Method for removing coating layer and device for removing coating layer
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-03
- Publication Date
- 2026-08-13
Smart Images
Figure JP2026003707_13082026_PF_FP_ABST
Abstract
Description
Method for Removing Coating Layer and Apparatus for Removing Coating Layer
[0001] The present invention relates to a method for removing a coating layer and an apparatus for removing a coating layer.
[0002] In recent years, from the perspective of protecting Earth's resources and the environment, there has been a growing movement in various fields to build a circular economy through efforts such as reducing waste generation, reusing, and recycling. For example, Patent Document 1 discloses a method for recycling plastic products having a painted film, characterized by peeling off the painted film formed on the plastic body with a high-pressure water jet, and then crushing and recycling the plastic body. Patent Document 2 discloses a web sheet joining adhesive tape inspection device, characterized by comprising: an ultrasonic sensor that detects the butt joints of the joined ends, positioned at a distance from the front and back of a good web sheet B which has been joined by cutting and removing a defective web sheet C and applying adhesive tape along the butt joints on both the front and back of the joined ends; an adhesive tape monitoring sensor that detects the presence or absence of the adhesive tape; an illumination light source that illuminates the front and back of the good web sheet B; and a determination control means that determines whether or not adhesive tape is applied along the butt joints on both the front and back of the joined ends based on the detection signals from the sensors. Patent Document 3 discloses a method for joining two film strips using a connecting tape and then removing the connecting tape from the film strips, comprising the steps of: (a) forming an opening at the rear edge of a first film strip; (b) joining the rear edge of the first film strip to the front edge of a second film strip using a connecting tape, and overlapping a portion of the connecting tape with a portion of the opening formed at the rear edge of the first film strip; (c) grasping the portion of the connecting tape that overlaps the opening; (d) pulling the connecting tape away from the rear edge of the first film strip; and (e) pulling the remaining portion of the connecting tape across one surface to separate the remaining portion of the connecting tape from the front edge of the second film strip.Patent Document 4 discloses a bar heater device for a packaging machine, comprising two heater bars positioned opposite each other with a portion of the packaging material to be sealed in between; a servo motor as a drive source for opening and closing the heater bars; a motion conversion mechanism that converts the rotational output of the servo motor into an opening and closing operation of the heater bars; and a control unit that controls the operation of the servo motor in order to cause the heater bars to perform the opening and closing operation in accordance with the transport of the packaging material, wherein the control unit detects the enlargement of the gap between the heater bars during the closing operation of the heater bars based on fluctuations in the amount of rotation or torque of the servo motor, thereby detecting the presence of foreign matter caught between the heater bars.
[0003] JP-A-5-269743 JP-A-5-201607 JP-A-9-104552 JP-A-2012-250756
[0004] In roll-to-roll technology for removing the coating layer from laminated film and recovering the base film roll, there is a need to improve the productivity (recoverability) of the base film roll. Roll-to-roll has the advantage of allowing the process to be carried out continuously and improving productivity, but once the continuous process is completed, the rolls must be replaced. Such work is a factor that reduces the productivity of the base film roll. The method described in Patent Document 1 is a technology in which the plastic body is crushed and recovered after removing the coating film from each molded product, and it is not a technology that employs roll-to-roll. Furthermore, Patent Documents 2 to 4 describe joining web sheets, etc. with connecting tape, and Patent Documents 2 and 4 describe detecting the connecting tape portion, but the web sheets, etc. described in these Patent Documents are not intended for the recovery of base film rolls.
[0005] The object of the present invention is to provide a method and apparatus for removing a coating layer that can remove the coating layer from a laminated film roll that is connected by a connecting tape, or may be connected by a connecting tape, in a roll-to-roll manner, and that can improve the productivity of the substrate film rolls from which the coating layer has been removed.
[0006] [1] A method for removing a coating layer from a plurality of laminated films having a base film and a coating layer, comprising: a step of preparing a laminated film roll by winding a long laminated film in which a plurality of the laminated films are connected by connecting tape into a roll; a step of unwinding the long laminated film from the laminated film roll; a detection step of directly or indirectly detecting the presence or absence of the connecting tape in the long laminated film; a spraying step of spraying pressurized water onto the coating layer to remove the coating layer of the long laminated film; a spraying condition control step of changing the spraying conditions of the pressurized water sprayed onto the coating layer in the spraying step based on the detection information of the detection step; and a base material recovery step of winding the base film in a roll after the coating layer has been removed from the long laminated film and recovering it. [2] If the detection information in the detection step detects that the connecting tape has changed from a state in which it is not detected to a state in which it is detected, the spray condition control step changes the spray conditions so as to reduce the water pressure of the pressurized water or stop the spraying of the pressurized water when the tip of the connecting tape reaches the spray range of the pressurized water in the spray step, and if the detection information in the detection step detects that the connecting tape has changed from a state in which it is detected to a state in which it is not detected, the spray condition control step returns the spray conditions to the conditions for removing the coating layer when the rear end of the connecting tape moves outside the spray range of the pressurized water in the spray step, the tip of the connecting tape is the downstream end of the connecting tape in the transport direction of the long laminated film, and the rear end of the connecting tape is the upstream end of the connecting tape in the transport direction of the long laminated film, the method for removing the coating layer according to [1]. [3] The method for removing a coating layer according to [1] or [2], wherein the detection step involves irradiating the long laminated film with electromagnetic waves or ultrasonic waves and detecting reflected waves reflected from the connecting tape, or detecting transmitted waves that pass through the long laminated film and the connecting tape, and the electromagnetic waves include visible light, ultraviolet light, or infrared light.[4] The method for removing a coating layer according to [2], wherein in the spraying step, the timing at which the tip of the connecting tape reaches the spraying range of the pressurized water is calculated based on the distance from the location where the tip of the connecting tape was detected in the detection step to the spraying range and the transport speed of the long laminated film, and the timing at which the rear end of the connecting tape moves outside the spraying range of the pressurized water is calculated based on the distance from the time when the rear end of the connecting tape is no longer detected in the detection step to outside the spraying range and the transport speed of the long laminated film. [5] The method for removing a coating layer according to any one of [1] to [4], wherein the coating layer includes a release agent layer. [6] The method for removing a coating layer according to [5], wherein the coating layer includes a ceramic green sheet. [7] A coating layer removal apparatus for removing a coating layer from a laminated film having a base film and a coating layer, wherein the laminated film is a single unbonded laminated film or a long laminated film in which two or more laminated films are joined together with a connecting tape, a feeding shaft for feeding the long laminated film from a laminated film roll in which the long laminated film is wound into a roll shape, a detection unit for directly or indirectly detecting the presence or absence of the connecting tape in the long laminated film, a backup roller disposed downstream of the feeding shaft for transporting the long laminated film downstream, a spray unit including one or more nozzles disposed opposite the backup roller for spraying pressurized water onto the coating layer from the one or more nozzles so as the long laminated film passes the backup roller to remove the coating layer, and a pressurized water supply unit for supplying pressurized water to the spray unit. A coating layer removal device comprising: a control unit that controls the conditions the long laminated film receives from the spray of pressurized water based on detection information from the detection unit; and a winding shaft that winds the base film, after the coating layer has been removed from the long laminated film, into a roll shape, wherein the detection unit is connected to the control unit, the pressurized water supply unit includes a pump, and the pump is connected to the spray unit.[8] The coating layer removal apparatus according to [7], wherein the control unit is connected to the pump and changes the injection conditions of the pressurized water ejected from the one or more nozzles. [9] The coating layer removal apparatus according to [7] or [8], wherein the detection unit is a means for irradiating the long laminated film with electromagnetic waves or ultrasonic waves and detecting reflected waves reflected from the connecting tape, or a means for detecting transmitted waves that pass through the long laminated film and the connecting tape, wherein the electromagnetic waves include visible light, ultraviolet rays, or infrared rays.
