Method for removing a coating layer and apparatus for removing a coating layer

Abstract

To provide a method for removing a coating layer capable of easily removing a coating layer from a laminated film conveyed in a roll-to-roll manner.SOLUTION: A method for removing a coating layer comprises: a step of delivering a first laminated film 50 having a first base material film and a first coating layer from a first roll 1; a step of delivering a second film (e.g., a second laminated film 50A) from a second roll 1A; a step of allowing a first coating layer side surface of the first laminated film 50 and one surface of the second film to face each other and bringing them into contact with each other; a step of stretching the first laminated film 50 and the second film; a step of releasing a contact between the first laminated film and the second film; a first removing step of removing a first coating layer 520 from a first laminated film 500 obtained by releasing the contact; and a first winding step of winding the first base material film 51 into a rolled shape.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for removing a coating layer and an apparatus for removing a coating layer.

Background Art

[0002] In recent years, from the viewpoints of global resource protection and environmental protection, etc., in various fields, movements aiming at building a recycling-based society have been actively carried out through measures such as suppressing the generation of waste, reusing, and recycling. For example, Patent Document 1 discloses a method for treating a plastic part with a coating film, which comprises exposing a plastic part with a coating film formed on the surface thereof to a high-temperature atmosphere of 400°C or higher and 1000°C or lower to embrittle and remove the coating film.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the treatment method described in Patent Document 1, since plastic parts of various sizes are directly exposed to a high-temperature atmosphere to embrittle the coating film on the surface, there may be portions where embrittlement is insufficient, and it may be impossible to easily remove the coating film. In the technology for recycling plastic films (base films), a technology capable of easily removing the coating layer from the laminated film is required.

[0005] An object of the present invention is to provide a method for removing a coating layer and an apparatus for removing a coating layer that can easily remove the coating layer from a laminated film conveyed roll-to-roll in a laminated film having a base film and a coating layer.

Means for Solving the Problems

[0006] [1] A method for removing a coating layer, comprising the steps of: preparing a first roll around which a first laminated film having a first base film and a first coating layer is wound, and a second roll around which a second film is wound; unwinding the first laminated film from the first roll; unwinding the second film from the second roll; bringing the side of the unwinded first laminated film facing the first coating layer and one side of the unwinded second film into contact; stretching the first laminated film and the second film while they are in contact; releasing the contact between the first laminated film and the second film; removing the first coating layer from the first laminated film from which the contact has been released; and winding the first base film from which the first coating layer has been removed into a roll.

[0007] [2] The method for removing a coating layer according to [1], wherein the first removal step is a step of transferring the first coating layer from the first substrate film to the first adhesive roll.

[0008] [3] The method for removing a coating layer according to [1], wherein the first removal step is a step of scraping the first coating layer off the first substrate film using a first blade or a first wire brush.

[0009] [4] The method for removing a coating layer according to [1], wherein the first removal step is a step of scraping the first coating layer off the first substrate film with a first blasting material.

[0010] [5] The method for removing a coating layer according to any one of [1] to [4], wherein the stretching step is performed while heating the first laminated film and the second film.

[0011] [6] A method for removing a coating layer according to any one of [1] to [5], comprising the step of blowing superheated steam onto the first coating layer of the first laminated film from which contact has been released, after the step of releasing the contact and before the first removal step.

[0012] [7] The method for removing a coating layer according to any one of [1] to [6], wherein the second film is a second laminated film, the second laminated film having a second base film and a second coating layer, the contact step is a step of bringing the side of the first laminated film facing the side of the first coating layer and the side of the second laminated film facing the side of the second coating layer into contact, and further comprising, after the step of releasing the contact, a second removal step of removing the second coating layer from the second laminated film from which the contact has been released, and a second winding step of winding the second base film from which the second coating layer has been removed into a roll.

[0013] [8] A method for removing a coating layer according to any one of [1] to [7], comprising: a step of further unwinding one or more third laminated films having a third base film and a third coating layer; a step of overlapping and bringing into contact one or more of the third laminated films, the first laminated film and the second film such that the surface of the third coating layer of the third laminated film is not positioned on the outside; a step of stretching the first laminated film, the second film and one or more of the third laminated films while the first laminated film, the second film and one or more of the third laminated films are in contact with each other; a step of releasing the contact between the first laminated film, the second film and one or more of the third laminated films after stretching; a third removal step of removing the third coating layer from one or more of the third laminated films from which contact has been released; and a third winding step of winding the third base film from which the third coating layer has been removed into a roll.

[0014] [9] The method for removing a coating layer according to any one of the claims [1] to [8], wherein the first laminated film is a laminated film with a ceramic green sheet, and the ceramic green sheet is attached to the side of the first coating layer opposite to the first substrate film.

[0015]

[10] A coating layer removal apparatus comprising: a first dispensing means for dispensing a first laminated film having a first base film and a first coating layer from a first roll around which the first laminated film is wound; a second dispensing means for dispensing a second film from a second roll around which a second film is wound; a contact means for bringing the side of the dispensed first laminated film facing the first coating layer and one side of the dispensed second film into contact; a stretching means for stretching the first laminated film and the second film while they are in contact; a contact release means for releasing the contact between the first laminated film and the second film; a first removal means for removing the first coating layer from the first laminated film from which the contact has been released; and a first winding means for winding the first base film into a roll.

[0016]

[11] The coating layer removal apparatus according to

[10] , wherein the first removal means comprises a first adhesive roll, and the first removal means is a means for transferring the first coating layer from the first substrate film to the first adhesive roll.

