Laminated film manufacturing method and manufacturing device

Abstract

To prevent application liquid to be applied to a laminate film from flowing to the back side.SOLUTION: A manufacturing method of a laminate film in which an application layer 102 is formed on a base material layer 101 comprises: an application step of forming the application layer 102 by discharging application liquid to the base material layer 101 from a nozzle array provided in the orthogonal direction orthogonal to the conveyance direction of the base material layer 101; and a drying step of drying the application layer 102. At least nozzles provided at positions facing both ends in the orthogonal direction of the application layer in the nozzle array are ink jet nozzles.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] Furthermore, 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 achieved by attaching films to both ends of the gravure roll to prevent transfer to the film. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-346534 [Non-patent literature]

[0008] [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> Summary of the Invention [Problem to be solved by the invention]

[0009] In the production of laminated films, when a coating layer is provided on a base layer, if the width of the base layer (sheet width) is changed, the position of the dry edge must be changed. However, in the above-mentioned conventional coating process using a roll coater, the work of changing the position of the dry edge in response to changes in the sheet width is complicated, resulting in a loss of production time.

[0010] One object of the present invention is to form a coating layer with a clear boundary with the dry edge when preparing a laminated film by providing a coating layer on a substrate layer. Another object of the present invention is to easily form a coating layer according to the width of the substrate. [Means for solving the problem]

[0011] Therefore, this method for manufacturing a laminated film is a method for manufacturing a laminated film having a coating layer formed on a base layer, and includes a coating step of ejecting a coating liquid onto the base layer from a nozzle row arranged in a direction perpendicular to the conveying direction of the base layer to form the coating layer, and a drying step of drying the coating layer. Furthermore, at least the nozzles in the nozzle row arranged at positions facing both ends of the coating layer in the perpendicular direction are inkjet nozzles. [Effects of the Invention]

[0012] According to one embodiment, when a laminated film is produced by providing a coating layer on a substrate layer, a coating layer with a clear boundary with the dry edge can be formed, and a coating layer corresponding to the width of the substrate layer can be easily formed. [Brief explanation of the drawings]

[0013] [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 an inkjet ejection 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] 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 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] FIG. 10 is a diagram schematically illustrating an example of the arrangement of inkjet ejection devices in a modified example of a laminated film manufacturing system as an example of an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0014] 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.

[0015] (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.

[0016] 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.

[0017] The base layer 101, that is, the material for forming the substrate layer, may be a resin composition containing a thermoplastic resin.

[0018] Examples of thermoplastic resins include olefin polymers, polyamides, polyesters, polycarbonates, polystyrenes, poly(meth)acrylates, polyvinyl chlorides, and mixed resins thereof. Among these, olefin polymers are preferred from the viewpoint of water resistance and solvent resistance.

[0019] As the olefin polymer, a propylene polymer such as polypropylene, an ethylene polymer such as polyethylene, etc. can be preferably used.

[0020] The resin composition may further contain a filler, which may be either an inorganic filler or an organic filler. Examples of inorganic fillers include calcium carbonate, calcined clay, silica, diatomaceous earth, talc, titanium oxide, barium sulfate, alumina, etc. As the organic filler, organic particles that are incompatible with the thermoplastic resin, have a melting point or glass transition temperature higher than that of the thermoplastic resin, and are finely dispersed under the melt-kneading conditions of the thermoplastic resin are preferred. For example, when the thermoplastic resin is a polyolefin-based resin, the organic filler is preferably polyethylene terephthalate, polybutylene terephthalate, polycarbonate, nylon-6, nylon-6,6, a homopolymer of a cyclic olefin, a copolymer of a cyclic olefin and ethylene, or the like, which has a melting point of 120°C to 300°C or a glass transition temperature of 120°C to 280°C.

[0021] The base layer 101 may further contain stabilizers, light stabilizers, dispersants, lubricants, fluorescent whitening agents, colorants, etc., as required.

[0022] The base layer 101 may have a single layer structure or a multi-layer structure of two or more layers.

[0023] The laminated film manufacturing 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 winder 17, a dryer 18, and an inkjet discharge device 30.

