WO2023190818A1 - Recycle material manufacturing method, recycle material, regenerated material manufacturing method, and recycle material manufacturing apparatus - Google Patents

Abstract

This recycle material manufacturing method comprises: a step for unspooling a laminate film in one direction from a roll on which the laminate film is spooled, the laminate film comprising an elongate base material film extending in the one direction and at least one layer of a function layer formed on one surface of the base material film; a step for pressing a removal member for peeling the function layer onto the one surface side of the laminate film to remove the function layer; and a step for spooling the laminate film from which the function layer has been removed into a roll. Between the unspooling step and the spooling step, the laminate film is not contacted with an organic solvent.

Description

Recycled material manufacturing method, recycled material, recycled material manufacturing method, and recycled material manufacturing equipment

The present invention relates to a method for manufacturing recycled materials, recycled materials, a method for manufacturing recycled materials, and an apparatus for manufacturing recycled materials.
This application claims priority based on Japanese Patent Application No. 2022-054763 filed on March 30, 2022 and Japanese Patent Application No. 2022-189933 filed on November 29, 2022, and the contents thereof is incorporated here.

Due to the recent rise in environmental awareness, the reduction and reuse of waste plastics is being actively considered as a response to a recycling-oriented society. For example, for a laminated film in which a functional layer such as a hard coat layer or an adhesive layer is provided on the surface of a polyester film (resin film), there is a technology that removes the functional layer to create a polyester film and reuses the resulting polyester film. known (for example, see Patent Document 1). Specifically, Patent Document 1 discloses a method of removing functional layers such as a hard coat layer and an adhesive layer by treating them with a chemical containing an alkalinizing agent and a compound having a hydroxyl group such as benzyl alcohol. There is.

Japanese Patent Application Publication No. 2021-160350

However, in the method described in Patent Document 1, there is a risk that the polyester constituting the polyester film will swell with benzyl alcohol used when removing the functional layer and deteriorate. Furthermore, there is a risk that the polyester constituting the polyester film may be hydrolyzed by the alkalizing agent used to remove the functional layer. Therefore, in the method described in Patent Document 1, the physical properties of the polyester film obtained as a recycled material deteriorated from those of the polyester film constituting the original laminated film, and there was a risk that the uses of the recycled material would be limited.

Furthermore, when the functional layer is removed from a laminated film using a material other than a polyester film as the resin film and the resin film is reused, a method that similarly suppresses the deterioration of the resin film is required.

The present invention has been made in view of the above circumstances, and provides a method for producing recycled materials in which a functional layer is removed from a laminated film of a base film and a functional layer without degrading the physical properties of the base film. The purpose is to provide equipment for manufacturing recycled materials. Another object of the present invention is to provide the obtained recycled material and a method for producing a recycled material for producing a molded article using the recycled material as a raw material.

In order to solve the above problems, one embodiment of the present invention includes the following embodiments.

[A1] The laminated film is rolled up from a roll including a long base film extending in one direction and at least one functional layer formed on one side of the base film. a step of pressing a removal member for peeling off the functional layer on the one side of the laminated film to remove the functional layer, and winding the laminated film from which the functional layer has been removed into a roll shape. and a step of taking the laminated film, wherein the base film is made of polyester, and the laminated film is not brought into contact with an alkaline solution between the feeding step and the winding step.

[A2] The method for producing a recycled material according to [A1], wherein the laminated film and the organic solvent are not brought into contact between the feeding step and the winding step.

[A3] The method for producing a recycled material according to [A1] or [A2], wherein in the step of removing the functional layer, the functional layer is polished while sprinkling water on the entire surface.

[A4] The method for producing a recycled material according to [A3], wherein in the step of removing the functional layer, warm water is sprinkled on the entire surface.

[A5] The method for producing a recycled material according to any one of [A1] to [A4], which includes a step of heating the laminated film prior to the step of removing the functional layer.

[A6] The method for producing a recycled material according to [A5], wherein in the heating step, the laminated film is immersed in hot water.