[0017]

[12] The coating layer removal apparatus according to

[10] , wherein the first removal means comprises a first blade or a first wire brush capable of scraping the first coating layer off the first substrate film.

[0018]

[13] The coating layer removal apparatus according to

[10] , wherein the first removal means comprises a first blasting apparatus capable of scraping the first coating layer off the first substrate film with a first blasting material.

[0019]

[14] Further comprising a steam spraying means, The steam spraying means is a means for spraying superheated steam toward the first coating layer of the first laminated film from which the contact has been released, and is the coating layer removing device according to any one of

[10] to

[13] above.

[0020]

[15] The stretching means includes a heating means for heating the first laminated film and the second film, and is the coating layer removing device according to any one of

[10] to

[14] above. [Advantages of the Invention]

[0021] According to one aspect of the present invention, there can be provided a method for removing a coating layer and a coating layer removing device capable of easily removing a coating layer from a laminated film conveyed in a roll-to-roll manner in a laminated film having a base film and a coating layer. [Brief Description of the Drawings]

[0022] [Figure 1A] It is a cross-sectional view of the first laminated film used in the removal method according to the first embodiment. [Figure 1B] It is a perspective view of a laminated film with a ceramic green sheet. [Figure 2A] It is a cross-sectional view of two laminated films after the contact step according to the first embodiment. [Figure 2B] It is a cross-sectional view of two laminated films after the stretching step according to the first embodiment. [Figure 3] It is a schematic view of the removing device according to the second embodiment. [Figure 4A] It is a schematic view of the removing means according to Modification 1. [Figure 4B] It is a schematic view of the removing means according to Modification 2. [Figure 4C] It is a schematic view of the removing means according to Modification 3. [Figure 4D] It is a schematic view of the removing means according to Modification 4. [Figure 5] This is a cross-sectional view of the three laminated films after the second contact process according to Modification Example 5. [Modes for carrying out the invention]

[0023] In this specification, ordinal numbers such as "1st," "2nd," and "3rd" are intended to distinguish the components and do not imply order. In this specification, expressions without ordinal numbers, such as "laminated film," refer to laminated films as a general term and are used when describing laminated films that have ordinal numbers such as "1st," "2nd," and "3rd." For example, when an explanation is given that applies to multiple configurations, such as "first laminated film" and "second laminated film," the "first laminated film" and "second laminated film" are collectively represented by simply stating "laminated film" without the ordinal number.

[0024] [First Embodiment] [Method for removing the coating layer] The method for removing a coating layer according to this embodiment (hereinafter also referred to as the removal method according to this embodiment) comprises the steps of: preparing a first roll around which a first laminated film having a first base film and a first coating layer is wound, and a second roll around which a second film is wound (hereinafter also referred to as the preparation step); unwinding the first laminated film from the first roll (hereinafter also referred to as the first unwinding step); unwinding the second film from the second roll (hereinafter also referred to as the second unwinding step); and removing the side of the unwinded first laminated film that has the first coating layer, and the unwinded... The process includes: bringing one side of the second film into contact with the first laminated film (hereinafter also referred to as the contact process); stretching the first laminated film and the second film while they are in contact (hereinafter also referred to as the stretching process); releasing the contact between the first laminated film and the second film (hereinafter also referred to as the contact release process); removing the first coating layer from the first laminated film from which the contact has been released; and winding the first base film from which the first coating layer has been removed into a roll.

[0025] Figure 1A is a cross-sectional view of the first laminated film 50 used in the removal method according to this embodiment. The first laminated film 50 comprises a first base film 51 and a first coating layer 52. In the first laminated film 50, the first base film 51 and the first coating layer 52 are in direct contact.

[0026] The second film used in the removal method according to this embodiment is not particularly limited as long as it has a base film. The second film may be, for example, a film consisting only of a base film, a laminated film in which a coating layer is laminated on a base film, or a laminated film with a ceramic green sheet attached to the coating layer (see Figure 1B described later).

[0027] The following explanation will focus primarily on the case where the second film is the second laminated film.

[0028] In the removal method according to this embodiment, the coating layers of the first laminated film 50 and the second laminated film 50A are brought into contact with each other (contact step), and the stretching step is performed in that state. Figure 2A shows a cross-sectional view of the two laminated films after the contact process, illustrating a structure in which the coating layers of the first laminated film 50 and the second laminated film 50A are in contact with each other. The structure shown in Figure 2A is sometimes referred to as the "laminated structure 600". As shown in Figure 2A, the second laminated film 50A has a second base film 51A and a second coating layer 52A. The second laminated film 50A may have the same configuration as the first laminated film 50, or it may have a different configuration. Figure 2B shows cross-sectional views of the two laminated films after the stretching process, illustrating the state in which cracks 602 have formed in the coating layer of the laminated structure 600. Specifically, after the stretching process, cracks 602 have formed in the first coating layer 520 of the first laminated film 500, and after the stretching process, cracks 602 have formed in the second coating layer 520A of the second laminated film 500A. The structure shown in Figure 2B is sometimes referred to as the "extended structure 600A".

