Device and method for producing multilayered article, and multilayered article

Abstract

A device for producing a multilayered article having a base material and a functional layer provided on one surface of the base material, the device comprising: a conveyance device for continuously conveying the base material along a conveyance path; a coating device for applying a coating liquid to one surface of the conveyed base material to form a coating layer; and a drying device for drying the coating layer The conveyance device has a first conveyance unit for conveying the base material from the coating device to the drying device. The first conveyance unit includes a conveyance member (A) for conveying the base material by bringing air into contact with the surface of the base material on the opposite side from the surface on which the coating layer is formed.

Description

Apparatus and method for manufacturing multilayered structures, and multilayered structures

[0001] This invention relates to a manufacturing apparatus and method for multilayered materials, as well as to multilayered materials themselves.

[0002] For example, a common method for forming a functional layer on a substrate such as a long resin film, metal foil, or paper involves continuously transporting the substrate from upstream to downstream along a transport path, applying a coating liquid containing a functional material using a coating device installed along the transport path, forming a coating layer on the substrate, and then curing it by drying or other means to form the functional layer.

[0003] Conventionally, a widely used method for conveying substrates involves bringing the substrate into contact with the surface of a conveying roll and feeding it in the conveying direction. Another method for conveying substrates involves using a levitation conveying device that supports the substrate in a non-contact state by spraying gas toward one side of the substrate, thereby conveying the substrate in a non-contact state relative to the device (for example, Patent Documents 1 to 6).

[0004] Japanese Utility Model Publication No. 01-156775, Japanese Patent Publication No. 05-31430, Japanese Patent Publication No. 02-300051, Japanese Patent Publication No. 2003-293297, Japanese Patent Publication No. 2011-056335, Japanese Patent Publication No. 2014-189357

[0005] Incidentally, in methods for forming functional layers using coating techniques, further quality improvements are required, specifically the formation of functional layers with greater uniformity of thickness. One possible method for forming functional layers with high uniformity of thickness is to uniformly apply the coating liquid, but even when adjusting the coating conditions to form a highly homogeneous coating layer, it is not always possible to obtain a functional layer with the desired uniformity of thickness.

[0006] This invention was made in view of the above circumstances, and aims to provide a manufacturing apparatus and method for a multilayer material that can form a functional layer with good thickness uniformity, as well as a multilayer material having a functional layer with good thickness uniformity.

[0007] The inventors of the present invention conducted extensive research to solve the above problems and discovered that when transporting the substrate from the coating apparatus to the drying apparatus, contact between the substrate and the transporting device, such as a transport roll, deteriorates the surface quality of the coating layer, and that this is due to heat transfer between the substrate and the transporting device. Therefore, the inventors of the present invention found that the above problems could be solved by insulating the space between the substrate and the transporting device with air, and thus completed the present invention.

[0008] The present invention includes the following: <1> A manufacturing apparatus for a multilayer material having a base material and a functional layer provided on one surface of the base material, comprising: a conveying device for continuously conveying the base material along a conveying path; a coating device for applying a coating liquid to one surface of the conveyed base material to form a coating layer; and a drying device for drying the coating layer, wherein the conveying device has a first conveying section for conveying the base material from the coating device to the drying device, and the first conveying section includes a conveying member (A) for conveying the base material by bringing air into contact with the surface of the base material opposite to the surface on which the coating layer is formed. <2> The manufacturing apparatus for a multilayer material according to <1>, wherein the conveying member (A) is a levitation conveying device, and the levitation conveying device includes a support, and air is ejected from the surface of the support to provide an air layer between the surface of the support and the base material, thereby supporting the base material without contact. <3> The multilayer manufacturing apparatus according to <2>, wherein the pressure of the air supplied to the support of the levitation conveying apparatus is 0.2 MPa or more and 0.5 MPa or less. <4> The flow rate of the air supplied to the support of the levitation conveying apparatus is 0.5 ml / cm² per second. ２ Above 10 ml / cm² ２The apparatus for manufacturing a multilayer material according to <2> or <3>, which is as follows: <5> The apparatus for manufacturing a multilayer material according to any one of <2> to <4>, wherein the support of the floating conveying device includes a porous body. <6> The apparatus for manufacturing a multilayer material according to <5>, wherein the porous body includes ceramics. <7> The apparatus for manufacturing a multilayer material according to <5> or <6>, wherein the average pore size of the porous body is 0.3 μm or more and 5 μm or less. <8> The apparatus for manufacturing a multilayer material according to any one of <2> to <7>, wherein the temperature of the air ejected from the surface of the support of the floating conveying device is within ±2°C of the ambient temperature in which the coating apparatus is placed. <9> The apparatus for manufacturing a multilayer material according to <1>, wherein the conveying member (A) has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts to allow air to come into contact with the surface of the substrate opposite to the surface on which the coating layer is formed. <10> The apparatus for manufacturing a multilayer material according to any one of <1> to <9>, wherein the transport member (A) has a structure that can bend the transport direction of the substrate in the transport path. <11> A method for manufacturing a multilayer material having a substrate and a functional layer provided on one side of the substrate, comprising: a coating step of applying a coating liquid to one side of the substrate which has been continuously transported along a transport path to form a coating layer; a drying step of drying the coating layer; and a first transport step of transporting the substrate before the drying step by bringing air into contact with the side of the substrate opposite to the side on which the coating layer has been formed. <12> The method for manufacturing a multilayer material according to <11>, wherein in the first transport step, the substrate is transported using a levitation transport device, the levitation transport device includes a support, and air is ejected from the surface of the support to provide an air layer between the surface of the support and the substrate, thereby supporting the substrate without contact. <13> The method for manufacturing a multilayer material according to <12>, wherein the pressure of the air supplied to the support of the flotation conveying device is 0.2 MPa or more and 0.5 MPa or less. <14> The flow rate of the air supplied to the support of the flotation conveying device is 0.5 ml / cm² per second. ２ Above 10 ml / cm² ２The method for manufacturing a multilayered material according to <12> or <13>, which is as follows: <15> The method for manufacturing a multilayered material according to any one of <12> to <14>, wherein the support of the flotation conveying device includes a porous body. <16> The method for manufacturing a multilayered material according to <15>, wherein the porous body includes ceramics. <17> The method for manufacturing a multilayered material according to <15> or <16>, wherein the average pore size of the porous body is 0.3 μm or more and 5 μm or less. <18> The method for manufacturing a multilayered material according to any one of <12> to <17>, wherein the temperature of the air ejected from the surface of the support of the flotation conveying device is within ±2°C of the ambient temperature in which the coating process is carried out. <19> The method for manufacturing a multilayered material according to <11>, wherein in the first transport step, the substrate is transported using a transport member (a), the transport member (a) has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts for bringing air into contact with the surface of the substrate opposite to the surface on which the coating layer is formed. <20> The method for manufacturing a multilayered material according to any one of <11> to <19>, wherein the first transport step includes bending the transport direction of the substrate in the transport path. <21> A multilayered material manufactured by the method for manufacturing a multilayered material according to any one of <11> to <20>.