[0007] According to one aspect of the present invention, a method and apparatus for removing a coating layer can be provided that can remove the coating layer from a laminated film roll that is connected by a connecting tape, or may be connected by a connecting tape, in a roll-to-roll manner, and that can improve the productivity of the substrate film rolls from which the coating layer has been removed.
[0008] A perspective view of a first example of a long laminated film used in the removal method of the first embodiment. A perspective view of a second example of a long laminated film used in the removal method of the first embodiment. A cross-sectional view of an example of a removal device of the second embodiment.
[0009] In this specification, ordinal numbers such as "first" and "second" are used to distinguish between components and do not indicate order. In this specification, expressions without ordinal numbers, such as "laminated film," are a general term for laminated films and are used when describing laminated films that have ordinal numbers such as "first" and "second." For example, when a description is made that applies to multiple components that are indicated with ordinal numbers, such as "first laminated film" and "second laminated film," the term "laminated film" without the ordinal number is used to collectively refer to "first laminated film" and "second laminated film."
[0010] [First Embodiment] [Method for Removing Coating Layers] The method for removing coating layers according to this embodiment (hereinafter also referred to as the removal method according to this embodiment) is a method for removing coating layers from a plurality of laminated films having a base film and a coating layer. The removal method according to this embodiment includes the steps of: preparing a laminated film roll by winding a long laminated film, in which a plurality of the laminated films are connected by connecting tape, into a roll; unwinding the long laminated film from the laminated film roll; detecting the presence or absence of the connecting tape in the long laminated film directly or indirectly; spraying pressurized water onto the coating layer to remove the coating layer of the long laminated film; spraying condition control step of changing the spraying conditions of the pressurized water sprayed onto the coating layer in the spraying step based on the detection information from the detection step; and recovering the base film after the coating layer has been removed from the long laminated film by winding it into a roll. The removal method according to this embodiment is carried out roll-to-roll.
[0011] In a roll-to-roll technique for removing the coating layer from a laminated film and recovering the base film roll, it is conceivable to connect the laminated films with connecting tape to create long laminated films (hereinafter also referred to as long laminated films with connecting tape) in order to improve efficiency. For example, laminated films used in the manufacture of ceramic green sheets are often cut at each lot changeover during the manufacturing process of ceramic green sheets (e.g., slurry coating process, conductive layer coating process, green sheet lamination process, and green sheet die-cutting process), resulting in shortened films. Even shortened laminated films can be lengthened by connecting them with connecting tape, allowing them to be fed into the roll-to-roll process, reducing the amount of work required for replacement, and improving the productivity of the base film roll. Furthermore, since used laminated films are often discarded, being able to process them by connecting them with connecting tape is also effective in reducing waste. Additionally, connecting used laminated films with connecting tape can reduce storage space. In this embodiment, when the coating layer is removed from a long laminated film with connecting tape by spraying pressurized water onto the coating layer, there is a problem that if strong force is applied to the connecting tape, the connecting tape will peel off, causing the long laminated film to break midway and the device to stop. When the device stops, a great deal of effort is required to restart the device, such as changing the rolls or cleaning the device. Despite this technical background, the technology for removing the coating layer has not yet reached a practical scale, and conventional methods for removing the coating layer have not taken into consideration how to handle the connecting tape. Therefore, no technology for removing the coating layer from a long laminated film with connecting tape has been proposed until now. The inventors have found that by directly or indirectly detecting the presence or absence of the connecting tape before the spraying step in which pressurized water is sprayed (detection step), and by controlling the spraying conditions of the pressurized water in the spraying step (spray condition control step), it is possible to remove the coating layer from a long laminated film with connecting tape in a roll-to-roll manner while suppressing the breakage of the connecting tape of the long laminated film.According to the removal method of this embodiment, the coating layer can be removed roll-to-roll using a laminated film roll in which a long laminated film with connecting tape is wound into a roll, which was previously difficult to do. This allows for continuous removal of the coating layer and recovery of the base film for a longer period of time. It also reduces the frequency of roll replacement. Furthermore, since the volume is reduced by reducing the number of cores, the space required for transportation and storage can be reduced. In addition, because the removal method of this embodiment has a detection step, even if laminated film rolls connected with connecting tape and laminated film rolls that may be connected with connecting tape (laminated film rolls whose connection status with connecting tape is unknown) are provided randomly, they can be processed without problems using the same device and the same operation. In summary, according to the removal method of this embodiment, the coating layer can be removed roll-to-roll from laminated film rolls that are connected with connecting tape or may be connected with connecting tape, and the productivity of the base film rolls from which the coating layer has been removed can be improved. Furthermore, since the removal method according to this embodiment uses virtually only water and no chemicals, there is no need to treat wastewater containing chemicals, thus keeping wastewater treatment costs low and minimizing the impact on the global environment.
[0012] In the removal method according to this embodiment, the water used in the spraying step is water for removing the coating layer and is water with adjusted water pressure. The water is preferably ordinary water, i.e., industrial water, and may be purified water or distilled water. It may also be recycled wastewater used in various industrial productions, or recycled wastewater after it has been used in the implementation of this embodiment. If wastewater is recycled, it may be treated to regenerate the wastewater as appropriate. From the viewpoint of improving work efficiency, the water may contain additives that add functionality as appropriate, but it is preferable not to include them. Examples of additives include surfactants and water-soluble organic solvents. If the water contains additives, the concentration of the active ingredients of the additives in the water is preferably 0.2% by mass or less, more preferably 0.1% by mass or less, relative to the total amount of water, and furthermore, it is preferable that the water is not water to which additives have been intentionally added. Furthermore, it is preferable that the water is not an alkaline aqueous solution prepared by intentionally adding a basic substance, nor is it preferable that it is not an acidic aqueous solution prepared by intentionally adding an acidic substance. Since wastewater can potentially be treated with simple recycling methods, the water may contain basic and acidic substances as additives. In such cases, it is preferable that the pH of the water be between 5.8 and 8.6 to comply with the uniform wastewater discharge standards (other items) based on the Water Pollution Control Law. The water used is preferably at room temperature and may be either cold or warm water.