[A7] A recycled material consisting of a long base film extending in one direction, in which a plurality of grooves extending in the one direction are formed on one surface of the base film, and the base film is A recycled material made of polyester and having an intrinsic viscosity of 0.5 dL/g or more.

[A8] A method for producing a recycled material, comprising a step of melting and molding the recycled material according to [A7].

Furthermore, the present invention includes the following aspects in order to solve the above problems.

[1] The laminated film is rolled up from a roll that includes a long base film extending in one direction and at least one functional layer formed on one side of the base film. a step of pressing a removal member for peeling off the functional layer on the one side of the laminated film to remove the functional layer, and winding the laminated film from which the functional layer has been removed into a roll shape. A method for producing a recycled material, comprising: a step of taking the laminated film and an organic solvent from the feeding step to the winding step.

[2] The method for producing a recycled material according to [1], wherein the base film is made of polyester, and the laminated film is not brought into contact with an alkaline solution from the feeding step to the winding step.

[3] The method for producing a recycled material according to [1] or [2], wherein in the step of removing the functional layer, the functional layer is removed while sprinkling water on the entire surface.

[4] The method for producing a recycled material according to [3], wherein in the step of removing the functional layer, warm water is sprinkled on the entire surface.

[5] The method for producing recycled materials according to any one of [1] to [4], which includes a step of heating the laminated film prior to the step of removing the functional layer.

[6] The method for producing recycled materials according to [5], wherein in the heating step, the laminated film is immersed in hot water.

[7] A recycled material consisting of a long base film extending in one direction, wherein one surface of the base film has a plurality of grooves extending in the one direction.

[8] The recycled material according to [7], wherein the base film is made of polyester, and the polyester has an intrinsic viscosity of 0.5 dL/g or more.

[9] A method for producing recycled material, comprising the step of melting and molding the recycled material according to [7] or [8].

[10] The laminated film is rolled up from a roll including a long base film extending in one direction and at least one functional layer formed on one side of the base film. A feeding part that feeds out the functional layer in a direction, a pretreatment part that performs a pretreatment that promotes removal of the functional layer without using an organic solvent, and a removal member that peels off the functional layer is pressed against the one surface of the laminated film. . A recycling material manufacturing apparatus comprising: a removing section that removes the functional layer; and a winding section that winds up the laminated film from which the functional layer has been removed into a roll.

According to the present invention, it is possible to provide a method for producing a recycled material and a device for producing a recycled material, in which a functional layer is removed from a laminated film of a base film and a functional layer without degrading the physical properties of the base film. . Further, it is possible to provide the obtained recycled material and a method for producing a recycled material, which produces a molded article using the recycled material as a raw material.

FIG. 1 is a schematic cross-sectional view showing a laminated film 5 processed in the method for producing recycled materials. FIG. 2 is a schematic explanatory diagram of the recycled material manufacturing method and recycled material manufacturing apparatus of this embodiment. FIG. 3 is an enlarged photograph of the recycled material 1. FIG. 4 is a schematic explanatory diagram of a modified example of the recycling material manufacturing apparatus. FIG. 5 is a schematic explanatory diagram of a modified example of the recycled material manufacturing apparatus. FIG. 6 is a graph showing the results of the example.

Hereinafter, with reference to FIGS. 1 to 5, a method for manufacturing recycled materials, recycled materials, a method for manufacturing recycled materials, and an apparatus for manufacturing recycled materials according to the present embodiment will be described. Note that in all the drawings below, the dimensions and ratios of each component are changed as appropriate to make the drawings easier to read.

FIG. 1 is a schematic cross-sectional view showing a laminated film 5 processed in the method for producing recycled materials of this embodiment. The laminated film 5 includes a base film 2 and a functional layer 3 provided on one surface 2a of the base film 2. Although the laminated film 5 shown in FIG. 1 has the functional layer 3 only on one surface 2a of the base film 2, the present invention is not limited to this. The laminated film 5 may have the functional layer 3 on both sides of the base film 2. Furthermore, the layer to be removed from the laminated film 5 may be provided discretely, such as dirt or partially printed paint.