[0024] Each of the raw material silos 10a, 10b, granulator 11, pellet silo 12, extruder 13, longitudinal stretching device 14, transverse stretching device 16, winder 17, dryer 18 and inkjet ejection device 20 that make up the laminated film manufacturing system 1 realizes the manufacturing process for producing the laminated film 100.

[0025] The raw material silos 10a and 10b store the 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.

[0026] 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.

[0027] The raw materials stored in the raw material silos 10a and 10b are fed into a granulator 11.

[0028] The granulator 11 adds fillers and various additives to the thermoplastic resin raw material as required to produce pellets of the resin composition.

[0029] 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.

[0030] The extruder 13 extrudes the molten resin composition in the form of a sheet from an extruder die (not shown) to form the base layer 101, which is a cast film layer.

[0031] 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).

[0032] 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).

[0033] 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.

[0034] The longitudinal stretching device 14 corresponds to a first stretching device that stretches the base layer 101 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).

[0035] In the longitudinal stretching device 14, for example, a plurality of (three in the example shown in FIG. 1 ) conveying rollers 141 are arranged parallel to one another in a direction perpendicular to the longitudinal stretching direction. Then, between these conveying rollers 141, for example, by making a difference in the peripheral speed of the conveying rollers 141, tension in the longitudinal direction is applied to the cast film layer, and the layer is stretched in the longitudinal direction. That is, the longitudinal stretching device 14 may perform inter-roll stretching using the difference in peripheral speed of the rolls.

[0036] 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°C 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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 .

[0042] 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.

[0043] The transverse stretching device 16 is disposed downstream of the longitudinal stretching device 14 .

[0044] 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.

[0045] 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 that stretches the base layer 101 (first stretched layer) in a transverse direction (width direction, second direction) perpendicular to the longitudinal direction (first direction). 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.

[0046] 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.

[0047] 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.

[0048] 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 in the horizontal direction (width direction).

[0049] 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.

[0050] An inkjet ejection device 30 is provided downstream of the transverse stretching device 16 .

[0051] The inkjet ejection device 30 ejects a coating liquid onto the surface of the base layer 101 that has been stretched by the transverse stretching device 16 and is being transported in the longitudinal direction (flow direction), thereby forming a uniform coating layer 102 on the surface of the base layer 101.

[0052] The inkjet ejection device 30 ejects particles of the coating liquid onto a first surface (front surface) of the base layer 101. The inkjet ejection device 30 may also eject particles of the coating liquid onto a second surface (rear surface) of the base layer 101.

[0053] The inkjet ejection device 30 performs a coating process in which a coating solution is ejected onto the base layer 101 (substrate layer) from a nozzle row arranged in a direction (horizontal direction) perpendicular to the transport direction (vertical direction) of the base layer 101 to form a coating layer 102. The nozzle row is formed by arranging a plurality of nozzles in a row.

[0054] FIG. 4 is a diagram illustrating the inkjet ejection device 30 of the laminated film manufacturing system 1 as one example of the embodiment.

[0055] The inkjet ejection device 30 is disposed along the width direction at a position facing the surface of the base layer 101. A plurality of inkjet heads 310 (see FIG. 6) are disposed at positions of the inkjet ejection device 30 facing the base layer 101.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] Inkjet head 310 has a plurality of nozzles (inkjet nozzles) formed at positions facing base layer 101.

[0060] 5, the nozzles (inkjet nozzles) formed in the inkjet head 310 are represented by black circles. 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.

[0061] The discharge of the coating liquid from each nozzle in the inkjet head 310 is controlled by a coating control unit 400 (see FIG. 4). The coating control unit 400 controls the discharge 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 discharged by controlling the on / off switching of discharge from the inkjet nozzles.

[0062] The function of the coating control unit 400 is realized by the processor of a computer (not shown) executing driver software.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] The inkjet heads 310 are arranged side by side in the width direction of the base layer 101 with their nozzle rows facing the surface of the base layer 101 .

[0067] The inkjet ejection device 30 corresponds to a coating section that ejects a coating liquid onto the base layer (substrate layer) 101 from a nozzle row having multiple nozzles arranged in a row perpendicular to the conveying direction (vertical direction) of the base layer 101 to form a coating layer 102.