[0013] Figure 1 is a perspective view of a first example of a long laminated film used in the removal method according to the first embodiment. Figure 1 shows a long laminated film 900 in which two laminated films (first laminated film 90A and second laminated film 90B) are connected by a connecting tape 96. The long laminated film 900 is obtained, for example, by the following method. The end 93A of the first laminated film 90A and the end 93B of the second laminated film 90B are brought together. Along the boundary line 94 of the joint, the connecting tape 96 is attached to the surface of the long laminated film 900 on the base film 91 side (hereinafter also referred to as the back surface of the long laminated film) with a length that is neither too long nor too short compared to the width of the laminated films 90A and 90B (preferably a length equivalent to the width of the laminated films 90A and 90B). In the case of Figure 1, the connecting tape 96 is attached to the back surface of the long laminated film, but it may also be attached to the surface of the long laminated film 900 on the side of the coating layers 92A and 92B (hereinafter also referred to as the surface of the long laminated film), or it may be attached to both sides of the long laminated film 900. Alternatively, the connecting tape 96 may be attached to the back surface of the long laminated film, and the excess connecting tape 96 may be folded back onto the film surface and attached to both ends (both ends in the width direction) of the surface of the long laminated film. It is preferable that the connecting tape 96 be attached to the back surface of the long laminated film to minimize waste.
[0014] The configurations of the laminated films 90A and 90B will now be described. The two laminated films 90A and 90B have similar configurations. Each of the laminated films 90A and 90B is elongated and has a base film 91A and 91B and a coating layer 92A and 92B. The base films 91A and 91B and the coating layers 92A and 92B are directly laminated together.
[0015] In the laminated films 90A and 90B, it is preferable that the coating layers 92A and 92B include a release agent layer. In Figure 1, the coating layers 92A and 92B are release agent layers. Alternatively, the coating layers 92A and 92B may include a ceramic green sheet, as shown in Figure 2.
[0016] Figure 2 is a perspective view of a second example of a long laminated film used in the removal method according to the first embodiment. Figure 2 shows a long laminated film 901 in which a first laminated film 90C and a second laminated film 90D are joined together by a connecting tape 96. The long laminated film 901 is the same as the long laminated film 900, except that the laminated films 90C and 90D are different from the laminated films 90A and 90B in the long laminated film 900 of Figure 1. The two laminated films 90C and 90D have the same configuration. The long laminated film 901 can be obtained in the same way as the long laminated film 900 of Figure 1.
[0017] The laminated films 90C and 90D are laminated films used in the manufacture of multilayer ceramic capacitors (MLCCs), and are laminated films after the necessary portions of the ceramic green sheets have been peeled off. The laminated films 90C and 90D have base films 91C and 91D and coating layers 92C and 92D. The coating layers 92C and 92D include release agent layers 921C and 921D and ceramic green sheets 922C and 922D, with the release agent layers 921C and 921D and the ceramic green sheets 922C and 922D (residue) arranged in this order from the side of the base films 91C and 91D. The base films 91C and 91D and the release agent layers 921C and 921D are directly laminated, and the release agent layers 921C and 921D and the ceramic green sheets 922C and 922D are directly laminated. The ceramic green sheets 922C and 922D are partially provided on the surface of the release agent layers 921C and 921D. After the ceramic green sheets are peeled off, a recess is formed, and the release agent layers 921C and 921D are exposed from the recess. Preferably, the ceramic green sheets 922C and 922D are green sheets composed of a dielectric as an active ingredient. The ceramic green sheets 922C and 922D may be multilayer structures including a green sheet composed of a dielectric as an active ingredient and a conductive layer (not shown) composed of a conductor as an active ingredient, on the side of the release agent layers 921C and 921D. A green sheet is an unfired sheet-like material, and a green sheet with ceramics as an active ingredient is called a ceramic green sheet. Figures 1 and 2 also show the leading end 96LE and trailing end 96TE of the connecting tape 96. The leading end 96LE of the connecting tape 96 is the downstream end of the connecting tape 96 in the transport direction of the long laminated films 900 and 901. The trailing end 96TE of the connecting tape is the upstream end of the connecting tape 96 in the transport direction of the long laminated films 900 and 901. The leading end 96LE and trailing end 96TE of the connecting tape 96 can serve as starting points for detecting the presence or absence of the connecting tape 96 in the detection process of this embodiment. In this embodiment, upstream refers to the side where the means for unwinding the long laminated film is located, and downstream refers to the side where the means for winding up and recovering the base film is located.
[0018] Each step of the removal method according to this embodiment will be described.
[0019] <Preparation Process, Dispensing Process> The preparation process involves preparing a laminated film roll, which is a long laminated film in which multiple laminated films are joined together with connecting tape, wound into a roll. The preparation process also includes selecting short laminated films that can be joined together with connecting tape, and joining the selected short laminated films together with connecting tape to form a long laminated film. The dispensing process involves dispensing the long laminated film from the laminated film roll. The width of the long laminated film is, for example, 100 mm or more and 1000 mm or less, preferably 200 mm or more and 600 mm or less. The length of the long laminated film is, for example, 50 m or more and 30000 m or less, preferably 100 m or more and 10000 m or less. The number of connecting tapes in the long laminated film is, for example, 1 or more and 100 or less. In this case, the number of laminated films joined together with connecting tape is 2 or more and 101 or less. The width of the laminated film before being joined with the connecting tape is preferably within the same range as the width of the long laminated film. The length of the laminated film before being joined with the connecting tape is, for example, 10 m or more and 1000 m or less. The winding diameter of the laminated film roll (the diameter of the roll including the core) is, for example, 100 mm or more and 1500 mm or less, preferably 150 mm or more and 1000 mm or less.
[0020] The thickness of the connecting tape is, for example, 20 μm to 200 μm. The width of the connecting tape is, for example, 10 mm to 100 mm. The connecting tape is not particularly limited, and for example, an adhesive tape with an adhesive layer formed on one side of a base material can be used. Examples of base materials for the adhesive tape include resin, paper, cloth, and metal foil. A known adhesive layer can be used as the adhesive layer. Conductive tape or the like may also be used as the connecting tape. When the detection step detects reflected light from the connecting tape, it is preferable that the tape is colored.
[0021] <Detection Process> The detection process directly or indirectly detects the presence or absence of splicing tape in a long laminated film. Preferably, the detection process involves irradiating the long laminated film with electromagnetic waves or ultrasonic waves and detecting the reflected waves reflected from the splicing tape, or detecting the transmitted waves that pass through the long laminated film and the splicing tape. Electromagnetic waves include visible light, ultraviolet rays, or infrared rays. Examples of methods for directly detecting the presence or absence of splicing tape include the following methods (D1) to (D4). (D1) Irradiate the long laminated film with electromagnetic waves and measure the reflected light from the splicing tape, detecting the portion where the reflected light is measured as the location where the splicing tape is present. (D2) Irradiate the long laminated film with electromagnetic waves and measure the changes in the amount of electromagnetic wave transmission and reflection, detecting the portion where a change different from that of the long laminated film is measured as the location where the splicing tape is present. (D3) Measure the thickness displacement (change in thickness due to the splicing tape) by interferometry, and detect the portion where the displacement is measured as the location where the splicing tape is present. (D4) Ultrasound is irradiated onto the long laminated film, and the reflected waves reflected by the long laminated film are received. In this case, the round-trip time from when the long laminated film is irradiated with ultrasound until the reflected waves are received is measured, and the portion where a round-trip time different from the round-trip time of the long laminated film (round-trip time of the connecting tape) is measured is detected as the location where the connecting tape exists. When detecting the presence or absence of the connecting tape 96 using the long laminated films 900 and 901 shown in Figures 1 and 2 by any of the above methods (D1) to (D4), the detection step may be defined as follows: the portion where the change in reflected light, electromagnetic wave transmission and reflection, thickness displacement by interference method, or change in round-trip time until the reflected waves are received from the aforementioned connecting tape 96 is detected is defined as the tip 96LE of the connecting tape 96, and the portion where the detection of the change (displacement) has ended is defined as the rear end 96TE of the connecting tape 96, and the area between the tip 96LE and the rear end 96TE of the connecting tape 96 is detected as the location where the connecting tape 96 exists.
