Recycled material production device and regenerated material production system

Abstract

The present invention provides a recycled material production device that removes a functional layer from a laminated film comprising a base material film and the functional layer without degrading the physical properties of the base material film, and a regenerated material production system that uses the recycled material as a starting material. More specifically, the present invention relates to: a recycled material production device that is provided with a feed unit that feeds a laminated film comprising a base material film and a functional layer in one direction from a roll on which the laminated film is wound, a pretreatment unit that performs a pretreatment to facilitate removal of the functional layer without the use of an organic solvent, a removal unit that removes the functional layer, and a winding unit that winds the laminated film having the functional layer removed therefrom into a roll, wherein the removal unit has a cylindrical removal member that rotates while in contact with one surface of the laminated film and a support member that supports the laminated film from the surface on the opposite side from said one surface, the removal member is capable of swinging in the axial direction of the removal member, and the support member has an abrasion-resistant layer that protects at least both end portions of the support member in the width direction of the laminated film; and a regenerated material production system that produces a molded body using the obtained recycled material as a starting material.

Description

Recycled material manufacturing equipment and recycled material manufacturing system

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

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

[0003] Japanese Patent Application Publication No. 2021-160350

[0004] However, in the method described in Patent Document 1, the polyester constituting the polyester film may be swollen and deteriorated by benzyl alcohol used to remove the functional layer. Furthermore, the polyester constituting the polyester film may be hydrolyzed by the alkalizing agent used to remove the functional layer. Therefore, in the method described in Patent Document 1, the physical properties of the polyester film obtained as a recycled material may be deteriorated compared to the polyester film constituting the original laminate film, potentially limiting the uses of the recycled material.

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

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

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

[0008] [1] A recycled material manufacturing device comprising: a roll of a laminated film having a long, unidirectionally extending substrate film and at least one functional layer formed on one side of the substrate film; a payout unit that pays out the laminated film in the same direction from the roll; a pre-treatment unit that performs pre-treatment to promote removal of the functional layer without using an organic solvent; a removal unit that removes the functional layer; and a winding unit that winds up the laminated film from which the functional layer has been removed into a roll, wherein the removal unit comprises a cylindrical removal member that rotates in contact with one side of the laminated film and a support member that supports the laminated film from the side opposite the one side, the removal member being axially oscillating; and the support member having a wear-resistant layer that faces the removal member and protects at least both ends of the support member in the width direction of the laminated film. [2] The recycled material manufacturing device described in [1], wherein the wear-resistant layer is a chromium oxide layer. [3] The recycled material manufacturing device described in [1] or [2], wherein the support member is a backup roll. [4] The recycled material manufacturing device according to any one of [1] to [3], wherein the removal member is a buff roll, the removal unit has a plurality of the buff rolls, the plurality of buff rolls are arranged in the conveying direction of the laminated film, and the buff roll arranged most downstream of the plurality of buff rolls has a larger count than the other buff rolls. [5] The recycled material manufacturing device according to any one of [1] to [4], wherein the pre-treatment unit is a heating unit that heats the laminated film. [6] The recycled material manufacturing device according to [5], wherein the heating unit heats the laminated film in a vapor phase. [7] A recycled material manufacturing system comprising the recycled material manufacturing device according to any one of [1] to [6], and a molding device that melts and molds the recycled material manufactured by the recycled material manufacturing device.

[0009] According to the present invention, it is possible to provide a recycled material manufacturing device that can remove a functional layer from a laminate film having a base film and a functional layer without deteriorating the physical properties of the base film, and a recycled material manufacturing system that uses the obtained recycled material as a raw material to manufacture a molded product.

[0010] 1 is a schematic cross-sectional view showing a laminated film 5 to be processed in the recycled material manufacturing apparatus of the present embodiment. FIG. 2 is a schematic explanatory diagram of the recycled material manufacturing apparatus of the present embodiment. FIG. 3 is an explanatory diagram showing a modified example of the heating section. FIG. 4 is an explanatory diagram showing another modified example of the heating section. FIG. 5 is a cross-sectional view of a backup roll 331. FIG. 6 is a plan view of the backup roll 331 viewed from the +x direction. FIG. 7 is an enlarged photograph of a recycled material 1 obtained by the manufacturing apparatus 100. FIG. 8 is a schematic diagram showing a recycled material manufacturing system 1000 of the present embodiment. FIG. 9 is a schematic explanatory diagram showing a modified example of the recycled material manufacturing apparatus. FIG. 10 is a schematic explanatory diagram showing another modified example of the recycled material manufacturing apparatus.

[0011] The recycled material manufacturing apparatus and the recycled material manufacturing system according to this embodiment will be described below with reference to Figures 1 to 10. Note that in all the following figures, the dimensions and proportions of the components have been changed as appropriate to make the drawings easier to understand.