[0068] In addition, the inkjet ejection device 30 realizes a coating process in which a coating liquid is ejected onto the base layer (substrate layer) 101 from a nozzle row having a plurality of nozzles arranged in a row perpendicular to the conveying direction (vertical direction) of the base layer 101 to form a coating layer 102.

[0069] 6 to 8 are diagrams showing examples of the arrangement of the inkjet heads 310 of the inkjet ejection device 30 of the laminated film manufacturing system 1 as one example of the embodiment.

[0070] 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.

[0071] 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.

[0072] A plurality of inkjet heads 310 arranged in a line may be referred to as an inkjet head row. In the examples shown in Figures 6 to 8, the inkjet head row is denoted by the reference numeral 300.

[0073] 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.

[0074] 6, the inkjet heads 310-1 and 310-5 arranged at both ends have ejection suppression nozzle regions that face a predetermined range from the edge 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.

[0075] The coating control unit 400 causes the inkjet heads 310-1 to 310-5 to eject the coating liquid from the ejection nozzle region 310a onto the base layer 101. As a result, the coating liquid is ejected in particulate form from each nozzle in the ejection nozzle region 310a of each inkjet head 310, and the coating liquid is evenly applied to the surface of the base layer 101.

[0076] A uniform coating layer 102 is formed on the surface of the base layer 101 at a position facing 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. 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).

[0077] 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.

[0078] As a result, dry edges, which are areas where no coating liquid is applied, are formed at positions facing 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.

[0079] 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.

[0080] 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).

[0081] 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 the coating liquid to be ejected onto the base layer 101.

[0082] As a result, a uniform coating layer 102 is formed on the surface of the base layer 101, and a coating layer region 100b is formed.

[0083] Furthermore, the coating liquid is not applied to the positions where no inkjet head 310 is present on both ends (both edges) of the base layer 101 in the width direction, thereby forming dry edges 100a.

[0084] In the third example shown in FIG. 8, the width of the base layer 101 is narrower than that in the example shown in FIG.

[0085] 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.

[0086] In addition, the inkjet heads 310-1 and 310-5 located at both ends of the inkjet head row 300 serve as the ejection suppression nozzle regions 310b. Furthermore, in the inkjet heads 310-2 and 310-4, the portions facing a predetermined range from the edge of the base layer 101 serve as the ejection suppression nozzle regions 310b.

[0087] The coating control unit 400 controls the inkjet heads 310-2 to 310-4 in the inkjet head row 300 to eject the coating liquid onto the base layer 101 from the ejection nozzle region 310a.

[0088] As a result, a uniform coating layer is formed on the surface of the base layer 101 at a position facing the discharge nozzle region 310a in the width direction thereof, forming a coating layer region 100b.

[0089] 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.

[0090] 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.

[0091] As described above, in the laminated film manufacturing system 1, the inkjet head array 300 has inkjet heads 310 arranged at positions facing at least the widthwise edges of the coating layer region 100b, i.e., the widthwise edges of the coating layer 102. By coating and forming both ends of the coating layer region 100b using inkjet nozzles, the edges can be precisely formed linearly, and the dry edge 100a can be formed with high accuracy.

[0092] 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 facing the widthwise edge of the coating layer area 100b (coating layer 102).

[0093] The dryer 18 dries the coating layer 102 formed on the surface of the base layer 101 by the inkjet ejection device 30. 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 of drying the coating layer 102.

[0094] Downstream of the dryer 18, the laminated film 100 may be processed, such as by cutting both edges of the laminated film 100, using a cutting device or the like (not shown). In addition, the thickness of the laminated film 100 may be measured using a measuring device or the like (not shown).

[0095] The winder 17 winds up the laminated film 100 whose coating layer 102 has been dried by the dryer 18 .

[0096] (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.

[0097] The pelletizer 11 adds fillers and various additives to the thermoplastic resin as a raw material as needed to produce pellets of a resin composition. The produced pellets are stored in a pellet silo 12.

[0098] The pellet silo 12 supplies the pellets stored therein to the extruder 13 .