[0029] The stretching process is a process in which cracks are created in the coating layer by stretching the laminated structure 600 shown in Figure 2A in the longitudinal direction (conveying direction). Inducing cracks in the coating layer means that cracks (fissures) occur in the thickness direction of the coating layer, and it is preferable that cracks reach the interface with the substrate film, as shown in Figure 2B. Cracks that occur in the coating layer are initially formed along a direction approximately perpendicular to the stretching direction, and further stretching causes cracks to form along the stretching direction. Furthermore, the impact that causes cracks in the coating layer may cause the coating layer to partially peel off from the surface of the base film. By creating cracks in the coating layer during the stretching process, the removal of the coating layer in the next process becomes easier.

[0030] Furthermore, according to the removal method of this embodiment, since the stretching process is carried out with the coating layers of the two laminated films 50 and 50A facing each other and in contact, even if the coating layer peels off from the surface of the base film during stretching, the fragments of the coating layer can be kept inside the two base films 51 and 51A. This makes it possible to transport the coating layer fragments without scattering them. Furthermore, when using a laminated film with a ceramic green sheet that has been used in the manufacture of multilayer ceramic capacitors (MLCCs) (see Figure 1B described later), the laminated film is prone to tearing during transport and stretching, starting from the half-cut portion (the blade marks created on the coating layer surface when punching into the ceramic green sheet). However, with the removal method according to this embodiment, the two laminated films 50 and 50A are transported and stretched in contact, so the tension applied to the half-cut portion can be distributed, and tearing of the laminated film during transport and stretching can be suppressed.

[0031] Furthermore, according to the removal method of this embodiment, since the laminated films 50 and 50A are unwound from two rolls in a roll-to-roll manner and each process is carried out continuously, the removal of the coating layer and winding of the base film can be performed efficiently, the amount of base film recovered can be increased, and as a result the regeneration efficiency of the base film is improved.

[0032] The removal method according to this embodiment can be carried out, for example, using the coating layer removal apparatus according to the second embodiment (hereinafter also referred to as the removal apparatus 100 according to the second embodiment). In the second embodiment, we will describe the case where the second film is the second laminated film 50A and the first removal means 30 is the first adhesive roll 5.

[0033] [Second Embodiment] [Coating layer removal device 100] Figure 3 is a schematic diagram of the removal device 100 according to the second embodiment.

[0034] The removal device 100 according to the second embodiment includes the steps of preparing a first roll 1 around which a first laminated film 50 having a first base film 51 and a first coating layer 52 is wound, and a second roll 1A around which a second laminated film 50A (an example of a second film) is wound; unwinding the first laminated film 50 from the first roll 1; unwinding the second laminated film 50A from the second roll 1A; and removing the side of the unwinded first laminated film 50 facing the first coating layer 52 and the unwinded second laminated film The process includes: bringing one side of the film 50A into contact with the first laminated film 50; stretching the first laminated film 50 and the second laminated film 50A while they are in contact; releasing the contact between the first laminated film 50 and the second laminated film 50A; removing the first coating layer 52 from the first laminated film 50 from which the contact has been released; and winding the first base film 51 from which the first coating layer 52 has been removed into a roll.

[0035] In the following description, the first unwinding means 10, the first removal means 30, and the first winding means 40 have the same configuration and operate similarly as the second unwinding means 10A, the second removal means 30A, and the second winding means 40A, respectively. Therefore, the "first" in the descriptions of the first unwinding means 10, the first removal means 30, and the first winding means 40 can be replaced with "second" in each case.

[0036] <First dispensing means 10, second dispensing means 10A> The first feeding means 10 includes a first roll 1 around which the first laminated film 50 is wound, a support member (not shown) that rotatably supports the first roll 1, and a drive roller (not shown). The configuration and operation of the second feeding means 10A are similar.

[0037] <Contact means 15> The contact means 15 brings the side of the first coating layer 52 of the unwound first laminated film 50 into contact with the side of the second coating layer 52A of the unwound second laminated film 50A. Examples of contact means include known pressing means (e.g., various types of rollers). In the case of Figure 3, the contact means 15 is a first nip roll NR1 and a first guide roll GR1 provided opposite the first nip roll NR1.

[0038] <Stretching means 20> The stretching means 20 includes a first stretching roll 21, a second stretching roll 22 provided downstream of the first stretching roll 21, a peripheral speed control means 23 for controlling the peripheral speed of the first stretching roll 21 and the second stretching roll 22, and an upstream nip roll NR21 and a downstream nip roll NR22 provided opposite the first stretching roll 21 and the second stretching roll 22, respectively. Drive motors M1 and M2 are connected to the shafts of the first stretching roll 21 and the second stretching roll 22, respectively. The peripheral speed control means 23 controls the peripheral speed of the first stretching roll 21 and the second stretching roll 22 by controlling these drive motors M1 and M2. The peripheral speed control means 23 is, for example, a computer.

[0039] The stretching means 20 preferably includes a heating means for heating the first laminated film 50 and the second laminated film 50A. The heating means is not particularly limited, but examples include infrared heaters, halogen heaters, UV lamps, and hot air generators. The arrangement of the heating means is not particularly limited. In the case of Figure 3, a heating means 24 is provided in the region R2 between the first stretching roll 21 and the second stretching roll 22. The heating means 24 may also be provided in the region R1 between the first nip roll NR1 or the first guide roll GR1 and the upstream nip roll NR21.

[0040] <Contact release means 25> The contact release means 25 is a means for releasing the contact between the stretched first laminated film 500 and the second laminated film 500A. Examples of contact release means 25 include members that guide the first laminated film 500 and the second laminated film 500A to different paths. In the case of Figure 3, the contact release means 25 consists of a guide roll GR31 that guides the first laminated film 500 and a guide roll GR32 that guides the second laminated film 500A.