[0009] According to the present invention, it is possible to provide a manufacturing apparatus and method for a multilayer material that can form a functional layer with good thickness uniformity, as well as a multilayer material having a functional layer with good thickness uniformity.

[0010] Figure 1 is a schematic side view showing an example of a multilayer manufacturing apparatus according to the first embodiment of the present invention. Figure 2 is a schematic perspective view showing an example of a levitation conveying device (conveying member (A)) used in the first embodiment. Figure 3 is a schematic side view showing an example of a multilayer manufacturing apparatus according to the second embodiment of the present invention. Figure 4 is a schematic diagram of an example of a conveying member (a) (conveying member (A)) used in the second embodiment, viewed from the conveying surface side.

[0011] The present invention will be described in detail below with reference to embodiments and examples. However, the present invention is not limited to the embodiments and examples shown below, and can be modified and implemented as appropriate without departing from the scope of the claims and equivalents of the present invention. The components of the embodiments shown below can be combined as appropriate. In addition, in the figures, the same reference numerals are used for the same components, and their descriptions may be omitted.

[0012] In the following description, "long" base material refers to a base material having a length of five times or more its width, preferably ten times or more, and specifically refers to a base material that is long enough to be rolled up for storage or transport. The upper limit of the ratio of length to width of the base material is not particularly limited, but for example, it may be 100,000 times or less.

[0013] <1. Overview of Manufacturing Apparatus and Manufacturing Method for Multilayered Materials> A manufacturing apparatus according to one embodiment of the present invention is a manufacturing apparatus for a multilayered material having a base material and a functional layer provided on one side of the base material, comprising: a conveying device that continuously conveys the base material along a conveying path; a coating device that applies a coating liquid to one side of the conveyed base material to form a coating layer; and a drying device that dries the coating layer, wherein the conveying device has a first conveying section that conveys the base material from the coating device to the drying device, and the first conveying section includes a conveying member (A) that conveys the base material by bringing air into contact with the side of the base material opposite to the side on which the coating layer is formed.

[0014] Furthermore, a manufacturing method according to one embodiment of the present invention is a method for manufacturing a multilayered material as described above, comprising: a coating step of applying a coating liquid to one surface of a substrate that has been continuously conveyed along a conveying path to form a coating layer; a drying step of drying the coating layer; and a first conveying step of conveying the substrate by bringing air into contact with the surface of the substrate opposite to the surface on which the coating layer has been formed, before the drying step. The method for manufacturing a multilayered material can usually be carried out by the multilayered material manufacturing apparatus described above.

[0015] In the following explanation, the side of the substrate on which the coating layer is formed may be referred to as the "coating layer side," and the side of the substrate opposite to the side on which the coating layer is formed may be referred to as the "back side."

[0016] According to the present invention, by having a conveying member (A) in the first conveying section of the conveying device, heat transfer between the substrate and the conveying device due to contact between the substrate and the conveying device can be suppressed from the time the substrate on which the coating layer is formed is dried in the drying device. Therefore, deterioration of the surface quality of the coating layer due to heat transfer can be suppressed, and the coating layer can be dried in a state with good surface quality, making it possible to manufacture a multilayer material with good thickness uniformity of the functional layer.

[0017] The mechanism by which the effects of the present invention are obtained is not clear, but the inventors surmise it to be as follows. However, the technical scope of the present invention is not limited to the mechanism shown below.

[0018] In methods for forming functional layers using coating techniques, the solvent in the coating layer typically evaporates immediately after the coating liquid is applied to the substrate to form the coating layer. As a result, the substrate with the coating layer is cooled by the latent heat of evaporation, and the substrate temperature may become lower than the temperature of the environment in which the manufacturing equipment is located. When the substrate, cooled by latent heat, comes into contact with the conveying equipment in the manufacturing equipment, heat transfer occurs between the two, causing the substrate temperature to rise and the conveying equipment temperature to fall. In particular, since materials with high thermal conductivity, such as stainless steel, iron, and aluminum, are often used for components such as conveying rolls in conventional conveying equipment, it is thought that heat transfer occurs even with slight contact between the continuously conveyed substrate and the conveying equipment. Furthermore, differences in surface roughness of the contact area between the substrate and the conveying equipment, as well as the surface pressure and contact time of the contact area, are also thought to affect heat transfer. Due to these factors, when heat is transferred between the substrate and the conveying device, changes occur in the temperature distribution of the coating layer, such that the temperature on the substrate side of the coating layer becomes higher than the temperature on the opposite surface, even in the thickness direction of the coating layer, resulting in non-uniformity in the surface tension of the coating layer. As a result, the inventors surmise that the fluidity of the coating liquid changes, such as convection occurring in the coating liquid within the coating layer, like Marangoni convection, and that surface defects of the coating layer occur, such as unevenness in the thickness of the coating layer.

[0019] Conventionally, while adjustments to the formation conditions of the coating layer and the temperature conditions of the conveying environment for drying a highly homogeneous coating layer have been studied, the effect of heat transfer due to contact between the substrate and the equipment on the coating layer had not been recognized until now. Therefore, in conventional manufacturing equipment, even when a highly homogeneous coating layer was formed by adjusting the coating conditions, it is thought that unintended temperature changes due to contact between the substrate and the conveying rolls caused deterioration of the surface quality of the coating layer. Furthermore, since a coating layer with a deteriorated surface quality is dried to become a functional layer, it is thought that the desired uniformity of thickness could not be obtained.

[0020] In contrast, in the present invention, the substrate with the coated layer is transported from the coating apparatus to the drying apparatus by bringing air into contact with the back side of the substrate. Compared to the thermal conductivity of stainless steel, iron, aluminum, etc., which are conventionally used in transport rolls, the thermal conductivity of air is extremely low. Therefore, when the substrate is transported with air in contact with the back side of the substrate, the temperature change of the substrate and the temperature change of the coated layer can be reduced. In addition, the presence of air between the substrate and the transport apparatus provides insulation between the substrate and the transport apparatus. As a result, heat transfer due to contact between the substrate and the transport apparatus can be suppressed, which in turn suppresses the deterioration of the surface condition of the coated layer as described above. By drying the coated layer with a good surface condition, a multilayer material with good thickness uniformity of the functional layer can be obtained.

[0021] Furthermore, according to the present invention, since heat transfer due to contact between the substrate and the conveying device can be suppressed, the thermal equilibrium of the coating layer can be maintained, and the evaporation of the solvent from the coating layer can be allowed to proceed slowly. Therefore, fluctuations in the solvent concentration in the air can be reduced. In addition, since the evaporation of the solvent can be allowed to proceed slowly, drying of the coating layer in the first conveying section can be suppressed.

[0022] <2. Multilayer Manufacturing Apparatus> A multilayer manufacturing apparatus according to one embodiment of the present invention comprises at least a conveying device, a coating device, and a drying device. In this manufacturing apparatus, the conveying device has a first conveying section that conveys the substrate from the coating device to the drying device, and the first conveying section includes a conveying member (A) that conveys the substrate by bringing air into contact with the surface of the substrate opposite to the surface on which the coating layer is formed.