[0099] 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 .

[0100] 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.

[0101] 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).

[0102] Thereafter, the inkjet ejection device 30 ejects particles of the coating liquid onto the surface of the base layer 101 being conveyed in the vertical direction, forming a uniform coating layer 102 on the surface.

[0103] The coating layer 102 formed on the surface of the base layer 101 is dried by a dryer 18. This produces a laminated film 100. The laminated film 100 is then subjected to processing such as cutting both edges and measuring the thickness. The laminated film 100 is wound up by a winder 17 and sent to the subsequent finishing process.

[0104] (C) Effects Thus, according to the laminated film manufacturing system 1 as an example of an embodiment, the inkjet ejection device 30 ejects a coating liquid onto the base layer 101 stretched in the transverse direction by the transverse stretching device 16, thereby forming a coating layer 102 of uniform thickness on the front and back surfaces of the base layer 101.

[0105] The coating control unit 400 controls the inkjet head array 300 of the inkjet ejection device 30 to eject the coating liquid only from the nozzles included in the ejection nozzle region 310a provided opposite 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 opposite the dry edge 100a of the base layer 101.

[0106] This allows the dry edges 100a to be easily formed at both widthwise ends (both 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 in droplets, and the coating control unit 400 can precisely control the coating amount, so the edges of the coated layer region 100b can be precisely formed linearly, and the dry edges 100a can be formed with high accuracy. As a result, the coating liquid can be prevented from running to the back of the base layer 101 at the edges.

[0107] 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.

[0108] This makes it possible to easily and accurately form dry edges at both ends (both edges) of the base layer 101 in the width direction at positions opposite the discharge suppression nozzle region 310b, thereby preventing the coating liquid from running to the back at both ends of the base layer 101.

[0109] 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 base layer 101.

[0110] This also makes it possible to precisely form the edges of the coating layer region 100b in a straight line by ejecting the coating liquid as tiny particles from an inkjet nozzle at both ends (both edges) in the width direction of the coating layer region 100b, thereby easily forming a dry edge with high accuracy and preventing the coating liquid from running to the back at both ends of the base layer 101.

[0111] 8, the coating control unit 400 controls the inkjet heads 310-2 to 310-4, which are provided opposite the coated layer region 100b of the base layer 101, to eject the coating liquid 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 opposite 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 have an opposing base layer 101.

[0112] This also makes it possible to easily and accurately form dry edges at both ends (both edges) of the base layer 101 in the width direction at positions opposite the discharge suppression nozzle region 310b, thereby preventing the coating liquid from running to the back at both ends of the base layer 101.

[0113] In the inkjet head row 300, inkjet heads 310 are arranged at least at positions facing 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 facing the widthwise edges of the coating layer region 100b (coating layer 102).

[0114] Inkjet heads 310 are arranged at positions facing the widthwise edges of the coating layer region 100b (coating layer 102), and the coating liquid is ejected in particulate form from each nozzle in the ejection nozzle region 310a of these inkjet heads 310, thereby applying the coating liquid thinly and evenly to the surface of the base layer 101. The edges of the coating layer region 100b can be precisely formed linearly, and the dry edge 100a can be formed with high precision. As a result, the coating liquid is prevented from running back at both ends of the base layer 101.

[0115] (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.

[0116] For example, in the above-described embodiment, as illustrated in FIGS. 6 to 8, the inkjet head array 300 in the inkjet ejection device 30 is configured with a plurality of inkjet heads 310, but this is not limited to this.

[0117] In the inkjet head array 300, inkjet heads 310 are arranged at positions facing 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.

[0118] That is, the inkjet head array 300 may be provided with spray nozzles between the inkjet nozzles provided at both ends.

[0119] 9 to 11 are diagrams showing modified examples of the inkjet ejection device 30 of the laminated film manufacturing system 1 as one example of the embodiment.

[0120] In the fourth example shown in Fig. 9, 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.

[0121] 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).

[0122] The spray device 320 sprays the coating liquid under the control of the coating control unit 400.

[0123] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the base layer 101, and causes the inkjet heads 310-1 and 310-5 to eject the coating liquid onto the base layer 101 from the ejection nozzle area 310a.