[0041] <First removal means 30, second removal means 30A> The first removal means 30 comprises a first adhesive roll 5 and is a means for transferring the first coating layer 520 (the first coating layer 520 after stretching) from the first base film 51 to the first adhesive roll 5. The first adhesive roll 5 is, for example, a roll around which a first adhesive sheet 60 having a base sheet and an adhesive layer is wound. The base sheet is not particularly limited and can be, for example, paper and resin sheets. The adhesive layer is not particularly limited and can be any known adhesive layer. The first removal means 30 comprises a first adhesive roll 5 and a first adhesive paper winding roll 6. In the case of Figure 3, the first coating layer 520 is transferred to the adhesive layer of the first adhesive sheet 60. The first adhesive paper winding roll 6 winds up the adhesive sheet to which the first coating layer 520 has been transferred (hereinafter also referred to as the adhesive sheet 61 with the first coating layer). The configuration and operation of the second removal means 30A are similar. The first removal means 30 and the second removal means 30A may be identical or different.

[0042] <First winding means 40, second winding means 40A> The first winding means 40 includes a first winding roll 4 for winding the first base film 51 into a roll shape, a support member (not shown) for rotatably supporting the first winding roll 4, and a drive roller (not shown). The configuration and operation of the second winding means 40A are similar.

[0043] When using the coating layer removal apparatus 100 according to the second embodiment, the coating layer removal method according to the first embodiment is carried out, for example, through the following steps.

[0044] In the following description, the first unwinding process, the first removal process, and the first winding process have the same configuration and operate similarly to the second unwinding process, the second removal process, and the second winding process, respectively. Therefore, the "first" in the descriptions of the first unwinding process, the first removal process, and the first winding process can be replaced with "second" in each case.

[0045] <Preparation process> The preparation step involves preparing a first roll 1 around which a first laminated film 50 having a first base film 51 and a first coating layer 52 is wound, and a second roll 1A around which a second laminated film 50A having a second base film 51A and a second coating layer 52A is wound. In the preparation process, it is preferable, for example, to select a combination of a first roll 1 and a second roll 1A having the same width and length, and to select a combination of a first roll 1 and a second roll 1A that have the same ease of breakage of the coating layers 52, 52A in the stretching process (ease of crack formation 602 in the coating layers 52, 52A). From the viewpoint of ensuring that the ease of fracture of the coating layers 52 and 52A is consistent, it is preferable that the first coating layer 52 and the second coating layer 52A are composed of the same or similar materials.

[0046] The first laminated film 50 is a laminated film with a ceramic green sheet, and it is preferable that the ceramic green sheet is attached to the side of the first coating layer 52 opposite to the first base film 51. The same applies when the second laminated film 50A is a laminated film with a ceramic green sheet. Figure 1B is a perspective view of the laminated film 50G when the first laminated film 50 is a laminated film 50G with a ceramic green sheet. Figure 1B shows the state in which the laminated film 50G with a ceramic green sheet is unwound from roll 1G. The residue 920 of the ceramic green sheet adheres to the surface of the first coating layer 52. After the ceramic green sheet is peeled off, a recess 910 is formed, and the first coating layer 52 is exposed from the recess 910.

[0047] <First feeding process, second feeding process> The first feeding process is the process of feeding the first laminated film 50 from the first roll 1. The configuration and operation of the second feeding process are similar.

[0048] <Contact process> The contact process involves bringing the side of the first coating layer of the unwound first laminated film into contact with the side of the second coating layer of the unwound second laminated film. In the case of Figure 3, the first laminated film 50 unwound from the first roll 1 and the second laminated film 50A unwound from the second roll 1A pass between the first nip roll NR1 and the first guide roll GR1, forming a structure (laminated structure 600) in which the coating layers of the two laminated films 50 and 50A are in contact with each other.

[0049] <Stretching process> The stretching process involves stretching the first laminated film and the second laminated film while they are in contact with each other. In the case of Figure 3, the laminated structure 600 after the contact process is sequentially wrapped around the upstream nip roll NR21 and the first stretching roll 21 and transported, and is stretched as it passes between the first stretching roll 21 and the second stretching roll 22 (stretching process). This stretching process causes cracks 602 to form in the coating layer of the laminated structure 600, resulting in the stretched structure 600A (Figure 2B). Methods for stretching the laminated structure 600 after the contact process include, for example, controlling the peripheral speed of the second stretching roll 22 provided on the downstream side of the transport path to be faster than the peripheral speed of the first stretching roll 21 provided on the upstream side of the transport path, and providing one or more other stretching rolls between the first stretching roll 21 and the second stretching roll 22, and transporting the laminated structure 600 while wrapping it around the first stretching roll 21, the other stretching rolls and the second stretching roll 22.

[0050] The stretching process is preferably carried out while heating the laminated structure 600 (the first laminated film 50 and the second laminated film 50A) after the contact process. This makes it easier for cracks to occur in the coating layer compared to when the stretching process is carried out at room temperature. In the case of Figure 3, the laminated structure 600 is heated using the heating means 24. Heating during the stretching process is more effective when at least one of the first laminated film 50 and the second laminated film 50A is a laminated film with a ceramic green sheet. As mentioned above, laminated films with ceramic green sheets are prone to tearing during transport, starting from the half-cut portion created after the ceramic green sheet is punched out. In contrast, in the stretching process of this embodiment, a structure (laminated structure 600) is formed by bringing two laminated films 50, 50A into contact, and by stretching this laminated structure 600 while heating it, it is possible to suppress the breakage of the laminated film with ceramic green sheet not only during transport but also during stretching. As a result, even when a laminated film with ceramic green sheet is used as the laminated film, the removal of the coating layer and winding of the base film can be completed without problems using a roll-to-roll method.

