JP2022119875A - 超広幅連続コーティング装置及びそれを用いたセパレータの製造方法 - Google Patents
超広幅連続コーティング装置及びそれを用いたセパレータの製造方法 Download PDFInfo
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Abstract
Description
20時間以上連続生産時、単位時間(1hr)当たり熱処理工程後の基材フィルムの良品生産量(m2/hr)と、熱処理工程が完了した基材フィルムにコーティングを施して製造されたセパレータの良品生産量(m2/hr)との割合を用いた。生産性(%)の算出には、下記の式1を用いた。同一の基準で比較するために、本発明による製造方法及び非連続式製造方法で熱処理工程が行われたフィルム(コーティング前の基材フィルム)の単位時間当り生産量を基材フィルムの生産量とした。具体的に、巻き取られるロールの交替による損失、非連続式工程で発生する損失などは、基材フィルムの生産量に含まれるが、セパレータの生産量からは除外される。
生産性(%)=(セパレータの生産量(m2/hr))/(基材フィルムの生産量(m2/hr))×100
ポリオレフィン系樹脂(重量平均分子量が3.0×105g/mol、融点が135℃である高密度ポリエチレン)と希釈剤(diluent、40℃で動粘度が160cStであるパラフィンオイル)がそれぞれ28重量%及び72重量%含有された組成物を、二軸コンパウンダを用いて230℃で押出し、T-dieとキャストロールを用いてシートを製造した後、縦方向に112℃で7.5倍、横方向に126℃で6倍逐次延伸した。その後、1.5倍に熱延伸及び熱固定する熱処理を行った。製造された基材フィルムの幅は4,300mmであった。前記製造された基材フィルムにコーティングを連続的に行った。コーティング液としては、Al2O3粉末(平均粒径0.5μm)、ポリビニルアルコール、アクリルラテックス固形分及び脱イオン水からなるものを使用した。
製造されたシートを縦方向に115℃で6.5倍、横方向に127℃で6.5倍逐次延伸したことを除き、実施例1と同様に行っており、熱処理後に製造された基材フィルムの幅は4,200mmであった。
実施例2と同様の方法により基材フィルムを製造し、この際に製造された基材フィルムの幅は実施例2と同様に4,200mmであった。
コーティング幅2,000mmの一般ワイヤバー両面コーティングに代えて、コーティング幅2,000mmの一般グラビア片面コーティングを用いたことを除き、比較例1と同様に行った。
コーティング幅2,000mmの一般ワイヤバー両面コーティングに代えて、コーティング幅2,000mmの一般ダイ(Die)両面コーティングを用いたことを除き、比較例1と同様に行った。この場合、基材フィルムの柔軟性及び乾燥器による揺れ現象によって均一にコーティングされず、製品化が不可能であった。
コーティング幅2,000mmの一般ダイを平行に取り付けることで片面コーティング時のコーティング幅を増やしたことを除き、比較例3と同様に行った。この場合、比較例3と同様に製品化が不可能であった。
12 接触式コーティングローラ
13、14 連結具
21 ローラ溝
22 ハウジング
31 コーティング液流入管
32 コーティング液供給器
41 モータ
111 キャストロール
112、113、114、115 がイドロール
210 延伸または熱処理手段
310 超広幅コーティング装置
410 乾燥器
510 巻き取りローラ
B 基材フィルムの幅
C 全コーティング幅
c1、c2、c3 コーティングされる幅
e1、e2 連結具のサイズ
Claims (10)
- 基材フィルムにコーティング液をコーティングする転写ローラと、
前記転写ローラの一部が挿入されて回転されるようにするローラ溝を備え、供給されるコーティング液が前記ローラ溝に満たされるハウジングと、
前記ハウジングにコーティング液を供給するコーティング液供給器と、を含み、
前記転写ローラは、2つ以上の接触式コーティングローラが連結具によって一体化されていることを特徴とする、コーティング装置。 - 前記連結具は、中心軸が前記コーティングローラの回転軸の延長線上にある、請求項1に記載のコーティング装置。
- 前記連結具の厚さが、前記コーティングローラの直径より小さい、請求項1に記載のコーティング装置。
- 前記コーティングローラは、グラビアロール、マイクログラビアロール、ワイヤバー、ミヤバー、ナノコータ、及びDMコータからなる群から選択される、請求項1に記載のコーティング装置。
- 前記ハウジングは、表面がポリテトラフルオロエチレン及び超高分子量ポリエチレンから選択される何れか1つ以上からなる、請求項1に記載のコーティング装置。
- シートを延伸して基材フィルムを形成するステップと、
前記基材フィルムの片面または両面上にコーティング液をコーティングするステップと、
前記コーティングされたフィルムを長さ方向に切断するステップと、
前記切断されたフィルムをそれぞれ巻き取るステップと、を含み、
前記コーティングステップでは、2つ以上の接触式コーティングローラが連結具によって一体化された転写ローラを用いる、超広幅セパレータの製造方法。 - 前記連結具の 厚さが、前記コーティングローラの直径より小さい、請求項6に記載の超広幅セパレータの製造方法。
- 前記連結具の長さは、前記転写ローラの長さに対して2~5%である、請求項6に記載の超広幅セパレータの製造方法。
- 前記コーティングされたフィルムを長さ方向に切断するステップでは、前記コーティングされたフィルムが連結具に当接する部分で、フィルムの長さ方向に平行にスリットされる、請求項6に記載の超広幅セパレータの製造方法。
- 前記コーティングローラは、グラビアロール、マイクログラビアロール、ワイヤバー、ミヤバー、ナノコータ、及びDMコータからなる群から選択される、請求項6に記載の超広幅セパレータの製造方法。
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