[0124] A coating layer 102 is formed on the surface of the base layer 101 at a position facing each spray device 320 in the width direction of the base layer 101 .

[0125] In the example shown in Figure 9, each spray device 320 sprays the coating liquid onto an area other than the edge of the coating layer area 100b, so that the coating liquid sprayed from each spray device 320 onto the base layer 101 does not run back at both ends of the base layer 101.

[0126] Furthermore, the coating control unit 400 controls the inkjet heads 310-1 and 310-5 to eject the coating liquid from the ejection nozzle regions 310a onto the base layer 101, whereby the coating liquid is ejected in particulate form from each nozzle in the ejection nozzle region 310a of each inkjet head 310-1 and 310-5, and the coating liquid is evenly applied to the surface of the base layer 101. Furthermore, the edge of the coating layer region 100b can be precisely formed linearly, and the dry edge 100a can be formed with high accuracy.

[0127] 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.

[0128] 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.

[0129] 7. In the fifth 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 second example shown in FIG.

[0130] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the base layer 101, and causes the inkjet heads 310-1 and 310-5 to eject the coating liquid onto the base layer 101 from the ejection nozzle area 310a.

[0131] A coating layer 102 is formed on the surface of the base layer 101 at a position facing each spray device 320 in the width direction of the base layer 101 .

[0132] In the example shown in Figure 10, each spray device 320 sprays the coating liquid onto areas other than the edge portions of the base layer 101, so the coating liquid sprayed onto the base layer 101 from each spray device 320 does not run behind at both ends of the base layer 101.

[0133] Furthermore, the coating control unit 400 controls the inkjet heads 310-1 and 310-5 to eject the coating liquid from the ejection nozzle regions 310a onto the base layer 101, whereby the coating liquid is ejected in particulate form from each nozzle in the ejection nozzle region 310a of each inkjet head 310-1 and 310-5, and the coating liquid is evenly applied to the surface of the base layer 101. Furthermore, the edge of the coating layer region 100b can be precisely formed linearly, and the dry edge 100a can be formed with high accuracy.

[0134] 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.

[0135] In the sixth example shown in FIG. 11, 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.

[0136] The coating control unit 400 causes each spray device 320 to spray the coating liquid onto the base layer 101, and causes the inkjet heads 310-2 and 310-4 to eject the coating liquid onto the base layer 101 from the ejection nozzle area 310a.

[0137] A coating layer 102 is formed on the surface of the base layer 101 at a position facing each spray device 320 in the width direction of the base layer 101 .

[0138] In the example shown in Figure 11, each spray device 320 sprays the coating liquid onto areas other than the edge portions of the base layer 101, so the coating liquid sprayed onto the base layer 101 from each spray device 320 does not run behind at both ends of the base layer 101.

[0139] Furthermore, the coating control unit 400 controls the inkjet heads 310-2 and 310-4 to eject the coating liquid from the ejection nozzle regions 310a onto the base layer 101, whereby the coating liquid is ejected in particulate form from each nozzle in the ejection nozzle region 310a of each inkjet head 310-2 and 310-4, and the coating liquid is evenly applied to the surface of the base layer 101. Furthermore, the edge of the coating layer region 100b can be precisely formed linearly, and the dry edge 100a can be formed with high accuracy.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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 limiting. For example, a coating layer may also be formed on the back side of the base layer 101.

[0144] FIG. 12 is a diagram schematically illustrating an example of the arrangement of inkjet ejection devices 30a and 30b in a modified example of the laminated film manufacturing system 1 as one example of the embodiment.

[0145] When forming coating layers 102 on both sides of the base layer 101, as illustrated in Figure 12, an inkjet ejection device 30a is provided to form the coating layer 102 on the front surface of the base layer 101, and an inkjet ejection device 30b is provided to form the coating layer 102 on the back surface of the base layer 101.

[0146] These inkjet ejection devices 30a and 30b have the same configuration as any of the inkjet ejection devices 30 described above.