[0012] 1 is a schematic cross-sectional view showing a laminated film 5 to be processed in the recycled material manufacturing apparatus of this embodiment. The laminated film 5 has a base film 2 and a functional layer 3 provided on one surface 2a of the base film 2. As will be described in detail later, the functional layer 3 is the layer to be removed in the recycled material manufacturing apparatus of this embodiment.

[0013] 1 has the functional layer 3 only on one surface 2 a of the base film 2, but is not limited thereto. The laminate film 5 may have the functional layer 3 on both surfaces of the base film 2.

[0014] Furthermore, the layer (functional layer 3) to be removed from the laminate film 5 may be discretely arranged, such as dirt or partially printed paint. In other words, dirt or partially printed paint is included in the "functional layer 3" to be removed in the recycled material manufacturing device.

[0015] The base film 2 is a long resin film extending in one direction. Polyester can be used as the material of the resin film. Examples of polyester that can be used include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). In addition to these, any polyester that can be used as a film material can be appropriately used. These polyesters may be used alone or in combination of two or more types (polymer blend).

[0016] Examples of materials for the resin film include polyolefins such as polyethylene and polypropylene, and polyamides. Any other resins known as materials for resin films may be used as appropriate.

[0017] The functional layer 3 is provided on one surface 2a of the base film 2 and provides various functions to the base film 2. There are no particular limitations on the functional layer 3, and examples of the functional layer 3 include a peeling layer, a release layer, an antistatic layer, a printing layer, and an adhesive layer. One layer of the functional layer 3 may be provided on one surface 2a, or two or more layers may be laminated.

[0018] For example, when the functional layer 3 is a release layer, the functional layer 3 can be formed on one surface 2 a of the base film 2 using, for example, a silicone-based release agent as the material for the release layer. The laminate film 5 having such a functional layer 3 is used as a release film to be attached to the adhesive surface of a surface protection film for various industrial products. The laminate film 5 is also used as a carrier film when manufacturing ceramic chip capacitors.

[0019] Conventionally, laminate films used for these applications have been collected and discarded by manufacturers after use for each application has been completed. Furthermore, even if attempts are made to materially recycle or chemically recycle these laminate films, the value of the laminate film as a recycled raw material is reduced due to contamination with the material of the functional layer 3 (for example, a silicone-based release agent if the functional layer 3 is a release layer).

[0020] Furthermore, a method using alkali treatment is known as a method for removing the functional layer 3 from the laminate film 5 (see Patent Document 1 mentioned above). However, when the base film 2 is made of polyester, the polyester is hydrolyzed by the alkali treatment. As a result, the molecular weight of the polyester in the base film 2 obtained by removing the functional layer 3 may decrease, which may reduce the value of the base film 2 as a material.

[0021] Although the conventional problems have been explained using the example of a case where the functional layer 3 is a peelable layer, similar problems may occur even when recycling a laminated film having a functional layer 3 with other functions, namely, contamination with materials from the functional layer and a decrease in the value of the base film due to the process of removing the functional layer.

[0022] The recycled material manufacturing apparatus of this embodiment solves the above-mentioned problems, and makes it possible to easily remove the functional layer 3 from the laminated film 5 and obtain a recycled material made of the base film 2.

[0023] Fig. 2 is a schematic diagram of a manufacturing apparatus for recycled material according to this embodiment. The manufacturing apparatus 100 for recycled material (hereinafter referred to as manufacturing apparatus 100) shown in Fig. 2 includes a payout section 10, a heating section 20, a removal section 30, a cleaning section 40, a drying section 50, a winding section 60, and a control section 90. The manufacturing apparatus 100 is an apparatus for producing a recycled material made of a substrate film 2 by conveying a long laminate film 5 in the longitudinal direction and removing the functional layer during the conveyance process.

[0024] In FIG. 2, the horizontal direction, which is the transport direction of the laminated film 5, is the x direction, and the vertical direction is the y direction, and the relative positions will be described.

[0025] 2 shows that the laminated film 5 is transported in the x direction while undergoing each treatment within the transport path, but this is not limited to this. For example, a section within the transport path may be provided where the laminated film 5 is transported in the y direction, and each treatment may be performed at that section. This configuration makes it possible to shorten the overall length of the recycled material manufacturing device and reduce the installation area of ​​the device.

[0026] The basic components of the recycled material manufacturing apparatus 100 will be described below in order.

[0027] (Unwinding section) The unwinding section 10 unwinds the laminate film 5 in the longitudinal direction of the laminate film 5 from the roll 5R on which the laminate film 5 is wound. The operation performed in the unwinding section 10 corresponds to the "unwinding step" in the present invention. Examples of the roll 5R include a used release film or carrier film wound into a roll.

[0028] These laminate films are usually wound into a roll after use and collected from the place where they were used. The roll-shaped laminate film thus collected may be used as is as the roll 5R. Furthermore, if the width (length in the short direction) of the laminate film 5 constituting the roll 5R is wider than the width that can be processed by the manufacturing apparatus 100, the laminate film 5 may be slit in advance to adjust the width to form the roll 5R.