[0051] In the stretching process, the heating temperature and heating time when heating the laminated structure 600 are determined by the materials of the base film and the coating layer. Furthermore, the process may include a step of heating the laminated structure 600 after the contact step and before the stretching step. Heating the laminated structure 600 before the stretching step makes it easier for cracks to form in the coating layer located inside the laminated structure 600.

[0052] For the following reasons, it is preferable to heat the laminated structure 600 at a temperature equal to or higher than the glass transition temperature Tg1 of the base film. The glass transition temperature Tg1 of the base film and the glass transition temperature Tg2 of the coating layer are determined according to the method specified in JIS K7121 (2012) and measured using a differential scanning calorimeter (DSC). The temperature during stretching is preferably above the glass transition temperature Tg1 of the base film, and more preferably above the glass transition temperature Tg1 of the base film and below the glass transition temperature Tg2 of the coating layer, in order to facilitate stretching without breaking the base film while making it easier to break the coating layer.

[0053] <Contact release process> The contact release step is a step of releasing contact between the first laminated film 50 and the second laminated film 50A. In the case of Figure 3, after the stretching process, when the stretched structure 600A passes through guide roll GR2 and then between guide rolls GR31 and GR32, the first laminated film 500 is wrapped around guide roll GR31 and nip roll NR31, and the second laminated film 500A is wrapped around guide roll GR32 and nip roll NR32, and they are guided to different paths. As a result, the contact between the first laminated film 500 and the second laminated film 500A is released.

[0054] <First removal process, second removal process> The first removal step is to remove the first coating layer 520 from the first laminated film 500 from which contact has been released. In the case of Figure 3, the first removal step is the step of transferring the first coating layer 520 of the first laminated film 500 from the first base film 51 to the first adhesive roll 5. After the contact is released, the first laminated film 500 passes between the guide rolls GR31 and GR32, and the first coating layer 520 is transferred from the first base film 51 to the adhesive layer of the first adhesive sheet 60. The adhesive sheet with the first coating layer 520 attached (adhesive sheet 61 with the first coating layer) is then wound up by the first adhesive paper winding roll 6. The configuration and operation of the second removal process are similar.

[0055] <First winding process, second winding process> The first winding step is the step of winding the first base film 51, from which the first coating layer 520 has been removed, into a roll shape. In the case of Figure 3, the first base film 51 is wound into a roll shape by the first winding roll 4. The configuration and operation of the second winding process are similar.

[0056] [Modification of the embodiment] [Variation 1] In the removal device 100 according to the second embodiment, the first removal means 30 in region R3 may be changed to the removal means 30B shown in Figure 4A, or the second removal means 30A in region R3 may be changed to the removal means 30C shown in Figure 4A. The following section describes the case where the first removal means 30 is changed to the removal means 30B shown in Figure 4A. The removal means 30B comprises a first blade 35 and is a means for scraping off the first coating layer 520, from which contact has been released, from the first substrate film 51. In the case of Figure 4A, the first blade 35 is positioned downstream of the opposing surfaces of the guide rolls GR31 and GR32 (contact release means 25) so as to contact the surface of the first laminated film 500 on the side of the first coating layer 520. The removal means 30B includes the first blade 35 for scraping off the first coating layer 520 and a receiving tray 71 for collecting the scraped-off first coating layer 520. The material of the first blade 35 is not particularly limited.

[0057] [Variation 2] In the removal device 100 according to the second embodiment, the first removal means 30 in region R3 may be changed to the removal means 30D shown in Figure 4B, or the second removal means 30A in region R3 may be changed to the removal means 30E shown in Figure 4B. The following section describes the case where the first removal means 30 is changed to the removal means 30D shown in Figure 4B. The removal means 30D comprises a first wire brush 36 and is a means for scraping off the first coating layer 520, from which contact has been released, from the first substrate film 51. In the case of Figure 4B, the first wire brush 36 is provided opposite the guide roll GR31 (contact release means 25). The removal means 30D includes the first wire brush 36 for scraping off the first coating layer 520 and a receiving tray 71 for collecting the scraped-off first coating layer 520. The material of the first wire brush 36 is not particularly limited. As shown in Figure 4B, the first wire brush 36 and the guide roll GR31 are arranged facing each other horizontally, and the first coating layer 520 can be efficiently recovered by scraping it downwards.

[0058] [Example 3] In the removal device 100 according to the second embodiment, the first removal means 30 in region R3 may be changed to the removal means 30F shown in Figure 4C, or the second removal means 30A in region R3 may be changed to the removal means 30G shown in Figure 4C. The following section describes the case where the first removal means 30 is changed to the removal means 30F shown in Figure 4C. The removal means 30F comprises a first blasting apparatus 37 and is a means for scraping off the first coating layer 520, from which contact has been released, from the first base material film 51 using a blasting material. In the case of Figure 4C, the first blasting apparatus 37 is provided at any position downstream of the opposing surfaces of the guide rolls GR31 and GR32 (contact release means 25), and the first coating layer 520 is scraped off from the first base film 51 by blasting the first coating layer 520 with blasting material. The removal means 30F includes a first blasting apparatus 37 and a receiving tray 71 for collecting the scraped-off first coating layer 520 together with blasting material (not shown). The first blasting apparatus 37 can be a known blasting apparatus. Examples of blasting materials include silica particles, calcium carbonate particles, silicon carbide particles, alumina particles, dry ice particles, and melamine resin particles. When dry ice particles are used as the blasting material, they disappear after the blasting process, which is preferable because it eliminates the need for particle removal. The particle size of the blasting material is preferably between 5 μm and 40 μm. The blasting conditions are determined by the material of the coating layer.