[0023] The manufacturing apparatus for multilayer materials according to the present invention can take the following two preferred embodiments, depending on the difference in the conveying member (A). However, the manufacturing apparatus for multilayer materials according to the present invention is not limited to the following two embodiments.

[0024] <2.1. First Embodiment> The manufacturing apparatus for multilayer material of the first embodiment is a manufacturing apparatus comprising a conveying device, a coating device, and a drying device, wherein the conveying member (A) included in the conveying device is a levitation conveying device.

[0025] Figure 1 is a schematic side view showing an example of a multilayer manufacturing apparatus according to a first embodiment of the present invention. The manufacturing apparatus 100 shown in Figure 1 comprises a conveying device 10, a coating device 20, and a drying device 30. In Figure 1, the manufacturing apparatus 100 further comprises a dispensing device 40 located upstream of the coating device 20 in the conveying path, which dispenses a long base material 1 wound in a roll shape.

[0026] The conveying device 10 is a device that continuously conveys the substrate 1 along the conveying direction indicated by arrows X1 to X4. The substrate 1 conveyed by the conveying device 10 is usually long in length. This conveying device 10 has a first conveying section that conveys the substrate 1 from the coating device 20 to the drying device 30. As shown in Figure 1, in the conveying device 10, the section from the contact point between the substrate 1 and the coating liquid 2 in the coating device 20, indicated by arrow P1, to the entrance of the drying device 30, indicated by arrow P2, corresponds to the first conveying section.

[0027] The first conveying section of the conveying device 10 includes conveying members (A) 11A1 and 11A2 that convey the base material 1 by bringing air into contact with the back surface of the base material 1. In Figure 1, the conveying members (A) 11A1 and 11A2 are provided with a structure that can bend the conveying direction of the base material 1 in the conveying path. Specifically, the conveying members (A) 11A1 and 11A2 are cylindrical members with a curved conveying surface. These conveying members (A) 11A1 and 11A2 are provided so as to be able to bend the conveying direction of the base material 1 in the circumferential direction along their conveying surface. The transport members (A) 11A1 and 11A2 are equipped with a structure that can bend the transport direction of the substrate 1, thereby changing the transport direction X2 before passing through transport member (A) 11A1 and the transport direction X3 after passing through transport member (A) 11A1, and changing the transport direction X3 before passing through transport member (A) 11A2 and the transport direction X4 after passing through transport member (A) 11A2. Therefore, in the manufacturing apparatus 100, the substrate 1 can be transported in the direction of gravity Z to the drying apparatus 30 located above the coating apparatus 20.

[0028] In the manufacturing apparatus 100, the transport members (A) 11A1 and 11A2 are levitation transport devices. The levitation transport device has, for example, the form shown in Figure 2.

[0029] Figure 2 is a schematic perspective view showing an example of a levitation conveying device (conveying member (A)) used in the first embodiment, and schematically shows the internal structure in part. The levitation conveying device 11A shown in Figure 2 includes a support body 110. The support body 110 has a cylindrical shape and includes a cylinder portion 112 having a supply passage 111 for supplying air from the center of the support body 110 to the surface side, and a jet portion 113 provided on the surface of the cylinder portion 112 for jetting air. The outer surface of the jet portion 113 is usually used as the conveying surface U1 of the substrate. In addition, the support body 110 of the levitation conveying device 11A has a flange 114 at its widthwise end to prevent air supplied to the cylinder portion 112 from leaking to the outside from anywhere other than the jet portion 113. The flange 114 is provided with a fixing portion 115 for fixing the support body 110 to the conveying device. Although not shown in the diagram, the levitation transport device 11A is typically used in conjunction with an air supply source, such as a compressed air device, to supply air to the supply passage 111 of the cylinder portion 112 of the support body 110.

[0030] The levitation conveying device 11A shown in Figure 2 has a structure that allows the conveying direction of the substrate 1 in the conveying path to be bent. Specifically, the support 110 is cylindrical in shape, and the conveying surface U1 of the substrate is curved.

[0031] As shown in Figure 1, the conveying device 10, in addition to the first conveying section, usually has a second conveying section that conveys the substrate 1 from upstream of the coating device 20 to the coating device 20, more specifically from upstream of the position indicated by arrow P1 to the position indicated by arrow P1, and a third conveying section that conveys the substrate 1 from the drying device 30 to the downstream side of the drying device 30, more specifically from the position indicated by arrow P2 to the downstream side. In Figure 1, an example is shown in which the second and third conveying sections include conveying members (B) 11B1 to 11B4 that come into contact with the substrate 1 and convey the substrate 1. Usually, general-purpose conveying rolls are used as conveying members (B) 11B1 to 11B4.

[0032] The coating apparatus 20 shown in Figure 1 is a device that applies a coating liquid 2 to one side of a conveyed substrate 1 to form a coating layer 3. In Figure 1, an example is shown where the coating apparatus 20 is a gravure coater.

[0033] The drying apparatus 30 shown in Figure 1 is a device for drying the coating layer 3. In Figure 1, an example is shown where the drying apparatus is an oven.

[0034] In the manufacturing apparatus 100 shown in Figure 1, the following manufacturing method can be carried out. First, the substrate 1 is fed out by the dispensing device 40 and continuously transported along the transport path by the transport device 10. Specifically, in the second transport section from the dispensing device 40 to the coating device 20, the substrate 1 is transported using transport members (B) 11B1 and 11B2. Next, in the coating device 20, a coating process is performed in which a coating liquid 2 is applied to the transported substrate 1 to form a coating layer 3. Next, in the first transport section from the coating device 20 to the drying device 30, a first transport process is performed in which the substrate 1 is transported by bringing air into contact with the side of the substrate 1 opposite to the side on which the coating layer 3 is formed, before the drying process. Specifically, the substrate 1 is transported by using levitation transport devices 11A1 and 11A2 to create an air layer between the substrate 1 and the support, thereby supporting the substrate 1 in a non-contact state. Next, a drying process is performed in the drying device 30 to dry the coating layer 3. By removing the solvent from the coating layer 3, a multilayer material 5 is obtained in which a functional layer 4 is provided on the substrate 1.

[0035] According to the first embodiment, since the transport member (A) is a levitation transport device, an air layer can be used to insulate the space between the substrate and the support, thereby suppressing heat transfer due to contact between the substrate and the transport device. Therefore, deterioration of the surface quality of the coating layer due to heat transfer can be suppressed, and a multilayer material with good uniformity of the thickness of the functional layer can be manufactured.

[0036] Furthermore, according to the first embodiment, by using a levitation conveying device, heat transfer due to contact between the substrate and the conveying device can be suppressed, thereby maintaining thermal equilibrium of the coating layer and slowing down the volatilization of the solvent. As a result, fluctuations in the concentration of the solvent in the air can be reduced. In addition, drying of the coating layer in the first conveying section can be suppressed.

[0037] Further, according to the first embodiment, since the base material can be conveyed in a non-contact state using the levitation conveyance device, the occurrence of scratches on the base material can be suppressed. Also, since the use of a heavy conveyance member such as a conveyance roll can be reduced, the driving force required for base material conveyance can be reduced.