[0029] The laminated film 5 is transported with the functional layer 3 facing upward (+y side). The transport speed of the laminated film 5 is, for example, 1 m / min to 10 m / min.

[0030] (Heating section) The heating section 20 is provided downstream (+x side) of the feeding section 10 in the transport direction of the laminate film 5, and heats the transported laminate film 5. The processing performed in the heating section 20 corresponds to the "heating process" in the present invention. Heating the laminate film 5 in the heating section 20 is expected to promote the removal of the functional layer 3 in the removal section 30 described below. The heating section 20 performs a pretreatment that promotes the removal of the functional layer 3 without using an organic solvent. For this reason, the heating section 20 corresponds to the "pretreatment section" in the present invention.

[0031] The heating unit 20 has a treatment tank 21 in which hot water HW is stored. The treatment tank 21 may have a heater (not shown) that adjusts the temperature of the hot water HW, and a water supply pipe and a drainage pipe (neither of which are shown) connected to the treatment tank 21.

[0032] In the heating section 20, the laminated film 5 is transported using transport rolls 101, 102, and 103. Of these, the transport roll 102 is placed in the hot water HW of the treatment tank 21. As a result, the transported laminated film 5 passes through the hot water HW and is heated.

[0033] The temperature of the hot water HW may be set according to the type of laminate film to be processed, based on the correspondence between the heating temperature of the laminate film 5 after passing through the heating section 20 and the effect of removing the functional layer 3 in the removal section 30, which will be described later. The correspondence between the temperature of the hot water HW and the effect of removing the functional layer 3 may be determined in advance by a preliminary experiment.

[0034] The heating temperature of the laminate film 5 means the "temperature of the laminate film 5 at the outlet of the heating section 20." The heating temperature of the laminate film 5 can be measured by a known non-contact thermometer.

[0035] Furthermore, when the conveying speed of the laminated film 5 is relatively fast within the settable speed range, the time for passing the hot water HW is relatively short. Therefore, when the conveying speed is fast, it is advisable to increase the temperature of the hot water HW so that the desired heating can be achieved in a short time.

[0036] As an example, the temperature of the hot water HW is 40° C. to 90° C. It is preferable to use a treatment tank 21 in which the hot water HW is stored as the heating unit 20 and immerse the laminate film 5 in the hot water HW, since this allows the laminate film 5 to be heated effectively in a short time.

[0037] The heating method in the heating section 20 is not limited to wet heating in which the laminated film 5 comes into direct contact with a heat medium, such as immersing the laminated film 5 in the warm water HW described above, but "gas phase heating" in which the laminated film 5 is heated in the gas phase without coming into direct contact with a heat medium can also be used.

[0038] 3 and 4 are explanatory diagrams showing modified examples of the heating unit.

[0039] 3 heats the functional layer 3 by blowing hot air HA onto the laminate film 5 from above (the +y side) of the laminate film 5. A known heat gun or hot air heater can be used as the heating unit 25.

[0040] 4 irradiates the laminate film 5 with infrared rays IR from above (the +y side) of the laminate film 5, thereby heating the functional layer 3. As the heating unit 26, a known heater such as a halogen lamp or an infrared heater can be used.

[0041] The heating units 25 and 26 may be configured to heat the laminate film 5 from below (-y side) of the laminate film 5, or may be configured to heat the laminate film 5 from above and below the laminate film 5.

[0042] When the heating units 25 and 26 are employed, the heating temperature of the laminate film 5 means "the temperature of the laminate film 5 that overlaps with the downstream end of the heating unit when viewed from the normal direction of the laminate film 5." The heating temperature of the laminate film 5 can be measured using a known non-contact thermometer.

[0043] Alternatively, the vapor phase heating may be performed by passing through a heated environment using the laminated film 5. The "passing through a heated environment" may be performed by passing through a chamber whose interior is heated.

[0044] Of the above-mentioned configurations, "vapor phase heating" is preferred as the heating section. Vapor phase heating has the advantage of consuming less energy to maintain the temperature of the heating section compared to wet heating. Among vapor phase heating methods, a configuration that locally heats the laminated film 5 without using a chamber, such as the heating sections 25 and 26, is preferred. By employing the heating sections 25 and 26, the installation size can be reduced.

[0045] When these methods are employed as the heating section, it becomes possible to heat the laminated film 5 to a temperature higher than the boiling point of water.

[0046] The heating temperature in the heating section is, for example, 20°C to 250°C. The lower limit of the heating temperature is set to a temperature higher than the ambient temperature in which the recycled material manufacturing device of this embodiment is installed. For example, when the recycled material manufacturing device is used in winter or in cold regions, heating to 20°C may be considered heating. Furthermore, the upper limit of the heating temperature is set to a temperature lower than the melting point of the substrate film that constitutes the laminated film to be treated.