[0022] The detection step may indirectly detect the presence or absence of a connecting tape in a long laminated film. For example, the detection step may directly detect the leading edge position of the connecting tape using one of the methods (D1) to (D4) above, and then detect the trailing edge position of the connecting tape when a predetermined time T calculated from the following formula (Equation 1) has elapsed. This method is an example of a method for indirectly detecting the location where a connecting tape is present. Furthermore, this method is limited to cases where the width of all connecting tapes used to connect long laminated films is constant. Predetermined time T = (width of connecting tape) / (conveying speed of long laminated film) ... (Equation 1) In the above formula (Equation 1), the unit of predetermined time T is [s], the unit of the width of the connecting tape is [cm], and the unit of the conveying speed of the long laminated film is [cm / s].
[0023] In the detection process, electromagnetic waves or ultrasonic waves may be irradiated from the side to which the connecting tape is attached, from the side to which the connecting tape is not attached, or from both sides of the long laminated film. However, when measuring reflected light, it is preferable to irradiate the electromagnetic waves from the side to which the connecting tape is attached.
[0024] <Injection Condition Control Process> The injection condition control process changes the injection conditions of the pressurized water injected into the coating layer in the injection process based on the detection information from the detection process. The injection condition control process preferably changes the injection conditions of the pressurized water by controlling as follows: (i) When the detection information from the detection process is detected to have changed from a state in which the connecting tape has not been detected to a state in which it has been detected, the injection condition control process changes the injection conditions in the injection process to reduce the water pressure of the pressurized water or stop the injection of pressurized water at the timing when the tip of the connecting tape reaches the injection range of the pressurized water (in the case of Figure 3, injection range R1) (in the case of Figure 3, arrival point T1). In this case, the injection process either injects pressurized water at a low water pressure toward the coating layer of the long laminated film or does not inject pressurized water at the timing when the tip of the connecting tape of the long laminated film reaches the injection range of the pressurized water (in the case of Figure 3, injection range R1) (in the case of Figure 3, arrival point T1). (ii) When the detection information in the detection step detects that the connecting tape has changed from being detected to not being detected, the spray condition control step returns the spray conditions to the conditions for removing the coating layer at the timing when the rear end of the connecting tape moves outside the spray range of the pressurized water (non-spray range R2 in Figure 3) (arrival point T2 in Figure 3). In this case, the spray step sprays pressurized water toward the coating layer of the long laminated film with a water pressure that removes the coating layer at the timing when the rear end of the connecting tape of the long laminated film moves outside the spray range of the pressurized water (non-spray range R2 in Figure 3) (arrival point T2 in Figure 3). The leading end of the connecting tape is the downstream end of the connecting tape in the transport direction of the long laminated film, and the rear end of the connecting tape is the upstream end of the connecting tape in the transport direction of the long laminated film (see Figures 1 and 2).
[0025] The injection condition control step preferably involves changing the injection conditions of the pressurized water by controlling the pump that supplies pressurized water to the nozzle. Alternatively, the injection condition control step may also involve changing the injection conditions of the pressurized water by controlling the operations (1) to (3) described below.
[0026] In the spraying process, the timing at which the leading edge of the connecting tape reaches the spray range of the pressurized water is preferably calculated based on the distance from the location where the leading edge of the connecting tape was detected in the detection process to the spray range (in the case of Figure 3, the distance the connecting tape travels from the detection unit 82 to the arrival point T1), and the transport speed of the long laminated film. Furthermore, the timing at which the trailing edge of the connecting tape moves outside the spray range of the pressurized water is preferably calculated based on the distance from the point at which the trailing edge of the connecting tape is no longer detected in the detection process to the outside of the spray range (in the case of Figure 3, the distance the connecting tape travels from the detection unit 82 to the arrival point T2), and the transport speed of the long laminated film.
[0027] <Spraying Process> The spraying process involves spraying pressurized water onto the coating layer of the long laminated film to remove the coating layer. As mentioned above, the spraying process involves spraying pressurized water onto the coating layer under spraying conditions controlled by the spraying condition control process. This suppresses the breakage of the long laminated film caused by the connecting tape.
[0028] In this specification, the water pressure when spraying pressurized water means the nozzle pressure (the water pressure applied to the nozzle outlet). Hereinafter, in the control of (i) above, the low water pressure when spraying pressurized water is referred to as the nozzle pressure P Ｌ In the control of (ii) above, the water pressure used to remove the coating layer is set to the nozzle pressure P. Ｈ It is sometimes referred to as the nozzle pressure P. Ｈ The nozzle pressure P Ｌ It is higher than that. In the injection process, nozzle pressure P Ｌ For example, the nozzle pressure P is 5 MPa or less, and more preferably 3 MPa or less. Ｈ For example, the pressure is 3.0 MPa or more and 70 MPa or less, and more preferably 10 MPa or more and 50 MPa or less.
[0029] The spraying process is preferably a process of spraying water toward the coating layer of a long laminated film, for example, while the long laminated film is supported by a backup roller. In this case, the spraying process is preferably a process of spraying water toward the coating layer from one or more nozzles positioned opposite the backup roller, while the backup roller is in contact with the surface of the base film (the surface of the base film opposite to the coating layer).
[0030] <Process of circulating to the pump> The removal method according to this embodiment preferably includes a step of filtering the water containing the coating layer removed in the spraying step and circulating it to the pump. The means for filtering the water containing the coating layer is, for example, a filter. It is preferable that the water circulated to the pump be reused as water used in the spraying step.
[0031] <Draining Process> The removal method according to this embodiment preferably includes a step of draining the water from the base film after the spraying step and before the base material recovery step. The draining step is, for example, a step of removing residue from the base film. Residue refers to, for example, the coating layer remaining on the base film, as well as water and foreign matter adhering to the base film. The means of draining the water are not particularly limited, but examples include a draining nozzle (also called an air knife) and a dryer.