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

Examples of the material for the resin film include polyolefins such as polyethylene and polypropylene, and polyamides. In addition, any resin known as a material for resin films may be used as appropriate.

The functional layer 3 is provided on one surface 2a of the base film 2, and provides the base film 2 with various functions. The functional layer 3 is not particularly limited, and examples include a release layer, a release layer, an antistatic layer, a printed layer, and an adhesive layer. One functional layer 3 may be provided on one surface 2a, or two or more layers may be stacked.

For example, when the functional layer 3 is a release layer, the functional layer 3 may be formed on one surface 2a of the base film 2 using a silicone release agent as the material for the release layer. The laminated film 5 having such a functional layer 3 is used as a release film that is bonded to the adhesive surface of a surface protection film of various industrial products. Moreover, the laminated film 5 is used as a carrier film when manufacturing a ceramic chip capacitor.

Conventionally, the laminated films used in these applications were collected by manufacturers and disposed of after their use in each application was completed. In addition, even if these laminated films are subjected to material recycling or chemical recycling, the material of the functional layer 3 (for example, silicone release agent if the functional layer 3 is a release layer) is mixed in, making it difficult to use as a recycled raw material. The value of laminated film was decreasing.

Further, as a method for removing the functional layer 3 from the laminated film 5, a method using alkali treatment is known (see Patent Document 1 mentioned above). However, when the base film 2 is made of polyester, the polyester undergoes hydrolysis by the alkali treatment. Therefore, in the base film 2 obtained by removing the functional layer 3, the polyester has a low molecular weight, and there is a possibility that the value of the base film 2 as a material decreases.

The conventional problems have been explained using the case where the functional layer 3 is a release layer as an example, but even when recycling a laminated film in which the functional layer 3 has other functions, the same problem occurs, that is, the problem of changing the material of the functional layer. There is a risk that the value of the base film may decrease due to contamination or functional layer removal processing.

In the method for producing a recycled material of this embodiment, each of the above-mentioned problems can be solved, the functional layer 3 can be easily removed from the laminated film 5, and a recycled material made of the base film 2 can be obtained.

FIG. 2 is a schematic explanatory diagram of the recycled material manufacturing method and recycled material manufacturing apparatus of the present embodiment. A recycled material manufacturing apparatus 100 (hereinafter referred to as manufacturing apparatus 100) shown in FIG. 2 is used to perform the recycled material manufacturing method of this embodiment.

The manufacturing apparatus 100 includes a feeding section 10, a heating section 20, a removing section 30, a cleaning section 40, a drying section 50, a winding section 60, and a control section 90. The manufacturing apparatus 100 is an apparatus that transports the long laminated film 5 in the longitudinal direction, removes the functional layer during the transport process, and manufactures a recycled material made of the base film 2.

In FIG. 2, the relative positions may be explained by assuming that the horizontal direction, which is the transport direction of the laminated film 5, is the x direction, and the vertical direction is the y direction.
Below, they will be explained in order.

(Feeding section)
The feeding unit 10 feeds out the laminated film 5 in the longitudinal direction of the laminated film 5 from the roll 5R on which the laminated film 5 is wound. The operation performed by the feeding section 10 corresponds to the "feeding out step" in the present invention. An example of the roll 5R is one in which a used release film or carrier film is wound up into a roll.

These laminated films are usually wound up into a roll after use and recovered from the location where they were used. As the roll 5R, the roll-shaped laminated film collected in this way may be used as it is. In addition, when the width (length in the transverse direction) of the laminated film 5 constituting the roll 5R is wider than the width that can be processed by the manufacturing apparatus 100, the laminated film 5 is slitted in advance to adjust the width of the roll 5R. You can also use it as

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

(heating part)
The heating unit 20 is provided on the downstream side (+x side) of the laminated film 5 in the transport direction with respect to the feeding unit 10, and heats the laminated film 5 being transported. The process performed in the heating unit 20 corresponds to the "heating process" in the present invention. By heating the laminated film 5 in the heating section 20, it can be expected that the removal of the functional layer 3 in the removal section 30, which will be described later, will be facilitated. In the heating section 20, pretreatment is performed to promote removal of the functional layer 3 without using an organic solvent. For this reason, the heating section 20 corresponds to the "pretreatment section" in the present invention.