[0038] <2.1.1. Conveyance Device> The conveyance device according to the first embodiment includes a first conveyance unit that conveys the base material from the coating device to the drying device. The first conveyance unit includes a conveyance member (A) that conveys the base material by bringing air into contact with the surface of the base material on the side opposite to the surface on which the coating layer is formed. In the first embodiment, the conveyance member (A) is a levitation conveyance device.

[0039] The levitation conveyance device includes a support body, and is a device that ejects air from the surface of the support body to provide an air layer between the surface of the support body and the base material, and supports the base material in a non-contact manner.

[0040] The conveyance member (A) usually has a conveyance surface that is disposed opposite to the surface of the base material on the side opposite to the surface on which the coating layer is formed. The conveyance member (A) preferably has a structure that can bend the conveyance direction of the base material in the conveyance path. Specifically, the conveyance surface is preferably a curved surface.

[0041] Here, conventionally, in a manufacturing apparatus for a multilayer product, for space saving, the conveyance direction of the base material may be bent to adjust the layout of the members constituting the manufacturing apparatus. When bending the conveyance direction of the base material, conventionally, for example, it was normal to bring into contact a conveyance member having a conveyance curved surface such as a rotated conveyance roll and the base material. Therefore, when bending the conveyance direction of the base material between the coating device and the drying device, heat transfer occurred due to the contact between the base material and the conveyance device, resulting in an unintended temperature change in the base material on which the coating layer was formed, and the planar shape of the coating layer may deteriorate.

[0042] In contrast, in the first embodiment, by adopting a structure that allows the conveying member (A) to bend the conveying direction of the base material in the conveying path, the conveying direction of the base material can be bent without bringing the base material into contact with the conveying member (A). Therefore, it is possible to suppress deterioration in the planar shape of the coating layer due to heat transfer between the base material and the conveying device. Since the deterioration in the planar shape of the coating layer is suppressed and the conveying direction of the base material can be bent, the degree of freedom in the layout of the constituent members and constituent devices in the manufacturing apparatus can be increased.

[0043] When the conveying member (A) has a structure that can bend the conveying direction of the base material in the conveying path, in the manufacturing apparatus for a multilayer product, usually, the conveying direction of the base material up to the coating apparatus and the conveying direction of the base material from the coating apparatus to the drying apparatus are rarely the same, and the conveying directions in the above two sections often differ. Therefore, in the manufacturing apparatus for a multilayer product, usually, the positions of the coating apparatus and the drying apparatus in the gravitational direction are different. For example, as shown in FIG. 1, in the gravitational direction Z of the manufacturing apparatus 100, the drying apparatus 30 may be located above the coating apparatus 20, and although not shown, the drying apparatus may be located below the coating apparatus. Also, in the manufacturing apparatus 100 for a multilayer product, when the positions of the coating apparatus 20 and the drying apparatus 30 in the gravitational direction Z are different, there is no limitation on the position of the conveying member (A) in the gravitational direction Z, but for example, it is preferably at an arbitrary position from the position of the coating apparatus 20 to the position of the drying apparatus 30.

[0044] When the conveying member (A) has a structure that can bend the conveying direction of the base material, usually, the support of the levitation conveying device has a structure that can bend the conveying direction of the base material. Specific shapes of the support include a cylindrical shape, a columnar shape with a semi-circular or semi-elliptical cross-section, etc. Among them, a cylindrical shape is preferable in terms of ease of installation in the conveying path.

[0045] While there are no restrictions on the support material for the levitation conveying device, it is preferable that it includes a porous material. When the support material includes a porous material, the ejection portion, which is usually provided on the surface of the support material, is formed from the porous material. When the support material includes a porous material, since the porous material has pores, it is easy to create a large number of minute holes on the surface of the support material. Therefore, compared to materials in which it is relatively difficult to form minute holes such as slit nozzles or punched holes, it becomes possible to support the substrate by ejecting air at a low flow velocity and with low pulsation. Thus, a stable air layer can be provided between the substrate and the support material to support the substrate.

[0046] A porous material is a structure with numerous minute voids, and these voids are in communication with adjacent voids. When the ejection section 113 shown in Figure 2 is formed from a porous material, the porous material has air passages on both its front and back surfaces. When pressure is applied to the interior, air passes through these interconnected passages, repeatedly merging and branching, so when air comes out to the surface, it can be ejected in a nearly uniform manner.

[0047] If the levitation conveying device has a conveying surface made of a porous material, connecting an air supply device to the levitation conveying device and pressurizing air into the inside of the levitation conveying device will cause gas to be ejected from the pores on the surface of the porous material on the curved conveying surface to the outside of the conveying surface, and the conveying surface will pressurize the substrate without contact.

[0048] Examples of materials for porous bodies include carbon, metals, metal oxides, and ceramics, and more specifically, porous carbon, porous metals, porous alumina, and porous ceramics. In this embodiment, the porous body material is preferably metal, metal oxide, or ceramic, and particularly preferably ceramic. This is because, since the porous body is made of metal, metal oxide, or ceramic, dust is less likely to be generated on the support of the levitation conveying device, even if the substrate comes into contact with the support of the levitation conveying device, dust contamination of the substrate can be reduced. Furthermore, if the porous body material is ceramic, even if foreign matter originating from the porous body is generated, it can be made into an insulating foreign matter, making it a suitable support for a functional layer where the adhesion and mixing of conductive foreign matter must be avoided.

[0049] The average pore diameter of the porous material is preferably 0.3 μm or more, more preferably 0.5 μm or more, even more preferably 1.0 μm or more, preferably 5.0 μm or less, more preferably 3.0 μm or less, and even more preferably 2.0 μm or less. If the pore diameter is too large, some pores may become blocked, causing air leakage from other pores. However, if the pore diameter is below the upper limit, the pressure loss within the porous material is large, so even if some pores are blocked, air leakage can be prevented. The average pore diameter in a porous material can be measured, for example, by observation using an optical microscope or a scanning electron microscope (SEM). Specifically, it can be determined by selecting any 20 pores from the observation image of the porous material and calculating the average value of the measured values ​​of each pore diameter.

[0050] The temperature of the air ejected from the support of the levitation conveying device should be such that it can suppress deterioration of the surface quality of the coating layer due to heat, but it is usually adjusted to a temperature close to the ambient temperature in which the coating device is placed. Specifically, the temperature of the air is usually within a range of ±2°C from the ambient temperature in which the coating device is placed (i.e., within a range of -2°C to +2°C from the ambient temperature), preferably within a range of ±1°C from the ambient temperature (i.e., within a range of -1°C to +1°C from the ambient temperature), and more preferably within a range of ±0.5°C from the ambient temperature (i.e., within a range of -0.5°C to +0.5°C from the ambient temperature). This is because, by keeping the air temperature within this range, the temperature change of the coating layer formed on the substrate can be reduced, thereby effectively suppressing deterioration of the surface quality of the coating layer. The ambient temperature in which the coating device is placed is usually measured by a thermometer installed on the coating device. The temperature of the air ejected from the support is measured by a thermometer installed within 5 mm of the surface of the support, without contact with the surface of the support.