[0032] <Substrate Recovery Process> In the substrate recovery process, the substrate film, after the coating layer has been removed from the long laminated film in areas other than where the connecting tape is attached, is wound into a roll and recovered as a substrate film roll. In this embodiment, the substrate film recovered in the substrate recovery process has connecting tape attached. Such substrate film with connecting tape can be recycled into resin that constitutes molded products such as films by the following method, for example: While unwinding the substrate film, it is cut into small pieces, and the areas where the connecting tape is attached are detected and removed. Subsequently, the small pieces without connecting tape are collected and compressed into lumps (pellets) of any size. The obtained pellets can be recycled into films by forming a film, or they can be used as raw materials for various resin molded products.
[0033] [Second Embodiment] [Coating Layer Removal Apparatus] In the second embodiment, the X-axis, Y-axis, and Z-axis are orthogonal to each other, the X-axis and Y-axis are axes in a predetermined plane, and the Z-axis is an axis orthogonal to the predetermined plane. Furthermore, in the second embodiment, when directions are indicated based on the view from the front direction of Figure 3, which is parallel to the Y-axis, "up" is the direction of the Z-axis arrow and "down" is the opposite direction, "right" is the direction of the X-axis arrow and "left" is the opposite direction, "front" is the front direction of Figure 3, which is parallel to the Y-axis and "back" is the opposite direction. Also, in Figure 3, the side closer to the feed shaft 10 is called the "upstream side", and the side closer to the winding shaft 40 is called the "downstream side".
[0034] Figure 3 is a schematic diagram of the coating layer removal device 100 according to the second embodiment. The removal device 100 is a device that removes the coating layer from a roll-to-roll laminated film roll that is connected by a connecting tape, or may be connected by a connecting tape. The long laminated film applicable to the removal device 100 is either a single laminated film without seams, or a long laminated film in which two or more laminated films are connected by a connecting tape. In the second embodiment, an example of removing coating layers 92A and 92B from the long laminated film 900 shown in Figure 1 using the removal device 100 will be described.
[0035] The removal device 100 according to the second embodiment includes a dispensing shaft 10 for dispensing the long laminated film 900 from a laminated film roll in which the long laminated film 900 is wound into a roll shape, a detection unit 82 for directly or indirectly detecting the presence or absence of connecting tape 96 in the long laminated film 900, a backup roller 20 arranged downstream of the dispensing shaft 10 for transporting the long laminated film 900 downstream, and one or more nozzles arranged opposite the backup roller 20, wherein the long laminated film 900 is transported by the backup roller 2 The removal device 100 includes a spray unit 31 that sprays pressurized water W3 onto the coating layers 92A and 92B from one or more nozzles so as the coating layers 92A and 92B pass through 0, a pressurized water supply unit 50 that pressurizes water and supplies pressurized water W3 to the spray unit 31, a control unit 81 that controls the conditions that the long laminated film 900 receives from the spray of pressurized water W3 based on detection information from a detection unit 82, and a winding shaft 40 that winds the base film 91 into a roll shape after the coating layers 92A and 92B have been removed from the long laminated film 900. The detection unit 82 is connected to the control unit 81. The pressurized water supply unit 50 includes a supply pump 51, which is connected to the spray unit 31. The removal device 100 also includes a water recovery and regeneration device 60, a residue detection device 75, a residue removal device 70, nip rollers NR1 and NR2, and a plurality of guide rollers GR. Known rollers can be used as guide rollers GR.
[0036] The removal device 100 according to the second embodiment includes a detection unit 82 that directly or indirectly detects the presence or absence of connecting tape 96 in the long laminated film 900, and a control unit 81 that controls the spraying conditions of pressurized water W3 based on the detection information from the detection unit 82. This makes it possible to remove the coating layer from a laminated film roll that is connected by connecting tape, or may be connected by connecting tape, in a roll-to-roll manner, and improves the productivity of the base film rolls from which the coating layer has been removed.
[0037] The components of the removal device 100 according to the second embodiment will now be described.
[0038] <Pay-out shaft 10> The pay-out shaft 10 pays out the long laminated film 900 from a laminated film roll in which the long laminated film 900 is wound in a roll shape. The pay-out shaft 10 is connected to a drive roller (not shown).
[0039] <Injection part 31> The injection part 31 includes one or more nozzles arranged to face the backup roller 20. Pressurized water W3 is injected from one or more nozzles onto the coating layer so as to remove the coating layer when the long laminated film 900 passes through the backup roller 20. In FIG. 3, the range where the pressurized water W3 is injected is indicated by an injection range R1. The injection range R1 is shown larger than the actual size for convenience of explanation. In the injection part 31, from the viewpoint of applying impact stress to the surfaces of the coating layers 92A and 92B, when viewed in a cross-section in a direction orthogonal to the central axis 20a of the backup roller 20, the central axis of one or more nozzles included in the injection part 31 is preferably orthogonal to the outer peripheral tangent line PT1 of the backup roller 20.
[0040] The injection part 31 is arranged in the injection chamber 301 and is configured such that the injected water is guided to the second tank 63 of the water recovery and regeneration device 60 through the discharge port 1a.
[0041] The nozzle shape is not particularly limited, but a constricting nozzle is preferable. A constricting nozzle refers to a nozzle that ejects water from a constricted ejection port, such as an orifice and a flow nozzle. When the nozzle is a constricting nozzle, the inner diameter of the ejection port of the nozzle is the inner diameter of the constriction part. The nozzle pattern is not particularly limited, and examples include a flat pattern (ejected fan-shaped from the ejection port), a full cone pattern (ejected conically from the ejection port), and a straight pattern (ejected linearly from the ejection port). Among them, the nozzle pattern is preferably a flat pattern. When removing the target layer (coating layers 92A and 92B) in a roll-to-roll method as in the present embodiment, the flat pattern can crush and remove the target layer with a smaller number of nozzles and a smaller amount of water compared to the straight pattern.
[0042] <Detection Unit 82> The detection unit 82 directly or indirectly detects the presence or absence of the connecting tape 96 in the long laminated film 900. The detection unit 82 is connected to the control unit 81. Preferably, the detection unit 82 is a means for irradiating the long laminated film 900 with electromagnetic waves or ultrasonic waves and detecting the reflected waves reflected from the connecting tape 96, or a means for detecting transmitted waves that pass through the long laminated film and the connecting tape. Examples of the detection unit 82 include a light receiving sensor, a CCD sensor, a CMOS sensor, a photodiode, an ultrasonic film thickness gauge, and an infrared film thickness gauge. By using these detection units 82 and performing the detection process described in the first embodiment, the presence or absence of the connecting tape 96 can be detected directly or indirectly.