[0047] (Removal section) The removal section 30 is provided downstream of the heating section 20 in the transport direction of the laminate film 5, and removes the functional layer 3 from the transported laminate film 5. The process performed in the heating section 20 corresponds to the "removing step" in the present invention. The removal section 30 has a first removal means 30A and a second removal means 30B.

[0048] The first removing means 30A has nip rolls 31 and 32, a buff roll (removing member) 33, a backup roll (supporting member) 331, and a water spraying means .

[0049] The nip roll 31 has rolls 311 and 312. The nip roll 31 conveys the laminated film 5 while sandwiching it between the rolls 311 and 312.

[0050] The nip roll 32 has rolls 321 and 322. The nip roll 32 is provided downstream of the nip roll 31, and the laminated film 5 is sandwiched between the rolls 321 and 322 and transported.

[0051] The buff roll 33 is a cylindrical member provided between the nip rolls 31 and 32, and rotates around the axis of the cylinder. The axial length of the buff roll 33 is longer than the width direction length of the transported laminate film 5. The buff roll 33 is disposed so as to intersect with and straddle the laminate film 5, and while rotating, is pressed against the one surface 2a of the laminate film 5 from above (the +y side). In this way, the buff roll 33 polishes and physically peels off the functional layer 3 provided on the one surface 2a.

[0052] The buff roll 33 oscillates in the axial direction of the cylinder, i.e., in the width direction of the laminated film 5. The buff roll 33 has an oscillating unit that oscillates the buff roll 33 in the width direction of the laminated film 5 while rotating. The oscillating unit can appropriately set the oscillation width and oscillation period of the buff roll 33.

[0053] The rotation direction of the buff roll 33 at the point of contact with the laminate film 5 may be the same as the transport direction of the laminate film 5 (forward rotation), or may be the opposite direction (reverse rotation) to the transport direction of the laminate film 5. When the buff roll 33 is set to rotate in the reverse direction, the effect of removing the functional layer 3 can be enhanced.

[0054] Furthermore, when the buff roll 33 rotates in the forward direction, the laminated film 5 is sent out in the transport direction, and it is expected that the film transport speed will be faster than the set film transport speed. Therefore, when the buff roll 33 is rotated in the forward direction, it is advisable to adjust the film transport speed so as not to exceed the winding speed of the winding section 60.

[0055] The buff roll 33 is a cylindrical member made of nonwoven fabric containing an abrasive. The buff roll 33 can be made of natural fibers such as cotton or linen, or synthetic fibers such as polyester or nylon. The material and particle size of the abrasive contained in the buff roll 33 can be selected appropriately depending on the configuration (material and thickness) of the functional layer 3 to be removed.

[0056] The rotation speed of the buff roll 33 may be set according to the type of laminated film to be processed, based on the correspondence between the rotation speed and the effect of removing the functional layer 3. The correspondence between the rotation speed and the effect of removing the functional layer 3 may be determined in advance through a preliminary experiment.

[0057] Fig. 5 is a cross-sectional view of the backup roll 331. As shown in Fig. 5, the backup roll 331 has a roll body 331a and an abrasion-resistant layer 331b provided on the surface (side surface) of the roll body 331a, which is a curved surface facing the buff roll 33.

[0058] The backup roll 331 is a cylindrical member that rotates freely around the axis of the cylinder. The axial length of the backup roll 331 is longer than the width direction length of the transported laminate film 5. The backup roll 331 is provided parallel to the buff roll 33 below the position where the buff roll 33 and the laminate film 5 contact each other (the opposite side of the laminate film 5 from the buff roll 33; the -y side). In other words, the backup roll 331 is positioned across the laminate film 5, intersecting the laminate film 5 (orthogonal in the drawing), and supports the laminate film 5 from below. This prevents the laminate film 5 from bending due to the pressure from the buff roll 33, allowing the functional layer 3 to be efficiently removed.

[0059] There is no limitation on the material of the roll body 331a, and any material used for known backup rolls can be used.

[0060] The wear-resistant layer 331b is formed of a material harder than the material forming the roll body 331a. For example, a thermally sprayed film made of chromium oxide can be used as the wear-resistant layer 331b. Furthermore, the material of the wear-resistant layer 331b can be a material having a hardness equal to or greater than that of chromium oxide (for example, a Mohs hardness of 6 or more (Vickers hardness of HV650 or more)). It is more preferable that the material of the wear-resistant layer 331b has a Vickers hardness of HV900 or more.

[0061] Furthermore, when the material of the roll body 331a is iron or an alloy containing iron, the wear-resistant layer 331b may be a film of iron carbonitride formed on the surface of the roll body 331a by subjecting the roll body 331a to gas soft nitriding treatment.