[0051] Furthermore, the temperature of the air ejected from the support of the levitation conveying device is usually the same as the temperature of the air supplied to the support. Therefore, the temperature of the air supplied to the support is usually within a range of ±2°C from the ambient temperature in which the coating device is placed (i.e., within a range of -2°C to +2°C from the ambient temperature), preferably within a range of ±1°C (i.e., within a range of -1°C to +1°C from the ambient temperature), and more preferably within a range of ±0.5°C (i.e., within a range of -0.5°C to +0.5°C from the ambient temperature).

[0052] There is no limit to the pressure of the air supplied to the support of the levitation transfer device, but it is usually 0.2 MPa or more, preferably 0.25 MPa or more, more preferably 0.3 MPa or more that is supplied to the levitation transfer device, and usually 0.5 MPa or less, preferably 0.45 MPa or less, more preferably 0.4 MPa or less. By having the pressure of the air within the above range, the flow velocity distribution of the air ejected from the support of the levitation transfer device can be made uniform, the required thickness of the air layer can be maintained, and it is possible to make it difficult for the coating layer to be disturbed by the flow of the ejected air. Also, since compressed air from factory equipment can be used as the air supplied to the levitation transfer device, it is possible to reduce the cost of separately preparing a source of air supply to the levitation transfer device. The pressure of the air can be read from the set value of the pressure at the air supply source.

[0053] There is no limit to the flow rate of the air supplied to the support of the levitation transfer device, but it is usually 0.5 ml / cm per second ２ (0.5 ml / cm ２ / sec) or more, preferably 1.0 ml / cm per second ２ or more, more preferably 2.0 ml / cm per second ２ or more, and usually 10 ml / cm per second ２ or less, preferably 9 ml / cm per second ２ or less, more preferably 8 ml / cm per second ２ or less. Here, the term "flow rate of the air supplied to the support" refers to the amount of air (ml) supplied per second per 1 cm ２ of the outer surface area of the ejection part of the support. By setting the air flow rate within the above range, usually, the flow velocity of the air ejected from the support of the levitation transfer device can be slowed down, so it is possible to make it difficult for the coating layer to be disturbed by the air pressure from the back side of the base material. Also, by setting the air flow rate within the above range, it is possible to suppress the air from flowing around from the back side of the base material to the surface on the coating layer side of the base material, and even if the air does flow around, it is possible to make it difficult for the coating layer to be disturbed by the air flow. Also, since the air flow rate being within the above range can reduce the amount of air used, energy savings can be achieved.

[0054] The air flow rate can be measured by the following method. A gas flow meter (for example, an SMC digital flow switch, model PF2M7 or PFMB) is installed on the piping route connected to the flotation conveying device, and the flow rate of air supplied to the entire flotation conveying device can be measured by reading its value. The air flow rate can be calculated by dividing the obtained measurement value by the area of ​​the outer surface of the ejection part of the support.

[0055] The distance between the support of the levitation conveying device and the back surface of the substrate, i.e., the thickness of the air layer, should be sufficient to provide insulation between the substrate and the support, but is usually 20 μm or more, preferably 50 μm or more, more preferably 100 μm or more, and usually 1000 μm or less, preferably 750 μm or less, and more preferably 500 μm or less. This is because having an air layer thickness within the above range effectively suppresses the thermal effects on the coating layer on the substrate, suppresses vibration of the substrate, stably supports the substrate in a non-contact state, and makes it less susceptible to scratches even if there are some irregularities or foreign matter gets inside.

[0056] The first conveying section typically includes one or more conveying members (A), and there is no limit to the number of conveying members installed. The first conveying section may also include conveying members (B) that have a conveying surface that contacts one side of the base material, but in order to fully realize the effects of the present invention, it is preferable to have only conveying members (A).

[0057] For example, a general-purpose conveying roll can be used as the conveying member (B).

[0058] The conveying device typically includes, in addition to the first conveying section, a second conveying section that conveys the substrate from the upstream side of the coating device to the coating device, and a third conveying section that conveys the substrate from the drying device to the downstream side of the drying device. The second and third conveying sections may have a conveying member (B) having a conveying surface that contacts one side of the substrate. The second and third conveying sections may also have a conveying member (C) that conveys the substrate by bringing one side of the substrate into contact with air. The conveying member (C) can be the same material as the conveying member (A), except that the side of the substrate that comes into contact with the air is not limited to the back surface. Specifically, the levitation conveying device described above and the conveying member (a) described later can be used.

[0059] The conveying speed of the substrate by the conveying device is adjusted as appropriate according to factors such as the size of the multilayered object, the type of substrate, the concentration of the coating liquid, and the thickness of the coating layer.

[0060] <2.1.2. Coating Apparatus> Any coating apparatus capable of applying a coating liquid to a long substrate in a desired width is acceptable, but bar coaters, gravure coaters, and die coaters are typically used.

[0061] <2.1.3. Drying Equipment> Any drying equipment capable of removing the solvent from the coating layer is acceptable, but typically, a drying equipment capable of heat treatment is used. Furthermore, it is preferable that the drying equipment be equipped with a drying chamber. This is because the drying conditions, such as drying temperature, solvent concentration, and pressure during drying, can be adjusted more appropriately for drying. Examples of such drying equipment include ovens and drying furnaces.

[0062] <2.1.4. Optional Equipment> The manufacturing apparatus according to the first embodiment typically includes at least a conveying device, a coating device, and a drying device, and any optional components can be added as needed. Examples of optional components in the manufacturing apparatus include a feeding device, a surface treatment device, a stretching device, a protective film laminating device, a winding device, and the like.

[0063] <2.2. Second Embodiment> The manufacturing apparatus for a multilayer material of the second embodiment comprises a conveying device, a coating device, and a drying device, wherein the conveying member (A) included in the conveying device has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts to allow air to come into contact with the back surface of the substrate.

[0064] Figure 3 is a schematic side view showing an example of a multilayer manufacturing apparatus according to a second embodiment of the present invention. The manufacturing apparatus 200 shown in Figure 3 comprises a dispensing device 40, a conveying device 50, a coating device 20, and a drying device 30.

[0065] The conveying device 50 is the same as the conveying device 10 in the manufacturing apparatus 100 of the first embodiment, except that the conveying members (A) 12a1 and 12a2 included in the first conveying section are conveying members (a). The conveying member (a) has, for example, the form shown in Figure 4.

[0066] Figure 4 is a schematic diagram showing an example of a conveying member (a), and is a front view with the conveying surface of the conveying member (a) facing forward. The conveying member (a) 12a has two support parts 121 that support both ends of the base material 1 in the width direction, and a space S is provided between the two support parts 121 to allow air to come into contact with the back surface of the base material 1. The conveying member (a) 12a has a cylindrical roll member 122, and a step is provided at both ends of the roll member 122 such that the diameter is larger than that of the central part of the roll member 122, thereby providing a space S between the support parts 121. In the conveying member (a) 12a, the surface of the support part 121 that comes into contact with the base material 1 corresponds to the conveying surface U2. Since the conveying surface U2 of the conveying member (a) 12a is a curved surface, it has a structure that allows the conveying direction of the base material 1 in the conveying path to be bent along the conveying surface U2. The conveying member (a) 12a usually has a shaft part 120 and is rotatably fixed in the manufacturing apparatus.

