the widthwise edges of the coating layer region 100b (coating layer 102). By discharging the coating liquid in particulate form from the nozzles in the discharge nozzle region 310a of these inkjet heads 310, the coating liquid can be applied thinly and evenly to the surface of the applicator roll 301. Furthermore, the edges of the coating liquid layer formed on the surface of the applicator roll 301 can be precisely linearly formed, and the edges of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be precisely linearly formed. As a result, the dry edge 100a can be formed with high precision. This prevents the coating liquid from running through to the back at both ends of the base layer 101.

[0139] Furthermore, the inkjet ejection device 30 is more economical than a method of applying a coating liquid to a sheet material using a roll coater, as there is less loss of the coating liquid.

[0140] The inkjet head 310 is smaller than the application roller used in a roll coater and has a high degree of freedom in installation, so that the laminated film manufacturing system 1 can be made smaller in size.

[0141] The coating control unit 400 controls the on / off switching of the discharge for each inkjet nozzle, so that the nozzle that discharges the coating liquid can be easily changed, and changes in the width of the laminated film 100 (base layer 101) can be easily accommodated.

[0142] (D) Other The disclosed technology is not limited to the above-described embodiment, and can be implemented in various modifications without departing from the spirit of the present embodiment.

[0143] For example, in the above-described embodiment, as illustrated in FIGS. 7 to 9, the inkjet head array 300 in the inkjet ejection device 30 is configured with a plurality of inkjet heads 310, but the present invention is not limited to this.

[0144] In the inkjet head array 300, inkjet heads 310 are arranged at positions corresponding to the edges of the coating layer 102 in the width direction, and spray devices may be provided in place of the inkjet heads 310 at other positions.

[0145] FIG. 9 is a diagram showing a modified example of the transfer device 350 of the laminated film manufacturing system 1 as one example of the embodiment.

[0146] 9, the inkjet head array 300 of the transfer device 350 illustrated in FIG. 4 is provided with one or more spray devices 320 instead of the inkjet heads 310-2 to 310-5. That is, the inkjet head array 300 is provided with the spray device 320 between the inkjet head 310-1 and the inkjet head 310-6 provided at both ends.

[0147] 10 to 12 are diagrams showing modified examples of the inkjet ejection device 30 of the laminated film manufacturing system 1 as one example of the embodiment.

[0148] In the fourth example shown in Fig. 10, a plurality of spray devices 320 are provided instead of the inkjet heads 310-2 to 310-4 of the inkjet ejection device 30 of the first example shown in Fig. 6. In the figure, the same reference numerals as those already described indicate similar parts, and therefore, description thereof will be omitted.

[0149] The spray device 320 is a device that sprays the coating liquid, and sprays (ejects) the coating liquid in the form of a mist or the like from a spray nozzle (not shown) using gas such as high-pressure air or mechanical motion (such as a piezoelectric element).

[0150] The spray device 320 sprays the coating liquid under the control of the coating control unit 400.

[0151] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the applicator roll 301, and also causes the inkjet heads 310-1 and 310-5 to eject the coating liquid onto the applicator roll 301 from the ejection nozzle area 310a.

[0152] As a result, the coating liquid is sprayed in a spray form from each spray device 320 onto the outer peripheral surface of the applicator roll 301, and the coating liquid is ejected in the form of particles from each nozzle in the ejection nozzle area 310a of each inkjet head 310 onto the outer peripheral surface of the applicator roll 301.

[0153] When the coating liquid is discharged from each nozzle in the discharge nozzle region 310a onto the rotating applicator roll 301, a uniform coating liquid layer is formed on the outer circumferential surface of the applicator roll 301 at a position facing the discharge nozzle region 310a.

[0154] Furthermore, by spraying the coating liquid from each spray device 320, a coating liquid layer is formed on the outer peripheral surface of the applicator roll 301 at a position facing each spray device 320.

[0155] Then, when the base layer 101 abuts against the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed in this manner, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101.

[0156] That is, in the width direction of the base layer 101, the coating layer 102 is formed at a position on the applicator roll 301 corresponding to the discharge nozzle region 310a and at a position in contact with a position corresponding to each spray device 320.