The heating unit 20 has a processing tank 21 in which hot water HW is stored. The processing tank 21 preferably includes a heater (not shown) that adjusts the temperature of the hot water HW, a water supply pipe, and a drainage pipe connected to the processing tank 21.

In the heating section 20, the laminated film 5 is transported using transport rolls 101, 102, and 103. Among these, the transport roll 102 is placed in the hot water HW of the processing tank 21. Thereby, the laminated film 5 being conveyed passes through the hot water HW and is heated.

The temperature of the hot water HW depends on the type of laminated film to be processed, based on the correspondence between the heating temperature of the laminated film 5 after passing through the heating section 20 and the effect of removing the functional layer 3 in the removal section 30, which will be described later. It is recommended to set the settings accordingly. The correspondence between the temperature of the hot water HW and the effect of removing the functional layer 3 is preferably determined in advance through a preliminary experiment.

Note that the heating temperature of the laminated film 5 means "the temperature of the laminated film 5 at the exit of the heating section 20." The heating temperature of the laminated film 5 can be measured using a known non-contact thermometer.

Furthermore, when the transport speed of the laminated film 5 is relatively fast within the settable speed range, the passage time of the hot water HW becomes relatively short. Therefore, when increasing the conveyance speed, it is preferable to raise the temperature of the hot water HW so that desired heating can be achieved in a short time.

As an example, the temperature of the hot water HW is 40°C to 90°C. It is preferable to use a processing tank 21 in which hot water HW is stored as the heating section 20, and to immerse the laminated film 5 in the hot water HW, since the laminated film 5 can be heated effectively in a short time.

In addition, as a heating method in the heating section 20, in addition to dipping the laminated film 5 in the hot water HW described above, blowing hot air onto the laminated film 5 or passing the laminated film 5 through a heating environment may also be adopted. can. Examples of "passing through a heated environment" include passing through a chamber whose interior is heated or passing near a heat source such as a heater. When these systems are adopted as the heating unit 20, the laminated film 5 can be heated to a temperature higher than the boiling point of water.

The heating temperature in the heating section 20 is, for example, 20°C to 250°C. The lower limit of the heating temperature is set to a temperature higher than the environmental temperature at which the method for producing recycled materials of this embodiment is carried out. For example, when implementing a method for manufacturing recycled materials in winter or in a cold region, heating to 20° C. may be considered heating. Moreover, the upper limit of the heating temperature is set to a temperature below the melting point of the base film that constitutes the laminated film to be treated.

(removal part)
The removing section 30 is provided on the downstream side of the heating section 20 in the conveying direction of the laminated film 5, and removes the functional layer 3 from the laminated film 5 being conveyed. The process performed in the heating unit 20 corresponds to the "removal process" in the present invention. (Step of removing). The removing section 30 includes a first removing means 30A and a second removing means 30B.

The first removal means 30A includes nip rolls 31 and 32, a buff roll (removal member) 33, and a water sprinkling means 34.

The nip roll 31 has rolls 311 and 312. The nip roll 31 conveys the laminated film 5 by sandwiching it between rolls 311 and 312.

Furthermore, the nip roll 32 includes rolls 321 and 322. The nip roll 32 is provided on the downstream side of the nip roll 31, and conveys the laminated film 5 while sandwiching it between rolls 321 and 322.

The buff roll 33 is a cylindrical member provided between the nip roll 31 and the nip roll 32, and rotates around the axis of the cylinder. The length of the buff roll 33 in the axial direction is longer than the length in the width direction of the laminated film 5 being conveyed. The buff roll 33 is disposed across the laminated film 5 so as to intersect with the laminated film 5, and is pressed against the one surface 2a side of the laminated film 5 from above (+y side) in a rotated state. As a result, the buff roll 33 polishes the functional layer 3 provided on the surface 2a and physically peels it off.