[0067] If the transport member (a) has a structure that can bend the transport structure of the substrate, as shown in Figure 3, the transport direction X2 before passing through the transport member (a) 12a1 and the transport direction X3 after passing through the transport member (a) 12a1 can be changed, and the transport direction X3 before passing through the transport member (a) 12a2 and the transport direction X4 after passing through the transport member (a) 12a2 can be changed. Therefore, in the manufacturing apparatus 200, the substrate 1 can be transported in the direction of gravity Z to the drying apparatus 30 located above the coating apparatus 20.

[0068] In the manufacturing apparatus 200 shown in Figure 3, the following manufacturing method can be carried out. First, the substrate 1 is fed out by the dispensing device 40 and continuously transported along the transport path by the transport device 50. Specifically, in the second transport section from the dispensing device 40 to the coating device 20, the substrate 1 is transported using transport members (B) 11B1 and 11B2. Next, in the coating device 20, a coating process is performed in which a coating liquid 2 is applied to the transported substrate 1 to form a coating layer 3. Next, in the first transport section from the coating device 20 to the drying device 30, a first transport process is performed in which the substrate 1 is transported by bringing air into contact with the side of the substrate 1 opposite to the side on which the coating layer 3 is formed, before the drying process. Specifically, transport is performed using transport members (a) 12a1 and 12a2, bringing the support part into contact with both ends of the substrate in the width direction, and bringing air into contact with the back surface of the central part of the substrate. Next, a drying process is performed in the drying device 30 to dry the coating layer 3. By removing the solvent from the coating layer 3, a multilayer material 5 is obtained in which a functional layer 4 is provided on the substrate 1.

[0069] The multilayer manufacturing apparatus 200 is the same as the manufacturing apparatus 100 of the first embodiment, except for the points mentioned above.

[0070] In multilayer products obtained by forming a functional layer on a long substrate, the central portion in the width direction of the substrate is usually used as the final product, and the ends in the width direction of the substrate are often removed without being used as the final product. According to the second embodiment, since the transport member (A) is transport member (a), contact between the substrate and the transport device can be suppressed in the central portion of the substrate on which the coating layer is formed. This suppresses deterioration of the surface of the coating layer due to heat transfer, and improves the uniformity of the thickness of the coating layer provided in the central portion of the substrate. Therefore, the uniformity of the thickness of the functional layer in the final multilayer product can be improved. Furthermore, by transporting the substrate with the ends in the width direction of the substrate that are not used as the final product in contact with the support portion of the transport member (a), vibration of the substrate can be further reduced.

[0071] The manufacturing apparatus of the second embodiment is the same as that described in the manufacturing apparatus of the first embodiment, except that the conveying member (A) included in the conveying device is conveying member (a). Therefore, conveying member (a) will be described below.

[0072] The conveying member (a) used in the manufacturing apparatus of the second embodiment has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts to allow air to come into contact with the surface of the substrate opposite to the surface on which the coating layer is formed.

[0073] In the conveying member (a), the two support parts typically contact the widthwise ends of the substrate, so the surfaces of the support parts correspond to the conveying surface. The conveying member (a) preferably has a structure that can bend the conveying direction of the substrate in the conveying path, and specifically, it is preferable that the conveying surface of the support part is curved. The support part of such a conveying member is preferably cylindrical in shape. The width of the support part can be adjusted as appropriate depending on the application of the multi-layered material.

[0074] In terms of the form of the conveying member (a), the conveying member (a) has a cylindrical roll member 122, and steps are provided at both ends of the roll member 122 such that the diameter is larger than that of the central part of the roll member 122, thereby creating a space S between the two support parts 121. It may also be a form in which tape is wrapped around the ends of an existing conveying roll to create steps, or a form in which the cylindrical members constituting the support parts are fixed with shaft members.

[0075] There is no limit to the height of the space between the central part of the conveying member (a) and the substrate supported by the support part (the step between the central part and the support part), but it is preferable that the height of the space be low. Specifically, the height of the space is preferably 20 μm or more, more preferably 50 μm or more, even more preferably 100 μm or more, preferably 1000 μm or less, more preferably 750 μm or less, and even more preferably 500 μm or less. Because the height of the space is within the above range, for example, the conveying member (a) can be prepared by creating a step at both ends in the width direction of an existing conveying roll with tape or the like, making it easy to change from existing manufacturing equipment and reducing costs. When the height of the space is within the above range, air can usually be drawn into the space between the support parts of the conveying member by co-flow, and the substrate can be pressurized from the back side by the drawn-in air in the space of the conveying member (a), so the substrate can be supported in a non-contact state by an action similar to compressed air in a levitation conveying device.

[0076] <2.3. Modifications> In the manufacturing apparatus according to the first embodiment, an example is shown where the conveying member (A) is a levitation conveying device, and in the manufacturing apparatus according to the second embodiment, an example is shown where the conveying member (A) is a conveying member (a). However, for example, the first conveying section may be equipped with a conveying device that includes both a levitation conveying device and a conveying member (a) as the conveying member (A).

[0077] <3. Method for Manufacturing a Multilayered Material> A method for manufacturing a multilayered material according to one embodiment of the present invention is a method for manufacturing a multilayered material having a base material and a functional layer provided on one side of the base material, comprising: a coating step of applying a coating liquid to one side of the base material that has been transported along a transport path to form a coating layer; a drying step of drying the coating layer; and a first transport step of transporting the base material by bringing air into contact with the side of the base material opposite to the side on which the coating layer has been formed, before the drying step.

[0078] A method for manufacturing a multilayered material according to one embodiment of the present invention can be carried out by the multilayered material manufacturing apparatus described above.

[0079] According to the present invention, heat transfer between the substrate on which the coating layer is formed and the conveying device due to contact between them can be suppressed before the drying process. Therefore, deterioration of the surface quality of the coating layer due to heat transfer can be suppressed, and the coating layer can be dried in a state with good surface quality, making it possible to manufacture a multilayer material with good uniformity of the thickness of the functional layer.

[0080] <3.1. Coating Process> The coating process is a process in which a coating liquid is applied to one side of a substrate that has been transported along a transport path to form a coating layer. The coating process is usually carried out by a coating apparatus in the multilayer manufacturing apparatus described above.

[0081] (Substrate) Typically, a long substrate is used. Examples of such substrates include resin films, metal foils, and glass films.

[0082] Various polymers can be used as the material for the resin film used as the base material. Examples of such polymers include olefin polymers such as polyethylene and polypropylene; polyesters such as polyethylene terephthalate and polybutylene terephthalate; polyarylene sulfides such as polyphenylene sulfide; polyvinyl alcohol; polycarbonate; polyarylate; cellulose ester; polyethersulfone; polysulfone; polyallylsulfone; polyvinyl chloride; alicyclic structure-containing polymers; acrylic polymers; styrene-based polymers such as polystyrene; and so on. These may be used individually or in combination of two or more in any ratio.