[0157] 10 , each spray device 320 sprays the coating liquid onto an area of ​​the outer circumferential surface of the applicator roll 301 other than the edge of the coating layer area 100b. Therefore, the coating liquid sprayed onto the outer circumferential surface of the applicator roll 301 by each spray device 320 and transferred to the base layer 101 does not run to the back side of the base layer 101.

[0158] Furthermore, the coating control unit 400 causes the inkjet heads 310-1 and 310-5 to discharge the coating liquid from the discharge nozzle region 310a onto the outer circumferential surface of the applicator roll 301. As a result, the coating liquid is discharged in the form of particles from each nozzle in the discharge nozzle region 310a of each of the inkjet heads 310-1 and 310-5, and the coating liquid is applied thinly and uniformly to the corresponding locations on the outer circumferential surface of the applicator roll 301.

[0159] The coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is then transferred to the surface of the base layer 101, forming a thin, uniform coating layer 102 on the surface of the base layer 101. Furthermore, the edges of the coating liquid layer formed on the surface of the applicator roll 301 can be precisely linear, and the edges of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be precisely linear. As a result, the dry edge 100a can be formed with high precision. Therefore, when the coating liquid layer is transferred from the outer peripheral surface of the applicator roll 301 to the base layer 101, the coating liquid can be prevented from running back at both ends of the base layer 101.

[0160] Furthermore, the coating control unit 400 controls the inkjet heads 310-1 and 310-5 in the inkjet head row 300 to suppress the ejection of the coating liquid from the ejection suppression nozzle region 310b.

[0161] As a result, dry edges 100a, which are areas where no coating liquid is applied, are formed at both ends (both edges) in the width direction of the base layer 101 at positions facing the discharge suppression nozzle areas 310b.

[0162] 8. In the fifth example shown in FIG. 11, a plurality of spray devices 320 are provided instead of the inkjet heads 310-2 to 310-4 of the inkjet ejection device 30 of the second example shown in FIG.

[0163] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the applicator roll 301, and also causes the inkjet heads 310-1 and 310-5 to eject the coating liquid onto the applicator roll 301 from the ejection nozzle area 310a.

[0164] As a result, the coating liquid is sprayed in a spray form from each spray device 320 onto the outer peripheral surface of the applicator roll 301, and the coating liquid is ejected in the form of particles from each nozzle in the ejection nozzle area 310a of each inkjet head 310 onto the outer peripheral surface of the applicator roll 301.

[0165] As the coating liquid is discharged from each nozzle in the discharge nozzle region 310a onto the rotating applicator roll 301, a thin and uniform layer of the coating liquid is formed on the outer peripheral surface of the applicator roll 301 at a position facing the discharge nozzle region 310a.

[0166] Furthermore, by spraying the coating liquid from each spray device 320, a coating liquid layer is formed on the outer peripheral surface of the applicator roll 301 at a position facing each spray device 320.

[0167] Then, when the base layer 101 abuts against the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed in this manner, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101.

[0168] That is, in the width direction of the base layer 101, the coating layer 102 is formed at a position on the applicator roll 301 corresponding to the discharge nozzle region 310a and at a position in contact with a position corresponding to each spray device 320.

[0169] 11 , each spray device 320 sprays the coating liquid onto an area on the surface of the applicator roll 301 other than the edge of the coating layer area 100b. Therefore, the coating liquid sprayed onto the outer peripheral surface of the applicator roll 301 by each spray device 320 and transferred to the base layer 101 does not run back at both ends of the base layer 101.

[0170] Furthermore, the coating control unit 400 controls the inkjet heads 310-1 and 310-5 to discharge the coating liquid from the discharge nozzle region 310a onto the outer circumferential surface of the applicator roll 301. As a result, the coating liquid is discharged in the form of particles from each nozzle in the discharge nozzle region 310a of each of the inkjet heads 310-1 and 310-5, and the coating liquid is uniformly applied to the corresponding locations on the outer circumferential surface of the applicator roll 301.