[0059] [Variation 4] In the removal device 100 according to the second embodiment, it is preferable that the first removal means 30 and the second removal means 30A in region R3 further have a steam blowing means 70 as shown in Figure 4D. The steam blowing means 70 is a means for blowing superheated steam toward the first coating layer 520 and the second coating layer 520A, from which contact has been released. The steam blowing means 70 only needs to include a heater for heating steam and a steam blowing nozzle for blowing superheated steam. The steam blowing means 70 comprises a superheater 72 and a boiler 74. The superheater 72 is connected to the boiler 74 and heats the steam generated in the boiler 74 to produce superheated steam, which is then blown from a steam blowing nozzle (not shown) toward the first coating layer 520 and the second coating layer 520A. The first coating layer 520 and the second coating layer 520A are rapidly cooled after superheated steam is sprayed onto them from a steam spray nozzle (not shown). This rapid cooling makes the first coating layer 520 more susceptible to distortion due to the difference in thermal expansion coefficients between the first coating layer 520 and the first substrate film 51, thereby promoting interfacial delamination of the first coating layer 520. As a result, in the subsequent first removal step, the first coating layer 520 becomes easier to remove from the first substrate film 51. The same applies to the second coating layer 520A. The temperature of the superheated steam is preferably between 100°C and 450°C, more preferably between 150°C and 400°C, and even more preferably between 200°C and 350°C. The duration of superheated steam application is determined by factors such as the material of the coating layer and the conveying speed of the laminated film.

[0060] [Variation 5] The removal method according to the first embodiment can also be carried out using one or more third laminated films having a third base film and a third coating layer. In this embodiment, the removal method according to the first embodiment includes a step of further unwinding one or more third laminated films having a third base film and a third coating layer (hereinafter also referred to as the third unwinding step), a step of overlapping and bringing into contact one or more third laminated films, a first laminated film, and a second film so that the surface of the third coating layer of the third laminated film is not positioned on the outside (hereinafter also referred to as the second contact step), and the first laminated film, the second film, and one or more third laminated films are in contact. The process includes: stretching the first laminated film, the second film, and one or more third laminated films in that state (hereinafter also referred to as the second stretching step); releasing contact between the first laminated film, the second film, and one or more third laminated films after stretching (hereinafter also referred to as the second contact release step); removing the third coating layer from the one or more third laminated films from which contact has been released; and winding the third base film from which the third coating layer has been removed into a roll shape.

[0061] The first unwinding step, contact step, stretching step, contact release step, first removal step, and first winding step described in the first embodiment have the same configuration and operate similarly to the third unwinding step, second contact step, second stretching step, second contact release step, third removal step, and third winding step according to Modified Example 3. Therefore, the "first" in the descriptions of the first unwinding step, first removal step, and first winding step can be replaced with "second" in each case. The descriptions of the contact step, stretching step, and contact release step can be replaced with the second contact step, second stretching step, and second contact release step, respectively.

[0062] Figure 5 shows a cross-sectional view of the three laminated films after the second contact process, illustrating the state in which the three laminated films 50, 50A, and 50B are stacked and in contact in such a way that the surfaces of all the coating layers 52, 52A, and 52B of the three laminated films 50, 50A, and 50B are not positioned on the outside (i.e., the surfaces of the coating layers 52, 52A, and 52B are positioned on the inside). The structure shown in Figure 5 is sometimes referred to as "Laminated Structure 600B". The third laminated film 50B comprises a third base film 51B and a third coating layer 52B. The third laminated film 50B, the first laminated film 50, and the second laminated film 50A may have the same configuration or different configurations.

[0063] The following describes the case where the removal method of the first embodiment is carried out using three laminated films 50, 50A, and 50B as the laminated film. The differences from the first embodiment will be explained. In the second stretching step according to Modification 5, the laminated structure 600B (Figure 5) obtained in the second contact step is stretched in the longitudinal direction (conveying direction), thereby causing cracks to form in the three coating layers 52, 52A, and 52B located inside the laminated structure 600B. According to the removal method of modified example 5, the second stretching step is performed with all surfaces of the coating layers 52, 52A, and 52B of the three laminated films 50, 50A, and 50B not facing outwards. Therefore, even if the coating layer peels off from the surface of the base film during stretching, the fragments of the coating layer can be kept inside the laminated structure 600B. This allows the coating layer fragments to be transported without scattering.

[0064] The second contact release step is a step of releasing the contact between the first laminated film, the second laminated film, and the third laminated film after stretching. The first laminated film, the second laminated film, and the third laminated film are separated from each other, for example, by being wrapped around guide rolls that are guided along different paths. Subsequently, the third coating layer is removed from the third laminated film in the same manner as the first removal step and the first winding step according to the first embodiment (third removal step), and the third base film is wound into a roll (third winding step).

[0065] The present invention is not limited to the embodiments described above. The present invention may include modifications and improvements to the extent that they can achieve the objectives of the present invention.