The buff roll 33 may be fixed in its operating position during operation, or may swing in the axial direction of the cylinder, that is, in the width direction of the laminated film 5. When the buff roll 33 is swingable, it is preferable to have a swing part that swings the buff roll 33 in the width direction of the laminated film 5 while being rotated. It is preferable that the swinging section can set the swing width and swing period of the buff roll 33 as appropriate.

The direction of rotation of the buff roll 33 may be the same direction as the conveying direction of the laminated film 5 (forward rotation) at the point of contact with the laminated film 5, or the direction opposite to the conveying direction of the laminated film 5 (reverse rotation). Good too. If the buff roll 33 is set to rotate in the opposite direction, it can be expected that the effect of removing the functional layer 3 will be enhanced.

Furthermore, when the buff roll 33 rotates forward, the laminated film 5 is sent out in the transport direction, and it is assumed that the speed is higher than the set film transport speed. Therefore, when the buff roll 33 is rotated in the forward direction, it is preferable to adjust the film transport speed so as not to exceed the winding speed of the winding section 60.

A backup roll or a backup support plate may be provided below the position where the buff roll 33 and the laminated film 5 contact (on the side opposite to the buff roll 33 with respect to the laminated film 5). By providing these backup loaves or support plates, the functional layer 3 can be removed efficiently without the laminated film 5 being bent by the pressure received from the buff roll 33.

The buff roll 33 is a member formed into a cylindrical shape from a nonwoven fabric containing an abrasive. As the material for the buff roll 33, natural fibers such as cotton and hemp, and synthetic fibers such as polyester and nylon can be used. The material and particle size of the abrasive contained in the buff roll 33 can be appropriately selected depending on the configuration (material, thickness) of the functional layer 3 to be removed.

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

The pressure applied from the buff roll 33 to the laminated film 5 can be adjusted by adjusting the height of the central axis of the buff roll 33. That is, the height position of the center axis of the buff roll 33 that contacts the laminated film 5 without pressing it when supported without slack by the nip rolls 31 and 32 is taken as the reference position, and the movement of the center axis when the buff roll 33 is lowered is Can be adjusted by distance. The above pressure may be set depending on the type of laminated film to be processed, based on the correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3. The correspondence between the position of the buff roll 33 and the effect of removing the functional layer 3 is preferably determined in advance through a preliminary experiment.

Alternatively, the pressure applied from the buff roll 33 to the laminated film 5 may adjust the approach angle of the laminated film 5 with respect to the buff roll. The "approach angle of the film to the buff roll" can be understood as the angle of depression with respect to the imaginary straight line connecting the laminated films supported by the nip rolls before and after the buff roll as a reference. For example, when a virtual straight line connecting the laminated film 5 supported by the nip rolls 31 and 32 (the conveyance position of the laminated film 5 when there is no buff roll 33) extends in the horizontal direction, the depression angle can be expressed as the depression angle with respect to the horizontal direction. can. By lowering the buff roll 33, the angle of depression can be increased. The relationship between the approach angle of the film with respect to the buff roll and the effect of removing the functional layer 3 may be determined in advance through preliminary experiments.

When the buff roll 33 pushes down the laminated film 5, strong pressure is applied from the buff roll 33 to the laminated film 5, and a force corresponding to the rotation direction of the buff roll 33 is easily applied. When the buff roll 33 rotates forward, a force is applied that pushes the laminated film 5 located downstream of the buff roll 33 further downstream. As a result, the laminated film 5 may loosen on the downstream side, resulting in uneven processing and difficulty in winding up at a winding section 60, which will be described later.

Furthermore, when the buff roll 33 rotates in the opposite direction, a force is applied that pulls the laminated film 5 located downstream of the buff roll 33 back to the upstream side. When the pressure applied to the laminated film 5 from the buff roll 33 is increased, the resulting "pull-back force" becomes stronger than the force of winding it downstream by the winding section 60, which will be described later, and the laminated film 5 runs backwards, preventing the processing from progressing. Sometimes.