[0171] The coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is then transferred to the surface of the base layer 101, forming a thin, uniform coating layer 102 on the surface of the base layer 101. Furthermore, the edges of the coating liquid layer formed on the surface of the applicator roll 301 can be precisely linear, and the edges of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be precisely linear. As a result, the dry edge 100a can be formed with high precision. Therefore, when the coating liquid layer is transferred from the outer peripheral surface of the applicator roll 301 to the base layer 101, the coating liquid can be prevented from running back at both ends of the base layer 101.

[0172] Furthermore, at positions on both ends (both edges) of the base layer 101 in the width direction where no inkjet head 310 is present, dry edges 100a are formed where no coating liquid is applied.

[0173] In the sixth example shown in FIG. 12, a plurality of spray devices 320 are provided instead of the inkjet head 310-3 of the inkjet ejection device 30 of the third example shown in FIG.

[0174] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the applicator roll 301, and also causes the inkjet heads 310-2 and 310-4 to eject the coating liquid onto the applicator roll 301 from the ejection nozzle area 310a.

[0175] As a result, the coating liquid is sprayed in a spray form from each spray device 320 onto the outer peripheral surface of the applicator roll 301, and the coating liquid is ejected in the form of particles from each nozzle in the ejection nozzle area 310a of each inkjet head 310 onto the outer peripheral surface of the applicator roll 301.

[0176] As the coating liquid is discharged from each nozzle in the discharge nozzle region 310a onto the rotating applicator roll 301, a thin and uniform layer of the coating liquid is formed on the outer peripheral surface of the applicator roll 301 at a position facing the discharge nozzle region 310a.

[0177] Furthermore, by spraying the coating liquid from each spray device 320, a coating liquid layer is formed on the outer peripheral surface of the applicator roll 301 at a position facing each spray device 320.

[0178] Then, when the base layer 101 abuts against the outer peripheral surface of the applicator roll 301 on which the coating liquid layer has been formed in this manner, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is transferred to the base layer 101, and a coating layer 102 is formed on the base layer 101.

[0179] That is, in the width direction of the base layer 101, the coating layer 102 is formed at a position on the applicator roll 301 corresponding to the discharge nozzle region 310a and at a position in contact with a position corresponding to each spray device 320.

[0180] 12, each spray device 320 sprays the coating liquid onto an area on the surface of the applicator roll 301 other than the edge of the coating layer area 100b. Therefore, the coating liquid is sprayed onto the outer circumferential surface of the applicator roll 301 by each spray device 320, and the coating liquid transferred to the base layer 101 does not run back at both ends of the base layer 101.

[0181] Furthermore, the coating control unit 400 causes the inkjet heads 310-2 and 310-4 to discharge the coating liquid from the discharge nozzle regions 310a onto the outer circumferential surface of the applicator roll 301. As a result, the coating liquid is discharged in the form of particles from each nozzle in the discharge nozzle regions 310a of the inkjet heads 310-2 and 310-4, and the coating liquid is uniformly applied to the corresponding locations on the outer circumferential surface of the applicator roll 301.

[0182] The coating liquid layer formed on the outer peripheral surface of the applicator roll 301 is then transferred to the surface of the base layer 101, forming a thin, uniform coating layer 102 on the peripheral portion of the base layer 101. Furthermore, the edges of the coating liquid layer formed on the surface of the applicator roll 301 can be precisely linear, and the edges of the coating layer region 100b obtained by transferring the coating liquid layer (the boundary between the coating layer region 100b and the dry edge 100a) can also be precisely linear. As a result, the dry edge 100a can be formed with high precision. Therefore, when the coating liquid is transferred from the outer peripheral surface of the applicator roll 301 to the base layer 101, the coating liquid can be prevented from running back at both ends of the base layer 101.

[0183] Furthermore, the coating control unit 400 controls the inkjet heads 310-1, 310-2, 310-4, and 310-5 in the inkjet head row 300 to suppress the ejection of the coating liquid from the ejection suppression nozzle region 310b.

[0184] As a result, dry edges 100a, which are areas where no coating liquid is applied, are formed at both ends (both edges) in the width direction of the base layer 101 at positions facing the discharge suppression nozzle areas 310b.

[0185] The spray device 320 is cheaper than the inkjet head 310, so by providing the spray device 320 instead of the inkjet head 310 as described above, the manufacturing cost of the device can be reduced.