[0066] The configuration of the laminated film used in the above-described embodiment will now be explained.

[0067] [Laminated film] The laminated film used in the above-described embodiment comprises a base film and a coating layer. The coating layer may be a single layer or a multi-layer consisting of two or more coating layers of the same or different types. Furthermore, the coating layer may be formed on both sides of the base film. From the viewpoint of making it easier to remove the coating layer from the laminated film and recover the remaining base film, it is preferable that the base film and the coating layer are directly laminated. Here, "direct lamination" refers to a configuration in which the base film and the coating layer are in direct contact with each other, for example, without any other layer between the base film and the coating layer.

[0068] <Base film> The base film used is a resin film on which the resin components intended for recovery have been formed. Examples of resin films that can be used include polyester films such as polyethylene terephthalate film, polybutylene terephthalate, and polyethylene naphthalate; polyolefin films such as polyethylene film and polypropylene film; polyimide film; polyamide film; polycarbonate film; polyacetate film; ethylene-vinyl acetate copolymer (EVA) film; ethylene-(meth)acrylic acid copolymer film; ethylene-(meth)acrylic acid ester copolymer film; cycloolefin polymer film; polyurethane film; polyphenylene sulfide film; cellophane; and others. Among these, polyester film is preferred from the viewpoint of heat resistance and strength. As for the polyester film, a polyester film whose main component is one of polyethylene terephthalate, polybutylene terephthalate, or polyethylene naphthalate is preferred from the viewpoint of ease of resin recovery and recycling. Furthermore, the resin film may contain known fillers, colorants, antistatic agents, antioxidants, organic lubricants, and catalysts. The resin film may be transparent or colored as desired. In addition, at least one surface of the base film may be subjected to surface treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, and oxidation etching as needed.

[0069] There are no particular restrictions on the thickness of the base film, but from the viewpoint of strength, rigidity, etc., it is preferably 10 μm to 500 μm, more preferably 15 μm to 300 μm, and even more preferably 20 μm to 200 μm.

[0070] <Coating layer> The coating layer is preferably a functional layer. Examples of functional layers include a release agent layer, a printing layer, a hard coat layer, an easy-adhesion layer, and an adhesive layer. Among these, the coating layer is preferably a release agent layer. If the coating layer is a release agent layer, it is preferable that the release agent layer is a layer formed from a release agent composition. The release agent composition used to form the release agent layer is not particularly limited as long as it has release properties. For example, release agent compositions mainly composed of silicone compounds, fluorine compounds, long-chain alkyl group-containing compounds, thermoplastic resin materials such as olefin resins and diene resins can be used. It is also preferable to use a release agent composition mainly composed of an energy ray curable or thermosetting resin. These release agent compositions may be used individually or in combination of two or more.

[0071] In a release agent composition mainly composed of a silicone compound, the silicone compound may include a silicone compound having an organopolysiloxane as its basic structure. Other examples of the silicone compound include thermosetting silicone compounds such as addition reaction type and condensation reaction type; and energy ray curing silicone compounds such as ultraviolet curing type and electron beam curing type.

[0072] In a release agent composition mainly composed of a fluorine compound, examples of the fluorine compound include fluorosilicone compounds, fluorineboron compounds, and poly(perfluoroalkylene ether) chain-containing compounds.

[0073] In a release agent composition mainly composed of a long-chain alkyl group-containing compound, examples of the long-chain alkyl group-containing compound include polyvinyl carbamate obtained by reacting a long-chain alkyl isocyanate with a polyvinyl alcohol polymer, alkylurea derivatives obtained by reacting a long-chain alkyl isocyanate with polyethyleneimine, or copolymers of long-chain alkyl (meth)acrylates. Furthermore, a long-chain alkyl-modified alkyd resin may be used, which is obtained by a condensation reaction of a polyhydric alcohol and a polybasic acid using a long-chain fatty acid as a modifying agent.

[0074] Preferably, the release agent composition mainly composed of an energy-ray curable resin contains, for example, an energy-ray curable compound having a reactive functional group selected from (meth)acryloyl group, alkenyl group, and maleimide group, and a polyorganosiloxane. In the release agent layer formed by this release agent composition, since the energy-ray curable compound and polyorganosiloxane, which have different molecular structures, polarities, and molecular weights from each other, are used, components derived from the polyorganosiloxane segregate near the outer surface of the release agent layer before curing, and then the segregation is fixed by curing with energy rays. This improves the release properties of the release agent layer. The release agent composition mainly composed of an energy-ray curable resin may further contain a photopolymerization initiator.

[0075] Examples of release agent compositions mainly composed of thermosetting resins include release agent compositions mainly composed of melamine resin and release agent compositions mainly composed of epoxy resin. Examples of release agent compositions mainly composed of melamine resin include a composition containing melamine resin as the main component, an acid catalyst for thermosetting the melamine resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Examples of release agent compositions mainly composed of epoxy resin include a composition containing epoxy resin as the main component, an acid or basic thermosetting catalyst for thermosetting the epoxy resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Before curing, components derived from polyorganosiloxane segregate near the outer surface of the release agent layer, and then the segregation becomes fixed after curing. This improves the release properties of the release agent layer.

[0076] Furthermore, the coating layer may contain other additives in addition to the resin components mentioned above. Examples of other additives include anti-aging agents, light stabilizers, flame retardants, conductive agents, antistatic agents, and plasticizers.