In these cases, by adjusting the holding force of the laminated film 5 by the nip rolls 31 and 32, the laminated film 5 between the nip rolls 31 and 32 can be held without loosening, and even if high pressure is applied from the buff roll 33, Reverse running of the laminated film 5 can be suppressed.

Note that the nip rolls 31 and 32 send the laminated film 5 downstream at the same speed as the winding speed by the winding section 60. Since the laminated film 5 is sent to the downstream side using the winding section 60 and the nip rolls 31 and 32, there is a difference in conveyance speed between the winding section 60 and the nip rolls 31 and 32. The laminated film 5 may become slack. Therefore, a dancer roll may be provided downstream of the nip roll 32 so that the tension of the laminated film 5 can be adjusted.

The water sprinkling means 34 sprinkles water onto the upper surface (+x side) of the laminated film 5 from the upstream side (-x side) of the contact point between the buff roll 33 and the laminated film 5. The buff roll 33 polishes the surface of the laminated film 5 while the surface of the laminated film 5 is wet. The water sprinkling means 34 suppresses frictional heat at the contact point between the buff roll 34 and the laminated film 5, and washes away fine shavings generated by polishing.

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

The water W to be sprinkled may be at room temperature or may be warm water. The temperature of the hot water is, for example, 30°C to 40°C.

The second removal means 30B includes nip rolls 35 and 36, a buff roll (removal member) 37, and a water sprinkling means 38. The nip roll 35 has rolls 351 and 352. The nip roll 36 has rolls 361 and 362. The nip rolls 35, 36 and the water sprinkling means 38 can have the same configuration as the first removing means 30A.

The buff roll 37 of the second removing means 30B may be the same as or different from the buff roll 33 of the first removing means 30A. Further, the operating conditions of the buff roll 37 may be the same as or different from those of the buff roll 33.

Note that in FIG. 2, the removal section 30 includes the first removal means 30A and the second removal means 30B, but the present invention is not limited to this. The removing unit 30 can have one or more removing means, with the same configuration as the first removing means 30A (nip roll, buff roll, water spraying means) as a set of removing means. It is preferable that the removing unit 30 has a structure including two or more and four or less removing means.

Further, in this embodiment, a buff roll is used as the removal member, but other configurations may be used as long as the functional layer can be peeled off. As the removal member, for example, a cylindrical rotating brush, a rubber roll, or a grindstone can be used.

The removal member is preferably configured to remove the functional layer by bringing it into contact with the functional layer while rotating to apply friction to the contact area. The rotation axis of the removal member is preferably set in a direction that intersects the conveyance direction of the laminated film 5. In the manufacturing apparatus 100 of FIG. 2, the buff rolls 33 and 37, which are removal members, are both set in a direction perpendicular to the conveyance direction of the laminated film 5. The angle of the rotation axis with respect to the film transport direction may be the same or different.

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

The cleaning section 40 has a water sprinkling means 41 provided above the substrate film 2 being transported, and washes the upper surface (one surface 2a side) of the laminated film 5 after the functional layer 3 has been removed. The water sprinkling means 41 sprinkles water on the upper surface of the laminated film 5. The configuration of the water spraying means 41 is not particularly limited, and for example, a known shower head capable of spraying water in the width direction of the laminated film 5 can be employed.

The drying section 50 includes an air knife 51 and a hot air blower 52 in this order from the upstream side.
The air knife 51 blows compressed air toward one surface 2a of the base film 2 to drain water from the one surface 2a. The blowing direction of the compressed air Air is preferably inclined toward the upstream side with respect to the one surface 2a.

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

(winding section)
The winding unit 60 winds up the transported base film 2 (namely, the recycled material 1) into a roll. The roll 1R wound up by the winding section 60 is used as a raw material for material recycling or chemical recycling.

In addition, in the laminated film to be processed, if the functional layer is formed on both sides of the base film, the laminated film can be passed through the manufacturing device 100 twice to remove the functional layer from both sides of the base film. Recycled materials can be obtained.