[0186] In addition, in the above-described embodiment and each modified example, the coating layer 102 is formed on one side (front side) of the base layer 101, but this is not limitative. The coating layer 102 may also be formed on the back side of the base layer 101.

[0187] FIG. 13 is a diagram for explaining a modified example of the transfer device 350 of the laminated film manufacturing system 1 as one example of the embodiment.

[0188] A transfer device 350 illustrated in FIG. 13 includes applicator rolls 301-1 and 301-2 and inkjet ejection devices 30-1 and 30-2.

[0189] Applicator roll 301-1 is disposed so as to contact the front surface (first surface) of base layer 101 along the width direction of base layer 101 with its rotation axis perpendicular to the longitudinal direction. Applicator roll 301-2 is disposed so as to contact the back surface (second surface) of base layer 101 along the width direction of base layer 101 with its rotation axis perpendicular to the longitudinal direction.

[0190] The applicator rolls 301-1 and 301-2 have the same configuration as the above-described applicator roll 301. Hereinafter, the applicator rolls 301-1 and 301-2 will be referred to as the applicator roll 301 unless otherwise distinguished.

[0191] Each applicator roll 301 is configured to be rotatable about a rotation axis by a drive motor (not shown), and rotates (subordinate rotation) in a direction along the flow of the base layer 101 while in contact with the base layer 101. Each applicator roll 301 rotates so that its peripheral speed matches the transport speed of the base layer 101, and rotates while in contact with the front or back surface of the base layer 101, following the movement of the base layer 101 transported in the flow direction.

[0192] 13, applicator rolls 301-1 and 301-2 are disposed at positions facing each other across the transport path of the base layer 101. It is desirable to bias at least one of applicator rolls 301-1 and 301-2 in a direction in which applicator rolls 301-1 and 301-2 approach each other.

[0193] Inkjet ejection device 30-1 is disposed opposite the outer peripheral surface of applicator roll 301-1 along the rotation axis of applicator roll 301-1, while inkjet ejection device 30-2 is disposed opposite the outer peripheral surface of applicator roll 301-2 along the rotation axis of applicator roll 301-2.

[0194] The inkjet ejection device 30-1 and the inkjet ejection device 30-2 have the same configuration. The inkjet ejection devices 30-1 and 30-2 may be any of the inkjet ejection devices 30 described above, and a description thereof will be omitted. Hereinafter, when there is no need to distinguish between the inkjet ejection devices 30-1 and 30-2, they will be referred to as the inkjet ejection device 30.

[0195] 13, the inkjet ejection device 30-1 is disposed above the applicator roll 301-1, and the inkjet ejection device 30-2 is disposed to the side of the applicator roll 301-2, but this is not limiting. The positions of the inkjet ejection devices 30 relative to the applicator roll 301 can be changed as appropriate.

[0196] A coating liquid is applied to the outer peripheral surface (cylindrical surface) of the applicator roll 301-1 by an inkjet discharge device 30-1 to form a coating liquid layer.

[0197] The inkjet discharge device 30-1 forms a coating liquid layer by discharging a coating liquid onto an applicator roll 301 (transfer roll) that rotates in contact with the surface (first surface) of the base layer 101. The inkjet discharge device 30-1 also realizes a process of forming a coating liquid layer by discharging a coating liquid onto an applicator roll 301-1 (transfer roll) that rotates in contact with the surface (first surface) of the base layer 101.

[0198] The coating liquid is applied to the outer peripheral surface (cylindrical surface) of the applicator roll 301-2 by the inkjet discharge device 30-2 to form a coating liquid layer. The applicator roll 301-2 corresponds to a second transfer roll that rotates in contact with the back surface (second surface) of the base layer 101.

[0199] The inkjet ejection device 30-2 corresponds to a second inkjet ejection device that ejects a coating liquid onto an applicator roll 301-2 (second transfer roll) to form a coating liquid layer.

[0200] The inkjet discharge device 30-2 corresponds to a coating unit that discharges a coating liquid to form a coating liquid layer on an applicator roll 301-2 (transfer roll) that rotates in contact with the back surface (second surface) of the base layer 101. The inkjet discharge device 30-2 also realizes the process of forming a coating liquid layer on the applicator roll 301-2 (second transfer roll) that rotates in contact with the back surface (second surface) of the base layer 101.