[0062] 6 is a plan view of the backup roll 331 viewed from the +x direction. As described above, the buff roll 33 oscillates in the width direction of the laminate film 5 (the direction of symbol X), and therefore the portion α of the backup roll 331 that does not overlap with the laminate film 5 in plan view comes into contact with the buff roll 33 and is polished. At this time, the backup roll 331 is provided with an abrasion-resistant layer 331b on its surface, so that it is less likely to deteriorate due to polishing by the buff roll 33, and has a long life.

[0063] In addition, the backup roll 331 does not need to have the wear-resistant layer 331b on the entire side surface thereof, as long as the wear-resistant layer 331b is provided on at least the portion α and is configured to protect at least both axial ends of the roll body 331a.

[0064] The pressure applied by the buff roll 33 to the laminate film 5 can be adjusted by the height position of the central axis of the buff roll 33. That is, the height position of the central axis of the buff roll 33 that contacts without pressing the laminate film 5 when supported without slack by the nip rolls 31 and 32 is set as the reference position, and the pressure can be adjusted by the distance the central axis moves when the buff roll 33 is lowered. The pressure can be set according to the type of laminate film to be treated, based on the correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3. The correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3 can be determined in advance by a preliminary experiment.

[0065] When the buff roll 33 presses down on the laminate film 5, a strong pressure is applied to the laminate film 5 from the buff roll 33, and a force is likely to be applied according to the rotation direction of the buff roll 33. When the buff roll 33 rotates forward, a force is applied that pushes the laminate film 5, which is located downstream of the buff roll 33, further downstream. This may cause the laminate film 5 to sag downstream, resulting in uneven processing and difficulty in winding in the winding section 60, which will be described later.

[0066] Furthermore, when the buff roll 33 rotates in the reverse direction, a force is applied that pulls the laminate film 5, which is located downstream of the buff roll 33, back upstream. If the pressure applied to the laminate film 5 from the buff roll 33 is increased, the resulting "pull-back force" becomes stronger than the force that is applied to the laminate film 5 by the winding section 60, which will be described later, to the downstream side, and the laminate film 5 may run in the reverse direction, preventing processing from proceeding.

[0067] In such cases, by adjusting the holding force of the laminated film 5 by the nip rolls 31, 32, the laminated film 5 can be held tightly between the nip rolls 31, 32, and the laminated film 5 can be prevented from moving backward even if high pressure is applied from the buff roll 33.

[0068] The nip rolls 31 and 32 feed the laminate film 5 downstream at the same speed as the winding speed of the winding unit 60. Because the laminate film 5 is fed downstream using the winding unit 60 and the nip rolls 31 and 32, a difference in transport speed occurs between the winding unit 60 and the nip rolls 31 and 32, which may cause slack in the laminate film 5 downstream of the nip roll 32. For this reason, a dancer roll may be provided downstream of the nip roll 32 to make it possible to adjust the tension of the laminate film 5.

[0069] The support member may be the backup roll described above, or may be a support plate that supports the laminate film 5 from below the laminate film 5. In this case, the support member is a portion that faces the buff roll (removal member) and has an abrasion-resistant layer that protects at least both ends of the support plate in the width direction of the laminate film 5. Even with such a configuration, the effects of the invention can be achieved.

[0070] The water spraying means 34 sprays water onto the upper surface (+x side) of the laminate film 5 from the upstream side (-x side) of the contact point between the buff roll 33 and the laminate film 5. The buff roll 33 polishes the surface of the laminate film 5 while the surface is wet. The water spraying means 34 suppresses frictional heat at the contact point between the buff roll 33 and the laminate film 5, and also washes away fine shavings (polishing debris) generated by polishing.

[0071] The configuration of the water spraying means 34 is not particularly limited, and for example, a known shower head capable of spraying water in the width direction of the laminated film 5 can be used.

[0072] The water W to be sprayed may be at room temperature or may be hot water, for example, at a temperature of 30°C to 40°C.

[0073] The second removing means 30B has nip rolls 35 and 36, a buff roll (removing member) 37, a backup roll 371, and a water spraying means 38. The nip roll 35 has rolls 351 and 352. The nip roll 36 has rolls 361 and 362. The nip rolls 35 and 36, the backup roll 371, and the water spraying means 38 can have the same configuration as those of the first removing means 30A.

[0074] The buff roll 37 is arranged in the transport direction of the laminated film 5 together with the buff roll 33 described above. The buff roll 37 may be the same as or different from the buff roll 33 of the first removing means 30A. The operating conditions of the buff roll 37 may be the same as or different from those of the buff roll 33.

[0075] 2, the removal unit 30 has the first removal means 30A and the second removal means 30B, but is not limited to this. The removal unit 30 can have one or more removal means, each of which has the same configuration as the first removal means 30A (nip roll, buff roll, and water spray means). The removal unit 30 preferably has a plurality of removal means, and preferably has, for example, two to four removal means.