[0077] The thickness of the coating layer can be selected as appropriate and is not particularly limited, but for example, it is preferably 0.02 μm to 5 μm, more preferably 0.03 μm to 2 μm, and even more preferably 0.05 μm to 1.5 μm.

[0078] The laminated films used in each embodiment are generally used to protect the surfaces of other functional sheets and various components used for specific applications during manufacturing, transportation, and storage. After fulfilling their protective role, they are often peeled off the surface and discarded. Therefore, by using the laminated film, the coating layer and the base film can be easily separated from the laminated film, making it a highly beneficial application from the standpoint of resource conservation and environmental protection. [Explanation of symbols]

[0079] 1...First roll, 4...First winding roll, 5...First adhesive roll, 10...First feeding means, 15...Contact means, 20...Stretching means, 21...First stretching roll, 22...Second stretching roll, 23...Peripheral speed control means, 24...Heating means, 25...Contact release means, 30...First removal means, 35...First blade, 36...First wire brush, 37...First blasting device, 40...First winding means, 50, 500...First laminated film, 51...First base film, 52, 520...First coating layer, 60...First adhesive sheet 60, 70...Steam blowing means, 72...Superheater, 74...Boiler, 100...Removal device, 600, 600B...Laminated structure, 600A...Stretched structure, 602...Crack.

Claims

1. A step of preparing a first roll around which a first laminated film having a first base film and a first coating layer is wound, and a second roll around which a second film is wound. A step of unwinding the first laminated film from the first roll, The process of unwinding the second film from the second roll, A step of bringing the side of the first coating layer of the unfurled first laminated film and one side of the unfurled second film into contact with each other, A step of stretching the first laminated film and the second film while they are in contact with each other, A step of releasing contact between the first laminated film and the second film, A first removal step of removing the first coating layer from the first laminated film from which contact has been released, The process includes a first winding step of winding the first base film, from which the first coating layer has been removed, into a roll shape. Method for removing the coating layer.

2. The first removal step is a step of transferring the first coating layer from the first substrate film to the first adhesive roll. A method for removing a coating layer according to claim 1.

3. The first removal step is a step of scraping off the first coating layer from the first substrate film using a first blade or a first wire brush. A method for removing a coating layer according to claim 1.

4. The first removal step is a step of scraping off the first coating layer from the first substrate film with a first blasting material. A method for removing a coating layer according to claim 1.

5. The stretching step is performed while heating the first laminated film and the second film. A method for removing a coating layer according to claim 1.

6. The process includes, after the step of releasing the contact and before the first removal step, a step of blowing superheated steam onto the first coating layer of the first laminated film from which the contact has been released. A method for removing a coating layer according to claim 1.

7. The aforementioned second film is a second laminated film, The second laminated film comprises a second substrate film and a second coating layer. The aforementioned contact step is a step of bringing the surface of the first laminated film on the side of the first coating layer and the surface of the second laminated film on the side of the second coating layer into contact with each other. After the step of releasing the contact, a second removal step is performed to remove the second coating layer from the second laminated film from which the contact has been released. The present invention further comprises a second winding step of winding the second substrate film, from which the second coating layer has been removed, into a roll shape. A method for removing a coating layer according to claim 1.

8. A step of further unwinding one or more third laminated films having a third base film and a third coating layer, A step of overlapping and bringing into contact one or more of the third laminated films, the first laminated film, and the second film, such that the surface of the third coating layer of the third laminated film is not positioned on the outside, A step of stretching the first laminated film, the second film, and one or more of the third laminated films while the first laminated film, the second film, and one or more of the third laminated films are in contact with each other, A step of releasing contact between the first laminated film, the second film, and one or more of the third laminated films after stretching, A third removal step of removing the third coating layer from one or more of the third laminated films from which contact has been released, The process includes a third winding step of winding the third base film, from which the third coating layer has been removed, into a roll shape. A method for removing a coating layer according to claim 1.

9. The first laminated film is a laminated film with a ceramic green sheet, A ceramic green sheet is attached to the side of the first coating layer opposite to the first substrate film. A method for removing a coating layer according to claim 1.

10. A first dispensing means for dispensing the first laminated film, which has a first base film and a first coating layer, from a first roll around which the first laminated film is wound, A second dispensing means for dispensing the second film from a second roll around which the second film is wound, A contact means for bringing the side of the first coating layer of the unfurled first laminated film and one side of the unfurled second film into contact with each other, A stretching means for stretching the first laminated film and the second film while the first laminated film and the second film are in contact with each other, A contact release means for releasing contact between the first laminated film and the second film, A first removal means for removing the first coating layer from the first laminated film from which contact has been released, The system comprises a first winding means for winding the first base film into a roll shape, A device for removing coating layers.

11. The first removal means comprises a first adhesive roll, and the first removal means is a means for transferring the first coating layer from the first substrate film to the first adhesive roll. Apparatus for removing a coating layer according to claim 10.

12. The first removal means comprises a first blade or a first wire brush capable of scraping off the first coating layer from the first substrate film. Apparatus for removing a coating layer according to claim 10.

13. The first removal means comprises a first blasting apparatus capable of scraping off the first coating layer from the first substrate film with a first blasting material. Apparatus for removing a coating layer according to claim 10.

14. The system further includes a means for spraying water vapor, The steam blowing means is a means for blowing superheated steam toward the first coating layer of the first laminated film from which contact has been released. Apparatus for removing a coating layer according to claim 10.

15. The stretching means includes a heating means for heating the first laminated film and the second film. Apparatus for removing a coating layer according to claim 10.

Images