[0201] The transported base layer 101 is sandwiched between the applicator roll 301-1 and the applicator roll 301-2 in the transfer device 350.

[0202] The applicator roll 301-1 rotates following the movement of the base layer 101 while in contact with the surface of the base layer 101, thereby transferring the coating liquid applied to its outer circumferential surface to the surface of the base layer 101. The applicator roll 301-2 rotates following the movement of the base layer 101 while in contact with the back surface of the base layer 101, thereby transferring the coating liquid applied to its outer circumferential surface to the back surface of the base layer 101.

[0203] Applicator roll 301-2 and applicator roll 301-1 correspond to a transfer section that contacts applicator roll 301 (transfer roll) with the surface (first side) of base layer 101 to transfer the coating liquid layer formed on applicator roll 301 to the first side (surface) of base layer 101.

[0204] In addition, applicator roll 301-2 and applicator roll 301-1 correspond to a second transfer section that contacts applicator roll 301-2 (second transfer roll) with the back surface (second surface) of base layer 101 to transfer the coating liquid layer formed on applicator roll 301-2 to the back surface (second surface) of base layer 101.

[0205] The base layer 101 is sandwiched and pressed between the applicator roll 301-1 and the applicator roll 301-2.

[0206] The coating liquid is transferred to the front and back surfaces of the base layer 101 between the applicator roll 301-1 and the applicator roll 301-2.

[0207] As described above, the surface of the base layer 101 is pressed against the applicator roll 301-1, and the back surface of the base layer 101 is pressed against the applicator roll 301-2. As a result, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301-1 is pressed and leveled between the surface of the applicator roll 301-1 and the surface of the base layer 101. Also, the coating liquid layer formed on the outer peripheral surface of the applicator roll 301-2 is pressed and leveled between the surface of the applicator roll 301-2 and the surface of the base layer 101.

[0208] In other words, even when a nozzle clog occurs in the inkjet head 310 of the inkjet ejection device 30, the coating liquid around the un-ejected portion flows into the un-ejected portion, filling in the coating defect, thereby suppressing a decrease in the coating quality of the un-ejected portion.

[0209] FIG. 14 is a diagram for explaining another modified example of the transfer device 350 of the laminated film manufacturing system 1 as one example of the embodiment.

[0210] The transfer device 350 illustrated in Fig. 14 includes an offset gravure coater 340 instead of the applicator roll 301-2 and the inkjet discharge device 30-2 of the transfer device 350 illustrated in Fig. 13. In the drawing, the same reference numerals as those already described indicate similar parts, and therefore, the description thereof will be omitted.

[0211] The offset gravure coater 340 includes a first roll 341 , a transfer roll 343 , and a liquid tank 344 .

[0212] The first roll 341 and the transfer roll 343 are disposed parallel to each other with their rotation axes aligned in a direction perpendicular to the longitudinal stretching direction.

[0213] A coating liquid is placed in the liquid tank 344, and the first roll 341 is immersed in the coating liquid. A transfer roll 343 is in contact with the outer circumferential surface of the first roll 341.

[0214] The transfer roll 343 is disposed along the width direction of the base layer 101 with its rotation axis perpendicular to the longitudinal direction. The transfer roll 343 is configured to be rotatable about its rotation axis by a drive motor (not shown), and rotates in a direction along the flow of the base layer 101 (subordinate rotation) while in contact with the back surface of the base layer 101. The transfer roll 343 also rotates so that its peripheral speed matches the conveyance speed of the base layer 101, and rotates in contact with the front surface of the base layer 101, following the movement of the base layer 101 conveyed in the flow direction.

[0215] The rotation of the first roll 341 and the transfer roll 343 may be controlled by the coating control unit 400.

[0216] The first roll 341 rotates in a direction following the rotation of the transfer roll 343 while in contact with the transfer roll 343. When the first roll 341 rotates around its rotation axis, the coating liquid contained in the liquid tank 344 is transported while adhering to the outer peripheral surface of the first roll 341.