[0076] When the removal unit 30 has multiple buff rolls, it is preferable that the buff roll located most downstream among the multiple buff rolls has a larger grit size than the other buff rolls, thereby enabling efficient removal of the functional layer 3. For example, it is preferable that the grit size of the upstream buff roll is 240 and the grit size of the most downstream buff roll is 600.

[0077] In this embodiment, a buff roll is used as the removal member, but other configurations can be used as long as they can peel off the functional layer. For example, a cylindrical rotating brush, a rubber roll, or a grindstone can also be used as the removal member.

[0078] The removal member is preferably configured to rotate while contacting the functional layer, thereby applying friction at the contact point and removing the functional layer. The rotation axis of the removal member is preferably set in a direction intersecting the conveyance direction of the laminate film 5. In the manufacturing apparatus 100 of Figure 2, the buff rolls 33 and 37, which are removal members, are both set in a direction perpendicular to the conveyance direction of the laminate film 5, but the angles of the rotation axes of the multiple buff rolls (removal members) relative to the conveyance direction of the laminate film may be the same or different.

[0079] (Cleaning section, drying section) The laminated film 5 (i.e., the base film 2) from which the functional layer 3 has been removed in the removal section 30 is transported downstream using transport rolls 104, 105, 106, and 107. The manufacturing apparatus 100 has a cleaning section 40 and a drying section 50, in this order, downstream of the removal section 30.

[0080] The cleaning unit 40 has a water spraying means 41 provided above the transported base film 2, and washes the upper surface (side 2a) of the laminate film 5 after the functional layer 3 has been removed with water. The water spraying means 41 sprays water onto the upper surface of the laminate film 5. There are no particular limitations on the configuration of the water spraying means 41, and for example, a known shower head capable of spraying water in the width direction of the laminate film 5 can be used.

[0081] The drying section 50 includes, in order from the upstream side, a squeegee (dewatering section) 51 and a hot air blower 52. The squeegee 51 contacts one surface 2a of the base film 2 and drains water from the surface 2a. The squeegee 51 is preferably longer than the width of the base film 2. The squeegee 51 also preferably intersects the base film 2 obliquely in a plan view.

[0082] An air knife may also be used as the dewatering unit. The air knife blows compressed air toward one surface 2a of the base film 2 to remove water from the one surface 2a. The blowing direction of the compressed air is preferably inclined toward the upstream side relative to the one surface 2a.

[0083] The hot air blower 52 blows hot air H toward the first surface 2a of the base film 2 to dry the first surface 2a. The temperature of the hot air H is, for example, 50°C to 70°C.

[0084] (Winding Section) The winding section 60 winds the transported base film 2 (i.e., the recycled material 1) into a roll. The roll 1R wound by the winding section 60 is used as a raw material for material recycling or chemical recycling.

[0085] In addition, if the laminated film to be processed has functional layers formed on both sides of the base film, the laminated film can be passed through the manufacturing apparatus 100 twice and the functional layers removed from both sides of the base film to obtain recycled material.

[0086] (Control Unit) The control unit 90 controls the operating conditions of each component of the manufacturing apparatus 100. The control unit 90 may store the correspondence between the type of laminate film 5 to be processed and the operating conditions of each component, so that the appropriate operating conditions can be retrieved and changed each time the type of laminate film 5 to be processed is changed.

[0087] For example, when the functional layer of the laminate film 5 is a release layer, a silicone-based release agent is applied to the entire surface of the laminate film 5. In this case, the buff roll pressed against the functional layer may slip on the surface of the functional layer (release layer), preventing removal. In this case, it is necessary to press the buff roll firmly against the laminate film.

[0088] Furthermore, when the functional layer is a printed layer, the ease of removal of the functional layer varies depending on the printing conditions, such as whether it is monochromatic or multicolored, whether it has a base coat (overcoat), and the type of ink used.

[0089] Therefore, it is necessary to set appropriate operating conditions according to the type of laminate film 5 to be processed, i.e., the type of functional layer. On the other hand, when recycling laminate films, it is expected that laminate films with the same configuration will be repeatedly processed. Therefore, by storing in the control unit 90 the correspondence between the type of laminate film 5 and the operating conditions of each unit, it becomes easy to switch the object to be processed.

[0090] As described above, in the manufacturing apparatus 100, the functional layer 3 is physically peeled off using the buff rolls 33, 37. That is, in the above-described manufacturing apparatus 100, the laminated film 5 does not come into contact with organic solvents from the unwinding section 10 to the winding section 60, i.e., from the unwinding process to the winding process. This makes it possible to suppress deterioration and swelling of the recycled material 1, and to produce the recycled material 1 by removing the functional layer 3 from the laminated film 5 without degrading the physical properties of the base film 2. Furthermore, the environmental impact of producing the recycled material 1 can be reduced.