[0083] Preferably, the resin constituting the film is a resin containing an alicyclic structure-containing polymer (hereinafter referred to as "alicyclic structure-containing polymer resin" as appropriate), a resin containing an acrylic polymer, or a resin containing polycarbonate. Alicyclic structure-containing polymer resins are particularly preferred because they offer excellent transparency, low moisture absorption, dimensional stability, and lightweight properties, making them suitable for use as optical films. Specific examples of resins constituting the film are those described in Japanese Patent Publication No. 5845895.

[0084] Examples of materials for the metal foil used as the base material include aluminum, platinum, nickel, tantalum, titanium, stainless steel, copper, and other alloys.

[0085] Examples of glass films used as substrates include films made of flexible low-alkali glass. Commercially available glass films may also be used. Examples of commercially available glass films include "G-Leaf®," an ultra-thin glass manufactured by Nippon Electric Glass Co., Ltd.

[0086] The substrate may have different properties on its front and back surfaces, or it may be the same. If the substrate has different properties on its front and back surfaces, for example, it may be processed to have different wettability or surface roughness.

[0087] Furthermore, the substrate may be a single-layer substrate such as the resin film, metal foil, or glass film mentioned above, but it may also be a multi-layer substrate such as a multi-layer film containing two or more resin layers, a multi-layer film in which a metal layer is provided on a resin film, or a multi-layer film in which a metal layer is provided on a glass film.

[0088] The thickness of the substrate is typically 1 μm or more, preferably 5 μm or more, more preferably 10 μm or more, and even more preferably 20 μm or more, and typically 1000 μm or less, preferably 800 μm or less, and even more preferably 600 μm or less. When the thickness of the substrate is within the above range, temperature changes of the substrate are particularly likely to occur due to heat transfer between the substrate and the conveying device, and the temperature changes of the coating layer tend to have a large impact. Therefore, the effects of using the multilayer manufacturing apparatus according to this embodiment can be fully realized.

[0089] (Coating liquid and coating layer) In this embodiment, a liquid containing a functional material and a solvent is usually used as the coating liquid for forming the functional layer.

[0090] Functional materials can be any material that exhibits some function when used as a functional layer. Examples include, but are not limited to, resins, transparent particles such as silica particles, adhesives, conductive materials, colorants such as pigments and dyes, and ultraviolet absorbers. The functional material contained in the coating solution may be one type or a combination of two or more types.

[0091] The solvent is usually selected appropriately depending on the type of functional material, taking into account its solubility, dispersibility, viscosity, and evaporation rate. Regarding the evaporation rate of the solvent, solvents with a high evaporation rate tend to cool more easily due to latent heat, which can easily cause uneven thickness due to heat transfer. Therefore, it is preferable to select a solvent with a low evaporation rate. The functional material may be dissolved in the solvent or dispersed without dissolving. Examples of solvents include inorganic solvents such as water and organic solvents.

[0092] The content of the functional material in the coating liquid is not limited and can be adjusted as appropriate depending on the type of functional layer, the type of coating apparatus, etc. When the first conveying process is performed using a levitation conveying device, the flow rate of air ejected from the levitation conveying device can be reduced, thereby suppressing vibration of the substrate. Similarly, when the first conveying is performed using a conveying member (a), the support portion of the conveying member (a) can be brought into contact with both ends of the substrate in the width direction during conveying, thereby suppressing vibration of the substrate. Therefore, even when the content of the functional material in the coating liquid is reduced and the viscosity of the coating liquid is lowered, the coating layer can be maintained, and a thin coating layer can be formed. From this viewpoint, the content of the functional layer in the coating liquid is preferably 0.1% by weight or more, more preferably 0.5% by weight or more, even more preferably 1% by weight or more, preferably 20% by weight or less, preferably 15% by weight or less, and more preferably 10% by weight or less.

[0093] The thickness of the coating layer can be appropriately selected depending on the functional layer, but is usually 1 μm or more, preferably 5 μm or more, more preferably 10 μm or more, and usually 100 μm or less, preferably 80 μm or less, and more preferably 50 μm or less. This is because the effects of the present invention can be fully realized when the thickness of the coating layer is within the above range.

[0094] <3.2. First Conveying Process> The first conveying process is a process in which the substrate is conveyed by bringing air into contact with the side of the substrate opposite to the side on which the coating layer is formed, before the drying process described later. In the first conveying process, the substrate is usually conveyed using the conveying member (A) described above.

[0095] The transport member (A) used in the first transport process is preferably a levitation transport device. In other words, it is preferable to transport the substrate using a levitation transport device in the first transport process. By using a levitation transport device, an air layer can be provided between the substrate and the support of the levitation transport device while the substrate is being transported. This allows for insulation between the substrate and the transport device by the air layer, effectively suppressing deterioration of the surface quality of the coating layer due to heat transfer between the substrate and the transport device. Preferred examples of the levitation transport device used in the first transport process and the thickness of the air layer are the same as those described in the section on the manufacturing apparatus of the first embodiment above.

[0096] Furthermore, it is preferable that the conveying member (A) used in the first conveying process is conveying member (a). In other words, it is also preferable to convey the substrate using conveying member (a) in the first conveying process. By conveying the substrate using conveying member (a), the substrate can be conveyed while suppressing vibrations by bringing both ends in the width direction of the substrate into contact with the support portion of conveying member (a). In addition, since the substrate can be conveyed with the back surface of the substrate in contact with air in the central part of the substrate, deterioration of the surface quality of the coating layer in the central part of the substrate can be effectively suppressed. Preferred examples of conveying member (a) used in the first conveying process are the same as those described in the section on the manufacturing apparatus of the second embodiment above.

[0097] Furthermore, in the first conveying step, it is preferable to bend the conveying direction of the substrate. In the first conveying step, by using a levitation conveying device or conveying member (a) with a structure that can bend the conveying direction of the substrate along the conveying path described above, the conveying direction of the substrate can be bent without the substrate coming into contact with the conveying device. Therefore, as in conventional manufacturing equipment, it is possible to suppress unintended temperature changes of the substrate due to contact between the substrate and the conveying device, and to suppress deterioration of the surface quality of the coating layer.

[0098] <3.3. Drying Process> The drying process is a process of removing solvents such as organic solvents contained in the coating layer and drying the surface layer. More specifically, in the drying process, drying usually proceeds by the evaporation of solvents from the surface layer, which is the outer surface of the coating layer. Preferably, the drying process is a process of drying the coating layer by heating the substrate. In addition, the drying process may be carried out under reduced pressure in the drying chamber as needed.

[0099] <3.4. Optional Steps> The method for manufacturing a multilayer material according to this embodiment includes at least a coating step, a first conveying step, and a drying step, and any optional steps can be appropriately selected and added as needed. Optional steps include, for example, a surface treatment step in which some kind of surface treatment is performed on the surface of the substrate before the coating step, and a stretching step in which the substrate on which the functional layer is formed is stretched.