[0217] In addition, a doctor blade 345 is disposed on the first roll 341 at a predetermined gap from its outer peripheral surface, and scrapes off unnecessary coating liquid from the outer peripheral surface of the first roll 341 so that the amount of coating liquid adhering to the outer peripheral surface of the first roll 341 remains constant.

[0218] The coating liquid adhered to the outer peripheral surface of the first roll 341 is transferred to the outer peripheral surface of the transfer roll 343, and a coating liquid layer of the coating liquid is formed on the outer peripheral surface of the transfer roll 343.

[0219] In this way, in the offset gravure coater 340, the speed difference between the forward-rotating first roll 341 and the transfer roll 343 is used to transfer the coating liquid between the rolls while stretching it into a thin film, thereby giving the coating liquid a uniform film thickness and metering it, and forming a coating liquid layer on the outer peripheral surface of the final roll (transfer roll 343).

[0220] The surface of the transfer roll 343 may be engraved to form irregularities on the surface, or may be made of a highly hydrophilic rubber material, so that the surface can retain the coating liquid and easily form a coating liquid layer.

[0221] The transfer roll 343 rotates in contact with the back surface of the base layer 101, following the transport of the base layer 101, so that the coating liquid applied to its outer peripheral surface is transferred to the back surface of the base layer 101.

[0222] In the offset gravure coater 340, the transfer roll 343 corresponds to a second transfer roll that rotates in contact with the back surface (second surface) of the base layer 101.

[0223] The first roll 341 and the liquid tank 344 correspond to a coating unit that forms a coating liquid layer on the transfer roll 343 (second transfer roll).

[0224] The first roll 341 and the liquid tank 344 also realize a process of forming a coating liquid layer on a transfer roll 343 (second transfer roll) that rotates in contact with the back surface (second surface) of the base layer 101.

[0225] Furthermore, the offset gravure coater 340 corresponds to a second transfer section that contacts a transfer roll 343 (second transfer roll) with the back surface (second surface) of the base layer 101 and transfers the coating liquid layer formed on this transfer roll 343 to the back surface (second surface) of the base layer 101.

[0226] In addition, the offset gravure coater 340 realizes a process of contacting a transfer roll 343 (second transfer roll) with the back surface (second surface) of the base layer 101 to transfer the coating liquid layer formed on this transfer roll 343 to the back surface (second surface) of the base layer 101.

[0227] Even in the modified example of the transfer device 350 illustrated in FIG. 14, when a nozzle blockage occurs in the inkjet head 310 of the inkjet ejection device 30, the coating liquid around the un-ejected portion flows into the un-ejected portion, filling in the coating defect and preventing a decrease in the coating quality of the un-ejected portion.

[0228] In the example shown in Figure 14, the coating layer 102 is formed on the surface of the base layer 101 using an inkjet ejection device 30-1 and an applicator roll 301-1, and the coating layer 102 is formed on the back surface of the base layer 101 using an offset gravure coater 340, but this is not limited to this.

[0229] The coating layer 102 may be formed on the back surface of the base layer 101 using the inkjet ejection device 30-1 and the applicator roll 301-1, and the coating layer 102 may be formed on the front surface of the base layer 101 using an offset gravure coater 340.

[0230] Moreover, instead of the offset gravure coater 340, other coaters such as a reverse gravure coater, a forward roll coater, a transfer roll coater, a rod metering size press, etc. may be used.

[0231] A surface layer and a back layer may be further formed on the base layer 101 on which the coating layer 102 is formed. The base layer 101 may also be multi-layered.

[0232] Furthermore, the above disclosure will enable those skilled in the art to implement and manufacture the present embodiment. [Explanation of symbols]

[0233] 1. Laminated film manufacturing system 10a, 10b Raw material silo 11 Granulator 12 Pellet silo 13 Extruder 14 Longitudinal stretching device 141a, 141b, 141c, 141d, 141 conveying rollers 16 Lateral stretching device 18 Hair dryer 30a, 30-1, 30-2, 30 Inkjet ejection device 100 Laminated Film 100a Dry Edge 100b Coating layer area 101 Base layer 102 Coating layer 161 clips 300 inkjet head rows 310-1~310-5,310 Inkjet Head 310a Discharge nozzle area 310b Discharge suppression nozzle area 320 Spray Equipment 330 Reverse Rotating Roller 350 Transfer device 350 350-1 First transfer device (surface) 350-2 Second transfer device (for back side) 301-1, 301-2, 301 Applicator Roll 302 Support roller 340 Offset Gravure Coater 341 Roll 1 343 Transfer Roll 344 Liquid tank 345 Doctor Blade 400 Coating control unit