(control unit)
The control unit 90 controls the operating conditions of each component of the manufacturing apparatus 100. The control unit 90 also stores the correspondence between the type of laminated film 5 to be processed and the operating conditions of each part, and sets appropriate operating conditions each time the type of laminated film 5 to be processed is changed. It would be good to be able to pull it out and change the conditions.

For example, when the functional layer of the laminated film 5 is a release layer, the laminated film 5 is provided with a silicone-based release agent over the entire surface of the film. In this case, the buff roll pressed against the functional layer may slip on the surface of the functional layer (release layer) and removal may not proceed. In this case, it is necessary to strongly press the buff roll against the laminated film.

In addition, when the functional layer is a printed layer, the ease of removing the functional layer depends on the difference between monochrome printing and multicolor printing, the printing conditions such as the presence or absence of a base (overcoating), and the type of ink used. different.

Therefore, it is necessary to set appropriate operating conditions depending on the type of laminated film 5 to be processed, that is, depending on the type of functional layer. On the other hand, when recycling a laminated film, it is assumed that the laminated film having the same configuration is repeatedly processed. Therefore, by storing the correspondence between the type of laminated film 5 and the operating conditions of each part in the control unit 90, switching of the processing target becomes easy.

As described above, in the manufacturing apparatus 100, the functional layer 3 is physically peeled off using the buff rolls 33 and 37. That is, in the method for manufacturing recycled materials using the above-described manufacturing apparatus 100, the laminated film 5 and the organic solvent are brought into contact from the feeding section 10 to the winding section 60, that is, from the feeding process to the winding process. Not yet. Thereby, deterioration and swelling of the recycled material 1 can be suppressed, and the functional layer 3 can be removed from the laminated film 5 without degrading the physical properties of the base film 2 to produce the recycled material 1. Moreover, the environmental burden in manufacturing the recycled material 1 can be reduced.

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

Note that in this embodiment, the "alkaline solution" refers to a solution with a pH of over 8. A weakly basic solution with a pH of 7 or more and 8 or less is not included in the alkaline solution in this embodiment. From this point of view, for example, the water W sprayed from the water spraying means in the above-mentioned removal section 30 may contain a small amount of surfactant to the extent that the effects of the invention are not impaired.

(recycled material)
FIG. 3 is an enlarged photograph of recycled material 1 obtained by the above method. The recycled material 1 consists of a polyester base film 2 from which the functional layer 3 has been removed.

The direction indicated by symbol A in the figure is the width direction of the laminated film, and the direction indicated by symbol B is the longitudinal direction of the laminated film. As shown in FIG. 3, a plurality of grooves extending in the longitudinal direction are formed on one surface 2a of the base film 2. In FIG. 3, the grooves can be confirmed as white streaks. The grooves are scratches formed by the buff roll described above.

Further, when the recycled material 1 is made of polyester, the intrinsic viscosity (IV value) of the polyester constituting the recycled material 1 (base film 2) is 0.5 dL/g or more. The intrinsic viscosity of the polyester constituting the base film 2 is preferably 0.55 dL/g or more, more preferably 0.6 dL/g or more.

The intrinsic viscosity of the film (base film, recycled material) can be measured by a method based on JIS K 7390.

Generally, in the laminated film 5 used as a release film or a carrier film, the intrinsic viscosity of the base film 2 is about 0.6 dL/g. If an alkaline solution (basic substance) is used when removing the functional layer 3 from such a laminated film 5, the base film 2 may be hydrolyzed and the intrinsic viscosity may decrease.

For example, when forming a film, the intrinsic viscosity of the polyester material is approximately 0.6 dL/g, and when spinning fibers, the intrinsic viscosity is approximately 0.5 dL/g. Therefore, when the recycled material obtained from the laminated film is used as a material for chemical recycling or material recycling, the recycled material needs to have the intrinsic viscosity of each of the above-mentioned molded bodies.

In contrast, in the method for producing recycled materials of the present embodiment, the alkaline solution does not come into contact with the laminated film 5 as described above. Therefore, the obtained recycled material 1 can also be suitably used as a material for chemical recycling or material recycling without reducing the intrinsic viscosity of polyester.