[0043] <Control Unit 81> The control unit 81 controls the conditions that the long laminated film 900 receives from the spray of pressurized water W3 based on the detection information from the detection unit 82. The control unit 81 is, for example, a computer. The control unit 81 is connected to the supply pump 51 of the pressurized water supply unit 50 and preferably changes the spraying conditions of the pressurized water W3 sprayed from one or more nozzles. In the case of Figure 3, the control unit 81 changes the conditions that the long laminated film 900 receives from the spray of pressurized water W3 by controlling the operation of the supply pump 51. Specifically, when the control unit 81 receives information from the detection unit 82 that the connecting tape 96 has been detected, it calculates the timing at which the tip 96LE of the connecting tape 96 will arrive at the destination point T1 of the spray range R1 from the transport speed of the long laminated film, etc., and at that timing, it sets the conditions to lower the water pressure of the pressurized water W3 (nozzle pressure P Ｌ ) or controls the operation of the supply pump 51 to stop the spraying of pressurized water W3. Also, when the control unit 81 receives information from the detection unit 82 that it does not detect the connecting tape 96, it calculates the timing at which the rear end 96TE of the connecting tape 96 arrives at the point T2 of the non-spray range R2 from the transport speed of the long laminated film, and at that timing, it sets the water pressure of the pressurized water W3 to the conditions for removing the coating layer (nozzle pressure P Ｈ The operation of the supply pump 51 is controlled to return the contents to the original position.
[0044] The control unit 81 is not limited to controlling the operation of the supply pump 51. The control unit 81 may control, for example, the operations (1) to (3) below to reduce the water pressure of the pressurized water W3 or stop the injection of the pressurized water W3. When returning the water pressure of the pressurized water W3 to the condition for removing the coating layer, the control unit 81 controls the reverse operations of the following (1) to (3). (1) Widen or block the diameter of the pipe (in the case of FIG. 3, the pipe 511) connected to the nozzle of the injection unit 31. (2) Arrange a water flow changing member (for example, a baffle plate, etc.) between the tip of the nozzle of the injection unit 31 and the backup roller 20 facing the nozzle. (3) Blow air toward the tip of the nozzle of the injection unit 31 so as to bend the water flow injected from the nozzle. The means for blowing air is, for example, an air nozzle.
[0045] <Backup roller 20> The backup roller 20 is arranged on the downstream side of the pay-out shaft 10 and conveys the long laminated film 900 to the downstream side. The backup roller 20 is arranged to contact the surface of the base film 91 opposite to the coating layers 92A and 92B. By passing the long laminated film 900 over the backup roller 20, the play (clearance) in the vertical direction (Z-axis direction) of the long laminated film 900 caused by the collision of the pressurized water W3 can be eliminated, and the tension in the plane direction of the long laminated film 900 can be made uniform. Thereby, the effect of the collision force of the pressurized water W3 can be maximized.
[0046] <Pressurized Water Supply Unit 50> The pressurized water supply unit 50 is, for example, a known pressurized water generator. The pressurized water supply unit 50 includes a water source 55, a first tank 53 for storing water W1 supplied from the water source 55, piping 54 connecting the water source 55 and the first tank 53, and a supply pump 51. The supply pump 51 is connected to tanks 53 and 63 via piping 531 and 631, respectively, and is also connected to the injection unit 31 via piping 511. The second tank 63 stores used and recycled water (also referred to as recycled water W2). In the pressurized water supply unit 50, water W1 stored in the first tank 53 and recycled water W2 stored in the second tank 63 are used when generating pressurized water. The supply pump 51 pressurizes the water W1 and recycled water W2 and supplies pressurized water W3 to the injection unit 31.
[0047] <Water Recovery and Recycling Device 60> The water recovery and recycling device 60 separates water from the coating layer (desorbed material) by passing the water ejected from the injection unit 31 through a filtration filter 71. The water recovery and recycling device 60 comprises a second tank 63, a filtration filter 71, and a recovery pump 61 positioned between the second tank 63 and the filtration filter 71. The second tank 63 is connected to the supply pump 51 via piping 631.
[0048] <Residue Removal Device 70> The residue removal device 70 is a device that removes residue adhering to the base film 91, and is an example of a means for dewatering the base film. The residue removal device 70 is located downstream of the backup roller 20 and upstream of the winding shaft 40. Residue refers to, for example, the coating layers 92A and 92B remaining on the base film 91, as well as water and foreign matter adhering to the base film 91. The residue removal device 70 is not particularly limited, but for example, the aforementioned means for dewatering can be cited. The residue removal device 70 only needs to be located on the side of the coating layers 92A and 92B. In the case of Figure 3, the residue removal device 70 is a pair of dewatering nozzles.
[0049] <Residual Detection Device 75> The residual detection device 75 is a device that detects the residual coating layers 92A and 92B, and is located downstream of the backup roller 20 and upstream of the winding shaft 40. The residual detection device 75 is, for example, a film thickness gauge that measures the film thickness of the coating layers 92A and 92B. The residual detection device 75 may have a foreign matter detection function in addition to the function of detecting residual coating layers 92A and 92B.
[0050] <Winding shaft 40> The winding shaft 40 winds the base film 91, after the coating layer has been removed from the long laminated film 900, into a roll shape. The winding shaft 40 is connected to a drive roller (not shown).
[0051] The present invention is not limited to the embodiments described above. The present invention may include modifications and improvements to the extent that the objectives of the present invention can be achieved. In the case of the long laminated film shown in Figure 1, the two laminated films connected by the connecting tape have the same configuration, but they may have different configurations. The same applies to the long laminated film shown in Figure 2. Furthermore, in the case of a long laminated film in which three or more laminated films are connected by a connecting tape, the three or more laminated films may have the same configuration, or they may have different configurations.
[0052] The structure of the laminated film will be explained below. The structure of the laminated film described below is common to each individual laminated film before it is joined with connecting tape, and also to the long laminated film after it has been joined with connecting tape.
[0053] [Laminated Film] The laminated film used in the above-described embodiment comprises a base film and a coating layer. The coating layer may be a single layer or a multi-layer consisting of two or more coating layers of the same or different type. From the viewpoint of making it easier to remove the coating layer from the laminated film and recover the remaining base film, it is preferable that the base film and the coating layer are directly laminated. Here, "direct lamination" refers to a configuration in which, for example, there is no other layer between the base film and the coating layer, and the base film and the coating layer are in direct contact with each other.
[0054] <Base Film> The base film used is a resin film on which the resin component intended for recovery has been formed. Suitable resin films include polyester films such as polyethylene terephthalate film, polybutylene terephthalate, and polyethylene naphthalate; polyolefin films such as polyethylene film and polypropylene film; polyimide film; polyamide film; polycarbonate film; polyacetate film; ethylene-vinyl acetate copolymer (EVA) film; ethylene-(meth)acrylic acid copolymer film; ethylene-(meth)acrylic acid ester copolymer film; cycloolefin polymer film; polyurethane film; polyphenylene sulfide film; cellophane; and others. Among the base films, polyester film is preferred due to its excellent heat resistance and strength. As for polyester films, polyester films with polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate as the main constituent component are preferred from the viewpoint of facilitating resin recovery and regeneration. In this specification, the main constituent component or principal component means that the proportion of the total mass of the material is 50% by mass or more. Furthermore, the resin film may contain known fillers, colorants, antistatic agents, antioxidants, organic lubricants, and catalysts. The resin film may be transparent or colored as desired. In addition, at least one surface of the base film may be subjected to surface treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, and oxidation etching as needed.
[0055] There are no particular restrictions on the thickness of the base film, but from the viewpoint of strength, rigidity, etc., it is preferably 10 μm to 500 μm, more preferably 15 μm to 300 μm, and even more preferably 20 μm to 200 μm.