Claims

1. A method for producing a laminated film having a coating layer formed on a substrate layer, comprising: forming a coating liquid layer on a transfer roll that rotates in contact with the base layer, using an inkjet discharge device that discharges a coating liquid from nozzles of inkjet heads provided at both ends of the base layer in a direction perpendicular to the conveyance direction, and a spray device that sprays the coating liquid from a spray nozzle provided between the inkjet heads; a step of bringing the transfer roll into contact with the substrate layer and transferring the coating liquid layer formed on the transfer roll to the substrate layer; A method for producing a laminated film, comprising:

2. The step of forming the coating liquid layer comprises: discharging the coating liquid using the inkjet discharge device and spraying the coating liquid using the spray device onto the transfer roll that rotates in contact with the first surface of the base material layer to form the coating liquid layer, The transferring step a step of bringing the transfer roll into contact with the first surface of the base layer, and transferring the coating liquid layer formed on the transfer roll to the first surface of the base layer, moreover, forming a coating liquid layer on a second transfer roll that rotates in contact with the second surface of the base layer; bringing the second transfer roll into contact with the second surface of the base layer, and transferring the coating liquid layer formed on the second transfer roll to the second surface of the base layer; The method for producing a laminated film according to claim 1, comprising:

3. The method for producing a laminated film according to claim 2, wherein the transfer roll and the second transfer roll are disposed at positions facing each other with the base layer interposed therebetween.

4. The step of forming a coating liquid layer on the second transfer roll includes: a step of discharging the coating liquid onto the second transfer roll using a second inkjet discharge device to form the coating liquid layer. The method for producing a laminated film according to claim 2 or 3,

5. The step of forming a coating liquid layer on the second transfer roll comprises: and applying the coating liquid to the second transfer roll using a roll coater to form the coating liquid layer. The method for producing a laminated film according to claim 2 or 3,

6. A manufacturing apparatus for manufacturing a laminated film having a coating layer formed on a substrate layer, comprising: an inkjet ejection device including inkjet heads at both ends in a direction perpendicular to the conveyance direction of the base material layer, and ejecting a coating liquid from nozzles of the inkjet heads onto a transfer roll that rotates in contact with the base material layer to form a coating liquid layer; a spray device provided between the inkjet heads and configured to spray the coating liquid from a spray nozzle onto the transfer roll to form the coating liquid layer; a transfer section that brings the transfer roll into contact with the base material layer to transfer the coating liquid layer formed on the transfer roll to the base material layer; A laminated film manufacturing apparatus comprising:

7. The inkjet ejection device the coating liquid is ejected onto the transfer roll that rotates in contact with the first surface of the base material layer to form the coating liquid layer; The spray device comprises: spraying the coating liquid onto the transfer roll that rotates in contact with the first surface of the base material layer to form the coating liquid layer; The transfer unit is bringing the transfer roll into contact with the first surface of the base layer, and transferring the coating liquid layer formed on the transfer roll to the first surface of the base layer; moreover, a coating unit that forms a coating liquid layer on a second transfer roll that rotates in contact with the second surface of the base layer; a second transfer section that brings the second transfer roll into contact with the second surface of the base material layer to transfer the coating liquid layer formed on the second transfer roll to the second surface of the base material layer; and The laminated film manufacturing apparatus according to claim 6, further comprising:

8. 8. The laminated film manufacturing apparatus according to claim 7, wherein the transfer roll and the second transfer roll are disposed at positions facing each other with the base material layer interposed therebetween.

9. The coating unit is a second inkjet ejection device that ejects the coating liquid onto the second transfer roll to form the coating liquid layer; The laminated film manufacturing apparatus according to claim 7 or 8, characterized in that

10. The coating unit is a roll coater that applies the coating liquid to the second transfer roll to form the coating liquid layer; The laminated film manufacturing apparatus according to claim 7 or 8, characterized in that

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