[0100] <3.5. Modifications> Modifications of the manufacturing method of the multilayer material according to this embodiment include a manufacturing method in which, when the multilayer material has two or more functional layers, the above-described coating process, first conveying process, and drying process are repeated two or more times when forming each functional layer. When the multilayer material has two or more functional layers, each functional layer may be formed by stacking two or more functional layers on one side of the substrate, or functional layers may be formed on both sides of the substrate.

[0101] <4. Multilayered Material> The multilayered material according to the present invention is manufactured by the method for manufacturing multilayered materials described above.

[0102] According to the present invention, since the multilayer material is manufactured by the above-described method for manufacturing multilayer materials, it is possible to obtain a multilayer material with good uniformity in the thickness of the functional layer.

[0103] A multilayered structure typically consists of a base material and a functional layer.

[0104] The base material is the same as described in the section on the manufacturing method of the multilayer material mentioned above.

[0105] The functional layer may contain a functional material, or it may contain reaction products obtained by the reaction of the functional material. The functional material is the same as described in the section on the method of manufacturing the multilayer material described above. The thickness of the functional layer can be appropriately selected depending on the type of multilayer material and is not particularly limited, but is usually 1 μm or more, preferably 5 μm or more, more preferably 10 μm or more, and usually 100 μm or less, preferably 80 μm or less, and more preferably 50 μm or less. In conventional methods of manufacturing multilayer materials, when the thickness of the functional layer is within the above range, thickness unevenness tends to occur, so the effects of using the method of manufacturing multilayer materials of the present invention can be greatly demonstrated.

[0106] Specific examples of multilayer materials include, but are not limited to, components of display devices such as liquid crystal displays and organic electroluminescent displays, battery electrodes, and optical films.

[0107] The multilayer material according to the present invention may be long or single-sheet. When the multilayer material is single-sheet, it can usually be obtained by cutting out the multilayer material into a desired shape from a long multilayer material.

[0108] 1 Substrate 2 Coating liquid 3 Coating layer 4 Functional layer 5 Multilayer material 100, 200 Manufacturing equipment 10, 50 Conveying equipment 11A, 11A1, 11A2 Floating conveying equipment (conveying member (A)) 12a, 12a1, 12a2 Conveying member (a) (conveying member (A)) 11B1, 11B2, 11B3, 11B4 Conveying member (B) 20 Coating equipment 30 Drying equipment 40 Dispensing equipment 110 Support 111 Supply path 112 Cylinder section 113 Discharge section 114 Flange 115 Fixing section 120 Shaft section 121 Support section 122 Roll member P1 Contact position between substrate and coating liquid in coating equipment P2 Position of the inlet of drying equipment S Space U1, U2 Conveying surfaces (of the substrate): X1, X2, X3, X4; Conveying direction: Z; Direction of gravity: Z

Claims

1. A manufacturing apparatus for a multilayer material having a base material and a functional layer provided on one surface of the base material, comprising: a conveying device for continuously conveying the base material along a conveying path; a coating device for applying a coating liquid to one surface of the conveyed base material to form a coating layer; and a drying device for drying the coating layer, wherein the conveying device has a first conveying section for conveying the base material from the coating device to the drying device, and the first conveying section includes a conveying member (A) for conveying the base material by bringing air into contact with the surface of the base material opposite to the surface on which the coating layer is formed.

2. The apparatus for manufacturing a multilayer material according to claim 1, wherein the transport member (A) is a levitation transport device, the levitation transport device includes a support, and the air is ejected from the surface of the support to create an air layer between the surface of the support and the substrate, thereby supporting the substrate without contact.

3. The apparatus for manufacturing a multilayer material according to claim 2, wherein the pressure of the air supplied to the support of the levitation conveying device is 0.2 MPa or more and 0.5 MPa or less.

4. The flow rate of the air supplied to the support of the levitation transport device is 0.5 ml / cm² per second. ２ Above 10 ml / cm² ２ The apparatus for manufacturing a multilayer material according to claim 2, which is as follows:

5. The apparatus for manufacturing a multilayer material according to claim 2, wherein the support of the levitation conveying device includes a porous body.

6. The apparatus for manufacturing a multilayer material according to claim 5, wherein the porous body includes ceramics.

7. The apparatus for manufacturing a multilayer material according to claim 5, wherein the average pore size of the porous body is 0.3 μm or more and 5 μm or less.

8. The apparatus for manufacturing a multilayer material according to claim 2, wherein the temperature of the air ejected from the surface of the support of the levitation conveying apparatus is within ±2°C of the ambient temperature in which the coating apparatus is placed.

9. The apparatus for manufacturing a multilayer material according to claim 1, wherein the conveying member (A) has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts for bringing air into contact with the surface of the substrate opposite to the surface on which the coating layer is formed.

10. The apparatus for manufacturing a multilayer material according to claim 1, wherein the transport member (A) has a structure that can bend the transport direction of the substrate in the transport path.

11. A method for manufacturing a multilayer material having a base material and a functional layer provided on one side of the base material, comprising: a coating step of applying a coating liquid to one side of a base material that has been continuously conveyed along a conveying path to form a coating layer; a drying step of drying the coating layer; and a first conveying step of conveying the base material by bringing air into contact with the side of the base material opposite to the side on which the coating layer has been formed, before the drying step.

12. The method for manufacturing a multilayer material according to claim 11, wherein in the first transport step, the substrate is transported using a levitation transport device, the levitation transport device includes a support, and air is ejected from the surface of the support to create an air layer between the surface of the support and the substrate, thereby supporting the substrate without contact.

13. The method for manufacturing a multilayer material according to claim 12, wherein the pressure of the air supplied to the support of the levitation conveying device is 0.2 MPa or more and 0.5 MPa or less.

14. The flow rate of the air supplied to the support of the levitation transport device is 0.5 ml / cm² per second. ２ Above 10 ml / cm² ２ The method for manufacturing a multilayered material according to claim 12, which is as follows:

15. The method for manufacturing a multilayer material according to claim 12, wherein the support of the levitation transport device includes a porous body.

16. The method for producing a multilayer material according to claim 15, wherein the porous body includes ceramics.

17. The method for producing a multilayer material according to claim 15, wherein the average pore size of the porous material is 0.3 μm or more and 5 μm or less.

18. The method for manufacturing a multilayer material according to claim 12, wherein the temperature of the air ejected from the surface of the support of the levitation conveying device is within ±2°C of the ambient temperature in which the coating process is performed.

19. The method for manufacturing a multilayer material according to claim 11, wherein in the first transport step, the substrate is transported using a transport member (a), the transport member (a) has two support parts that support both ends of the substrate in the width direction, and a space is provided between the two support parts for bringing air into contact with the surface of the substrate opposite to the surface on which the coating layer is formed.

20. The method for manufacturing a multilayer material according to claim 11, wherein the first transport step includes bending the transport direction of the substrate in the transport path.

21. A multilayered material manufactured by the method for manufacturing a multilayered material described in claim 11.

Images