[0056] <Coating Layer> The coating layer is preferably a functional layer. Examples of functional layers include a release agent layer, an intermediate layer, a printing layer, a hard coat layer, an easy-adhesion layer, and an adhesive layer. The coating layer may include a functional layer and a ceramic green sheet, or a functional layer, a ceramic green sheet, and a conductive layer. The coating layer preferably includes at least a release agent layer.
[0057] (Release Agent Layer) When the coating layer is a release agent layer, it is preferable that the release agent layer is formed from a release agent composition. The release agent composition used to form the release agent layer is not particularly limited as long as it has release properties, and for example, release agent compositions mainly composed of silicone compounds, fluorine compounds, long-chain alkyl group-containing compounds, thermoplastic resin materials such as olefin resins and diene resins can be used. It is also preferable to use a release agent composition mainly composed of an energy ray curable or thermosetting resin. These release agent compositions may be used individually or in combination of two or more.
[0058] In a release agent composition mainly composed of a silicone compound, the silicone compound may include a silicone compound having an organopolysiloxane as its basic structure. Other examples of the silicone compound include thermosetting silicone compounds such as addition reaction type and condensation reaction type; and energy ray curing silicone compounds such as ultraviolet curing type and electron beam curing type.
[0059] In a release agent composition mainly composed of a fluorine compound, examples of the fluorine compound include fluorosilicone compounds, fluoroboron compounds, and poly(perfluoroalkylene ether) chain-containing compounds.
[0060] In a release agent composition mainly composed of a long-chain alkyl group-containing compound, examples of the long-chain alkyl group-containing compound include polyvinyl carbamate obtained by reacting a long-chain alkyl isocyanate with a polyvinyl alcohol polymer, alkylurea derivatives obtained by reacting a long-chain alkyl isocyanate with polyethyleneimine, or copolymers of long-chain alkyl (meth)acrylates. Furthermore, a long-chain alkyl-modified alkyd resin obtained by a condensation reaction of a polyhydric alcohol and a polybasic acid, using a long-chain fatty acid as a modifying agent, may also be used.
[0061] Preferably, the release agent composition mainly composed of an energy-ray curable resin contains, for example, an energy-ray curable compound having a reactive functional group selected from a (meth)acryloyl group, an alkenyl group, and a maleimide group, and a polyorganosiloxane. In the release agent layer formed by this release agent composition, since the energy-ray curable compound and the polyorganosiloxane have different molecular structures, polarities, and molecular weights, components derived from the polyorganosiloxane segregate near the outer surface of the release agent layer before curing, and then the segregation is fixed by curing with energy rays. This improves the release properties of the release agent layer. The release agent composition mainly composed of an energy-ray curable resin may further contain a photopolymerization initiator.
[0062] Examples of release agent compositions mainly composed of thermosetting resins include release agent compositions mainly composed of melamine resin and release agent compositions mainly composed of epoxy resin. Examples of release agent compositions mainly composed of melamine resin include a composition containing melamine resin as the main component, an acid catalyst for thermosetting the melamine resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Examples of release agent compositions mainly composed of epoxy resin include a composition containing epoxy resin as the main component, an acid or basic thermosetting catalyst for thermosetting the epoxy resin, and a polyorganosiloxane that imparts release properties to the release agent layer. Before curing, components derived from polyorganosiloxane segregate near the outer surface of the release agent layer, and then the segregation becomes fixed after curing. This improves the release properties of the release agent layer.
[0063] Furthermore, the coating layer may contain other additives in addition to the resin components mentioned above. Examples of other additives include anti-aging agents, light stabilizers, flame retardants, conductive agents, antistatic agents, and plasticizers.
[0064] The thickness of the coating layer can be selected as appropriate and is not particularly limited, but for example, it is preferably 0.02 μm to 5 μm, more preferably 0.03 μm to 2 μm, and even more preferably 0.05 μm to 1.5 μm.
[0065] (Ceramic Green Sheet) When the coating layer includes a release agent layer and a ceramic green sheet, it is preferable that the laminated film is directly laminated in the order of the base film, the release agent layer, and the ceramic green sheet.
[0066] A ceramic green sheet can be obtained, for example, by coating the surface of a coating layer opposite the substrate film with a ceramic slurry, and then drying the ceramic slurry. Coating can be performed using, for example, a slot die coating method or a doctor blade method. The ceramic slurry contains ceramic powder, a binder component, and a solvent. Examples of ceramic powders include dielectric powders such as barium titanate, titanium oxide, alumina, zirconia, zinc oxide, aluminum silicate, and silicon nitride. When dielectric powder is used as the ceramic powder, a green sheet used in the manufacture of multilayer ceramic capacitors (MLCCs) can be obtained (specifically, a green sheet composed of dielectric as the active ingredient). The ceramic powder may also be a ceramic powder other than a dielectric. The thickness of the ceramic green sheet is, for example, 0.1 μm to 10 μm.
[0067] (Conductive layer) When the coating layer includes a release agent layer, a ceramic green sheet, and a conductive layer, it is preferable that the laminated film is directly laminated in this order: the base film, the release agent layer, the ceramic green sheet, and the conductive layer. The conductive layer is not particularly limited, and a conductive layer used in the manufacture of electronic components can be used. The conductive layer is formed on the ceramic green sheet, for example, by applying a conductive paste. The thickness of the conductive layer is, for example, 0.1 μm or more and 5 μm or less.
[0068] (Intermediate layer) The coating layer may include a release agent layer and an intermediate layer. In this case, it is preferable that the intermediate layer and the release agent layer are directly laminated in this order from the base film side. Alternatively, the coating layer may be directly laminated with the intermediate layer, release agent layer and ceramic green sheet in this order from the base film side. Or, the coating layer may be directly laminated with the intermediate layer, release agent layer, ceramic green sheet and conductive layer in this order from the base film side. Examples of intermediate layers include a water-soluble intermediate layer, an alkali-degradable intermediate layer, and a layer that is hydrophilic and water-insoluble.
[0069] (Water-soluble intermediate layer) When the intermediate layer is a water-soluble intermediate layer, examples of water-soluble resins included in the intermediate layer include water-soluble polyvinyl alcohol resin, water-soluble acrylic resin, water-soluble polyester resin, water-soluble polyester urethane resin, water-soluble ethylene ionomer resin, water-soluble polyvinylpyrrolidone resin, water-soluble poly-N-vinylacetamide resin, water-soluble polyamide resin, water-soluble ethylene-vinyl alcohol resin, and water-soluble starch. The content of water-soluble resin in the intermediate layer is preferably 30% by mass or more and 90% by mass or less, and more preferably 40% by mass or more and 80% by mass or less, based on the total mass of the intermediate layer. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.
[0070] (Alkali-degradable intermediate layer) When the intermediate layer is an alkali-degradable intermediate layer, examples of alkali-degradable resins included in the intermediate layer include phenolic resin, polyacrylic acid, polyamide resin, polyester resin, and polylactic acid. The content of alkali-degradable resin in the intermediate layer is preferably 30% by mass or more and 90% by mass or less, and more preferably 40% by mass or more and 80% by mass or less, based on the total mass of the intermediate layer. The upper limit of the content of water-soluble resin in the intermediate layer is 100% by mass.