[0147] 12, the inkjet discharge device 30b and the inkjet discharge device 30a are arranged side by side in the vertical direction. The conveyance path of the base layer 101 stretched by the transverse stretching device 16 is bent and folded back using a plurality of conveyance rollers 201, so that the inkjet discharge device 30a forms a coating layer 102 on the front surface (first surface) of the base layer 101, on whose back surface (second surface) the inkjet discharge device 30b has formed a coating layer 102.

[0148] The inkjet discharge device 30a corresponds to a first coating unit that discharges a coating liquid from a first nozzle row to form a coating layer 102 on the surface of the base layer 101. The inkjet discharge device 30a also performs the process of discharging a coating liquid from the first nozzle row to form a coating layer 102 on the surface of the base layer 101.

[0149] The inkjet discharge device 30b corresponds to a first coating unit that discharges a coating liquid from the second nozzle row to form a coating layer 102 on the back surface of the base layer 101. The inkjet discharge device 30b also realizes the process of discharging a coating liquid from the second nozzle row to form a coating layer 102 on the back surface of the base layer 101.

[0150] By arranging the inkjet ejection device 30b and the inkjet ejection device 30a side by side in the vertical direction in this manner, it is possible to achieve space saving in the laminated film manufacturing system 1.

[0151] Furthermore, in the inkjet ejection device 30b and the inkjet ejection device 30a as well, the inkjet head array 300 may be provided with spray nozzles between the inkjet nozzles provided at both ends.

[0152] The inkjet head 310 and the spray device 320 are both smaller than the application roller and have a high degree of freedom in installation, which allows the laminated film manufacturing system 1 to be space-saving.

[0153] A surface layer and a back layer may be further formed on the base layer 101 on which the coating layer 102 is formed.

[0154] Furthermore, the above disclosure will enable those skilled in the art to implement and manufacture the present embodiment.

[0155] (E) Supplementary Note The following additional notes are provided regarding the above-described embodiments.

[0156] (Appendix 1) A method for producing a laminated film having a coating layer formed on a substrate layer, comprising: a coating step of discharging a coating liquid onto the base material layer from a nozzle row having a plurality of nozzles arranged in a row in a direction perpendicular to the conveyance direction of the base material layer to form the coating layer; a drying step of drying the coating layer, A method for producing a laminated film, wherein at least the nozzles in the nozzle row provided at positions facing both ends of the coating layer in the orthogonal direction are inkjet nozzles.

[0157] (Appendix 2) non-coated regions in which the coating layer is not formed are defined along both end portions of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is approximately the same as the width of the coating layer; 2. The method for producing a laminated film according to claim 1, wherein the inkjet nozzles are provided in the nozzle row at positions facing both ends of the coating layer in the perpendicular direction.

[0158] (Appendix 3) non-coated regions in which the coating layer is not formed are defined along both end portions of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is greater than the width of the coating layer; In the nozzle row, nozzles provided at positions facing both end portions of the coating layer in the orthogonal direction and at positions facing the uncoated region are inkjet nozzles, The coating step and suppressing the ejection of the coating liquid from the inkjet nozzles provided in the nozzle row at positions facing the non-coated region. 2. A method for producing a laminated film according to claim 1.

[0159] (Appendix 4) 4. The method for producing a laminated film according to any one of claims 1 to 3, wherein the nozzle row further includes inkjet nozzles between the inkjet nozzles provided at both ends.

[0160] (Appendix 5) 4. The method for producing a laminated film according to any one of claims 1 to 3, wherein the nozzle row includes a spray nozzle between the inkjet nozzles provided at both ends.

[0161] (Appendix 6) The coating step a step of ejecting the coating liquid from a first nozzle row to form the coating layer on the surface of the base material layer; a step of ejecting the coating liquid from a second nozzle row to form the coating layer on the back surface of the base layer; 6. A method for producing a laminated film according to any one of claims 1 to 5, comprising:

[0162] (Appendix 7) A manufacturing apparatus for manufacturing a laminated film having a coating layer formed on a substrate layer, comprising: a coating unit that forms the coating layer by ejecting a coating solution onto the base material layer from a nozzle row having a plurality of nozzles arranged in a row in a direction perpendicular to the conveyance direction of the base material layer; a drying section for drying the coating layer, The laminated film manufacturing apparatus, wherein at least the nozzles in the nozzle row provided at positions facing both ends of the coating layer in the orthogonal direction are inkjet nozzles.