[0091] Furthermore, in the manufacturing apparatus 100, the removal unit has backup rolls 331, 371, and the buff rolls 33, 37 are oscillated to facilitate removal of the functional layer 3. At this time, a wear-resistant layer is provided on the surface of the backup rolls 331, 371, which prevents the surface of the backup roll from being polished by the buff roll and thereby preventing the backup roll from being deteriorated.

[0092] Furthermore, in the manufacturing apparatus 100, the laminated film 5 is not brought into contact with an alkaline solution. As a result, when the material of the base film 2 is polyester, hydrolysis of the base film 2 can be suppressed, and the functional layer 3 can be removed from the laminated film 5 without deteriorating the physical properties of the base film 2, thereby producing the recycled material 1.

[0093] In this embodiment, the term "alkaline solution" refers to a solution having a pH greater than 8. Weakly basic solutions having a pH of 7 to 8 are not included in the alkaline solution in this embodiment. In this respect, for example, the water W sprayed from the spraying means in the removal unit 30 may contain a small amount of surfactant to the extent that the effect of the invention is not impaired.

[0094] (Recycled Material) Fig. 7 is an enlarged photograph of the recycled material 1 obtained by the manufacturing apparatus 100. The recycled material 1 is made of a polyester substrate film 2 from which the functional layer 3 has been removed.

[0095] In the figure, the direction indicated by the symbol A is the width direction of the laminate film, and the direction indicated by the symbol B is the longitudinal direction of the laminate film. As shown in Fig. 7, one surface 2a of the base film 2 has a plurality of grooves extending in the longitudinal direction. In Fig. 7, the grooves are confirmed as white streaks. The grooves are scratches formed by the buff roll described above.

[0096] When the recycled material 1 is made of polyester, the intrinsic viscosity (IV value) of the polyester constituting the recycled material 1 (substrate film 2) is 0.5 dL / g or more. The intrinsic viscosity of the polyester constituting the substrate film 2 is preferably 0.55 dL / g or more, more preferably 0.6 dL / g or more.

[0097] The intrinsic viscosity of the film (substrate film, recycled material) can be measured by a method in accordance with JIS K 7390.

[0098] Generally, in a laminate film 5 used as a release film or a carrier film, the intrinsic viscosity of the base film 2 is about 0.6 dL / g. If an alkaline solution (basic substance) is used to remove the functional layer 3 from such a laminate film 5, the base film 2 may be hydrolyzed, resulting in a decrease in the intrinsic viscosity.

[0099] For example, when molding a film, the intrinsic viscosity of the polyester material is approximately 0.6 dL / g, and when spinning fibers, the intrinsic viscosity is approximately 0.5 dL / g. Therefore, when using recycled materials obtained from laminated films as materials for chemical recycling or material recycling, the recycled materials must have the intrinsic viscosity of the molded products.

[0100] In contrast, in the recycled material manufacturing apparatus of the present embodiment, the laminated film 5 does not come into contact with the alkaline solution as described above, and therefore the intrinsic viscosity of the polyester in the resulting recycled material 1 is not reduced, making it suitable for use as a material for chemical recycling or material recycling.

[0101] The phrase "without a decrease" means that a decrease in intrinsic viscosity within the range of measurement error is permitted.

[0102] Furthermore, the recycled material 1 may be made of a resin other than polyester, which is exemplified as a material for the resin film.

[0103] The obtained recycled material can be melted and molded to produce a regenerated material.

[0104] 8 is a schematic diagram showing a recycled material manufacturing system 1000 of this embodiment. The recycled material manufacturing system 1000 has the above-mentioned recycled material manufacturing apparatus 100 and a molding apparatus 500 that melts and molds the above-mentioned recycled material (substrate film 2). The recycled material manufacturing system 1000 may have, as the molding apparatus 500, a re-pelletizing unit that re-pellets the recycled material and a molding unit that molds the target object. Examples of recycled materials include the above-mentioned films and fibers.

[0105] According to the recycled material manufacturing device configured as described above, the functional layer can be removed from a laminated film of a base film and a functional layer without degrading the physical properties of the base film, and recycled material can be produced that can be suitably used as a material for chemical recycling or material recycling.

[0106] Furthermore, in the recycled material manufacturing system configured as described above, the recycled materials are used as raw materials, which reduces the environmental impact and makes it possible to contribute to a recycling-oriented society.

[0107] 9 and 10 are schematic explanatory diagrams showing modified examples of the recycled material manufacturing apparatus.

[0108] 9, in a manufacturing apparatus 150 for recycled materials (hereinafter referred to as manufacturing apparatus 150), a payout unit 10 pays out laminate film 5 from two rolls 5R in the longitudinal direction of laminate film 5. For example, payout unit 10 pays out laminate film 5 from roll 5RA, and immediately after payout from roll 5RA is completed, payout from roll 5RB begins.