[0071] (Hydrophilic and water-insoluble layer) When the intermediate layer is a hydrophilic and water-insoluble layer, it is preferable that the intermediate layer is made of a silane compound that exhibits polycondensation by hydrolysis, from the viewpoint of more easily separating the coating layer from the substrate film side surface of the intermediate layer.
[0072] When the intermediate layer is hydrophilic and water-insoluble, the silane compound is preferably a tetraalkoxysilane. More preferred specific examples of the tetraalkoxysilane include tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, and tetrabutoxysilane. Among these, from the viewpoint of ease of availability and reactivity of the hydrolysis reaction, at least one of tetramethoxysilane and tetraethoxysilane, or a mixture of tetramethoxysilane and tetraethoxysilane, is preferred. Commercially available products can also be used as the hydrolysis polycondensate of the silane compound.
[0073] When the intermediate layer contains a hydrophilic and water-insoluble resin (preferably the silane compound), the content of the hydrophilic and water-insoluble resin is preferably 30% to 90% by mass, and more preferably 40% to 80% by mass, relative to the total mass of the intermediate layer. The upper limit for the content of the hydrophilic and water-insoluble resin in the intermediate layer is 100% by mass.
[0074] The thickness of the intermediate layer is preferably 0.01 μm to 1 μm, more preferably 0.03 μm to 0.5 μm, and even more preferably 0.05 μm to 0.3 μm, from the viewpoint of facilitating moisture penetration when the intermediate layer comes into contact with water.
[0075] The laminated films used in each embodiment are generally used to protect the surfaces of other functional sheets and various components used for specific applications during manufacturing, transportation, and storage. After they have served their protective purpose, they are often peeled off the surface and discarded. In the embodiments described above, the coating layer and the base film are separated from a long laminated film formed by joining these laminated films with connecting tape, making this a highly beneficial application from the standpoint of resource conservation and environmental protection.
[0076] 10... Feeding shaft, 20... Backup roller, 31... Spray unit, 40... Winding shaft, 50... Pressurized water supply unit, 51... Supply pump, 53... First tank, 54... Piping, 55... Water source, 60... Water recovery and recycling device, 61... Recovery pump, 63... Second tank, 70... Residue removal device, 71... Filtration filter, 75... Residue detection device, 81... Control unit, 82... Detection unit, 90A, 90B, 90C, 90D ...Laminated film, 91, 91A, 91B, 91C, 91D...Base film, 92A, 92B, 92C, 92D...Coating layer, 94...Boundary line, 96...Connecting tape, 100...Removal device, 301...Injection chamber, 511, 531, 631...Piping, 900, 901...Long laminated film, 921C...Release agent layer, 922C...Ceramic green sheet, 1a...Discharge port, 20a...Central axis.
Claims
1. A method for removing a coating layer from a plurality of laminated films having a base film and a coating layer, comprising: a step of preparing a laminated film roll by winding a long laminated film in which a plurality of the laminated films are connected by connecting tape into a roll; a step of unwinding the long laminated film from the laminated film roll; a detection step of directly or indirectly detecting the presence or absence of the connecting tape in the long laminated film; a spraying step of spraying pressurized water onto the coating layer to remove the coating layer of the long laminated film; a spraying condition control step of changing the spraying conditions of the pressurized water sprayed onto the coating layer in the spraying step based on the detection information from the detection step; and a base material recovery step of winding the base film, after the coating layer has been removed from the long laminated film, into a roll and recovering it.
2. When the detection information in the detection step detects that the connecting tape has changed from a state in which it is not detected to a state in which it is detected, the spray condition control step changes the spray conditions so as to reduce the water pressure of the pressurized water or stop the spraying of the pressurized water when the tip of the connecting tape reaches the spray range of the pressurized water in the spray step. When the detection information in the detection step detects that the connecting tape has changed from a state in which it is detected to a state in which it is not detected, the spray condition control step returns the spray conditions to the conditions for removing the coating layer when the rear end of the connecting tape moves outside the spray range of the pressurized water in the spray step. The tip of the connecting tape is the downstream end of the connecting tape in the transport direction of the long laminated film, and the rear end of the connecting tape is the upstream end of the connecting tape in the transport direction of the long laminated film. The method for removing a coating layer according to claim 1.
3. The method for removing a coating layer according to claim 1, wherein the detection step involves irradiating the long laminated film with electromagnetic waves or ultrasonic waves and detecting reflected waves reflected from the connecting tape, or detecting transmitted waves that pass through the long laminated film and the connecting tape, and the electromagnetic waves include visible light, ultraviolet light, or infrared light.
4. The method for removing a coating layer according to claim 2, wherein in the spraying step, the timing at which the leading edge of the connecting tape reaches the spraying range of the pressurized water is calculated based on the distance from the location where the leading edge of the connecting tape was detected in the detection step to the spraying range and the transport speed of the long laminated film, and the timing at which the rear end of the connecting tape moves outside the spraying range of the pressurized water is calculated based on the distance from the time when the rear end of the connecting tape is no longer detected in the detection step to outside the spraying range and the transport speed of the long laminated film.
5. The method for removing a coating layer according to claim 1 or claim 2, wherein the coating layer includes a release agent layer.
6. The method for removing a coating layer according to claim 5, wherein the coating layer includes a ceramic green sheet.
7. A coating layer removal apparatus for removing a coating layer from a laminated film having a base film and a coating layer, wherein the laminated film is a single unbonded laminated film or a long laminated film in which two or more laminated films are joined together with a connecting tape, the apparatus includes: a feeding shaft for feeding the long laminated film from a laminated film roll in which the long laminated film is wound into a roll shape; a detection unit for directly or indirectly detecting the presence or absence of the connecting tape in the long laminated film; a backup roller disposed downstream of the feeding shaft for transporting the long laminated film downstream; a spray unit including one or more nozzles disposed opposite the backup roller, for spraying pressurized water from the one or more nozzles onto the coating layer so as the long laminated film passes the backup roller to remove the coating layer; and a pressurized water supply unit for supplying pressurized water to the spray unit. A coating layer removal device comprising: a control unit that controls the conditions the long laminated film receives from the spray of pressurized water based on detection information from the detection unit; and a winding shaft that winds the base film, after the coating layer has been removed from the long laminated film, into a roll shape, wherein the detection unit is connected to the control unit, the pressurized water supply unit includes a pump, and the pump is connected to the spray unit.
8. The coating layer removal apparatus according to claim 7, wherein the control unit is connected to the pump and changes the injection conditions of the pressurized water ejected from the one or more nozzles.
9. The apparatus for removing a coating layer according to claim 7 or claim 8, wherein the detection unit is a means for irradiating the long laminated film with electromagnetic waves or ultrasonic waves and detecting reflected waves reflected from the connecting tape, or a means for detecting transmitted waves that pass through the long laminated film and the connecting tape, and the electromagnetic waves include visible light, ultraviolet rays, or infrared rays.