[0163] (Appendix 8) non-coated regions in which the coating layer is not formed are defined along both end portions of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is approximately the same as the width of the coating layer; 8. The laminated film manufacturing device according to claim 7, wherein the inkjet nozzles are provided in the nozzle row at positions facing both ends of the coating layer in the orthogonal direction.

[0164] (Appendix 9) an uncoated region in which the coating layer is not formed is defined along an edge of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is greater than the width of the coating layer; In the nozzle row, nozzles provided at positions facing both end portions of the coating layer in the orthogonal direction and at positions facing the uncoated region are inkjet nozzles, a control unit that inhibits the coating liquid from being ejected from the inkjet nozzles that are provided in the nozzle row at positions that face the non-coating region; 8. The laminated film manufacturing apparatus according to claim 7,

[0165] (Appendix 10) 10. The laminated film manufacturing device according to any one of claims 7 to 9, wherein the nozzle rows further include inkjet nozzles between the inkjet nozzles provided at both ends.

[0166] (Appendix 11) 10. The laminated film manufacturing device according to any one of claims 7 to 9, wherein the nozzle rows each include a spray nozzle between the inkjet nozzles provided at both ends.

[0167] (Appendix 12) The coating unit is a first coating unit that ejects the coating liquid from a first nozzle row to form the coating layer on the surface of the base material layer; a second coating unit that ejects the coating liquid from a second nozzle row to form the coating layer on the back surface of the base material layer; 12. The laminated film manufacturing apparatus according to any one of claims 7 to 11, comprising: [Explanation of symbols]

[0168] 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 17 Winder 18 Hair dryer 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 400 Coating control unit

Claims

1. A method for producing a laminated film having a coating layer formed on a substrate layer, comprising: a coating step of discharging a coating liquid onto the base material layer from a nozzle row having a plurality of nozzles arranged in a row in a direction perpendicular to the conveyance direction of the base material layer to form the coating layer; a drying step of drying the coating layer, at least the nozzles in the nozzle row that are provided at positions facing both ends of the coating layer in the orthogonal direction are inkjet nozzles; a nozzle row including a spray nozzle between the inkjet nozzles provided at both ends of the film;

2. non-coated regions in which the coating layer is not formed are defined along both end portions of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is approximately the same as the width of the coating layer; The method for producing a laminated film according to claim 1 , wherein the inkjet nozzles are provided in the nozzle row at positions facing both ends of the coating layer in the orthogonal direction.

3. non-coated regions in which the coating layer is not formed are defined along both end portions of the base material layer in the orthogonal direction; the width of the nozzle row in the orthogonal direction is greater than the width of the coating layer; In the nozzle row, nozzles provided at positions facing both end portions of the coating layer in the orthogonal direction and at positions facing the uncoated region are inkjet nozzles, The coating step and suppressing the ejection of the coating liquid from the inkjet nozzles provided in the nozzle row at positions facing the non-coated region. The method for producing a laminated film according to claim 1 .

4. The method for producing a laminated film according to any one of claims 1 to 3, wherein the nozzle row further includes inkjet nozzles between the inkjet nozzles provided at both end portions.

5. The coating step a step of ejecting the coating liquid from a first nozzle row to form the coating layer on the surface of the base material layer; a step of ejecting the coating liquid from a second nozzle row to form the coating layer on the back surface of the base material layer; The method for producing a laminated film according to claim 1, comprising:

6. A manufacturing apparatus for manufacturing a laminated film having a coating layer formed on a substrate layer, comprising: a coating unit that forms the coating layer by ejecting a coating liquid onto the base material layer from a nozzle row having a plurality of nozzles arranged in a row in a direction perpendicular to the conveyance direction of the base material layer; a drying section for drying the coating layer, at least the nozzles in the nozzle row that are provided at positions facing both ends of the coating layer in the orthogonal direction are inkjet nozzles; a nozzle row including a spray nozzle between the inkjet nozzles provided at both ends of the laminated film manufacturing apparatus;

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