[0109] In the manufacturing apparatus 150, the roll 5RA is replaced with a new roll while the roll 5RB is being unwound. The roll replacement may be performed manually by an operator or an administrator of the manufacturing apparatus 150, or may be performed automatically by the manufacturing apparatus 150.

[0110] The manufacturing apparatus 150 has a connection unit 80 that connects the laminate film 5A unwound from the roll 5RA and the laminate film 5B unwound from the roll 5RB within the transport path between the unwinding unit 10 and the heating unit 20. The connection unit 80 connects the rear end of one laminate film (e.g., laminate film 5A) to the front end of the other laminate film (e.g., laminate film 5B), and has the function of combining the two laminate films 5 unwound from the two rolls 5R into one.

[0111] The manufacturing apparatus 150 also has a dividing section 85 that divides the transported recycled material 1 into two recycled materials 1A and 1B in the longitudinal direction between the hot air blower 52 (drying section 50) and the winding section 60. The dividing section 85 may divide the recycled material 1 into two recycled materials 1A and 1B at a location corresponding to the location where the laminated film 5A and the laminated film 5B are joined, or may divide the recycled material 1 at any location.

[0112] The unwinding section 10 and the connecting section 80 may be implemented by, for example, a known turret unwinder.

[0113] The winding section 60 and the dividing section 85 may be implemented by, for example, a known turret winding machine.

[0114] The winding unit 60 alternately winds the recycled material 1 onto two rolls 1RA and 1RB. For example, the winding unit 60 winds the recycled material 1A onto the roll 1RA, and then switches to winding onto the roll 1RB once the set amount of winding onto the roll 1RA has been reached.

[0115] The roll replacement may be performed manually by an operator or a manager of the manufacturing apparatus 150, or may be performed automatically by the manufacturing apparatus 150.

[0116] The control unit 90 controls the connection unit 80 and the division unit 85, and can continuously perform the unwinding of the laminated film 5 and the winding of the recycled material 1. This allows the manufacturing apparatus 150 to operate continuously.

[0117] As shown in FIG. 10, in the removal section 30 of the manufacturing apparatus 150 , the water spraying means 34 may include a wastewater tank 341 , a filter 342 , piping 343 , a pump 344 , and a shower head 345 .

[0118] The waste water tank 341 is located below the buff roll 33 and receives and stores the waste water WW generated at the contact point between the buff roll 33 and the laminated film 5 .

[0119] The filter 342 removes solid matter (polishing debris) contained in the wastewater WW.

[0120] The pipe 343 connects the wastewater tank 341, the filter 342, and the shower head 345. The wastewater WW from which solids have been removed is supplied to the shower head 345 via the pipe 343 by a pump 344 arranged in the path of the pipe 343.

[0121] The shower head 345 sprays water W, which has been obtained by removing solids from wastewater WW, onto the buff roll 33.

[0122] Similarly, in the removal unit 30, the water spraying means 38 may include a wastewater tank 381, a filter 382, ​​piping 383, a pump 384, and a shower head 385. The components of the water spraying means 38 may be the same as those of the water spraying means 34.

[0123] The water sprinkler means 34, 38 may also be equipped with a heating device that heats the water flowing through the piping.

[0124] By providing the manufacturing apparatus 150 with the above-described water spraying means, it becomes possible to recycle the water sprayed onto the buff rolls, thereby reducing the amount of wastewater and the environmental load.

[0125] By using the recycled material manufacturing device of this embodiment, for example, it is possible to recover used release films and remove the functional layer from the recovered release films to produce recycled materials. Furthermore, the obtained recycled materials can be melt-processed to produce a base film as a recycled material, and a release layer (functional layer) can be formed on one side to regenerate and reuse the release film. In this way, the present invention can contribute to a recycling-oriented society.

[0126] While the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to these embodiments. The shapes and combinations of the components shown in the above-described embodiments are merely examples, and various modifications can be made based on design requirements, etc., without departing from the spirit of the present invention.

[0127] 1, 1A, 1B... recycled material, 2... base film, 2a... one side, 3... functional layer, 5, 5A, 5B... laminated film, 10... feeding section, 20, 25, 26... heating section, 30... removal section, 33, 37... buff roll (removal member), 60... winding section, 100, 150... recycled material manufacturing apparatus, 331, 371... backup roll (support member), 331b... wear-resistant layer, 500... molding device, 1000... recycled material manufacturing system, α... part

Claims

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

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

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

5. The recycling material manufacturing device according to claim 1, wherein the pre-treatment section is a heating section that heats the laminated film. 　 The recycling material manufacturing device according to claim 5 , wherein the heating section heats the laminated film in a gas phase. 　 The recycling material manufacturing apparatus according to any one of claims 1 to 6, A recycled material manufacturing system having a molding device that melts and molds the recycled material produced by the recycled material manufacturing device.

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