Note that "without decreasing" means that a decrease in the intrinsic viscosity within the measurement error range is allowed.

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

The obtained recycled material can be melted and molded to produce recycled material. That is, the method for manufacturing recycled material according to the present embodiment includes a step of melting and molding the above-mentioned recycled material. Examples of recycled materials include the above-mentioned films and fibers.

According to the recycled material manufacturing method and recycled material manufacturing apparatus configured as described above, it is possible to remove the functional layer from the laminated film of the base film and the functional layer without reducing the physical properties of the base film. It is possible to produce recycled materials that can be suitably used as materials for chemical recycling and material recycling.

Furthermore, the recycled material having the above structure can be suitably used as a material for chemical recycling or material recycling.

Furthermore, in the method for manufacturing recycled materials with the above configuration, since the above-mentioned recycled materials are used as raw materials, the environmental impact is low and it is possible to contribute to a recycling-oriented society.

FIGS. 4 and 5 are schematic explanatory diagrams showing a modification of the recycled material manufacturing apparatus.

As shown in FIG. 4, in the recycling material manufacturing apparatus 150 (hereinafter referred to as manufacturing apparatus 150), the feeding unit 10 feeds out the laminated film 5 from two rolls 5R in the longitudinal direction of the laminated film 5. The feeding unit 10 feeds out the laminated film 5 from the roll 5RA, for example, and then feeds it from the roll 5RB as soon as the feeding from the roll 5RA is finished.

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

The manufacturing apparatus 150 has a connecting part 80 between the feeding part 10 and the heating part 20, which connects the laminated film 5A fed out from the roll 5RA and the laminated film 5RB fed out from the roll 5RB within the conveyance path. The connecting portion 80 connects the rear end of one laminated film (for example, the laminated film 5A) and the tip of the other laminated film (for example, the laminated film 5B), and connects the two laminated films 5 that are unwound from the two rolls 5R. It has the function of combining into one.

The manufacturing apparatus 150 also includes a dividing section 90 between the warm air blower 52 (drying section 50) and the winding section 60 that divides the recycled material 1 being conveyed into two recycled materials 1A and 1B in the longitudinal direction. has. The dividing part 90 is a part corresponding to the part where the above-mentioned laminated film 5A and laminated film 5B are connected, and the recycled material 1 may be divided into two recycled materials 1A and 1B, or it can be divided at an arbitrary part. Good too.

For the feeding section 10 and the connecting section 80, for example, a known turret unwinding machine can be employed.

For the winding section 60 and the dividing section 90, for example, a known turret winding machine can be employed.

The winding unit 60 alternately winds the recycled material 1 onto two rolls 1RA and 1RB. The winding section 60 winds the recycled material 1A onto the roll 1RA, for example, and switches to winding onto the roll 1RB as soon as the set value for the amount of winding onto the roll 1RA is reached.

The roll replacement may be performed manually by a worker or an administrator of the manufacturing apparatus 150, or may be performed automatically by the manufacturing apparatus 150.

The control unit 90 controls the connecting unit 80 and the dividing unit 90, and continuously unwinds the laminated film 5 and winds up the recycled material 1. Thereby, continuous operation is possible in the manufacturing apparatus 150.

Further, as shown in FIG. 5, in the removing section 30 of the manufacturing apparatus 150, the water sprinkling means 34 may include a waste water tank 341, a filter 342, piping 343, a pump 344, and a shower head 345. good.

The wastewater tank 341 receives and stores wastewater WW generated from the contact point between the buffroll 33 and the laminated film 5 below the buffroll 33 .

The filter 342 removes solid matter (shavings) contained in the wastewater WW.

Piping 343 connects waste water tank 341, filter 342, and shower head 345. The wastewater WW from which solids have been removed is supplied to the shower head 345 via a pipe 343 by a pump 344 disposed within the path of the pipe 343.

The shower head 345 sprays the buff roll 33 with water W from which solids have been removed from the waste water WW.

Similarly, in the removal section 30, the water sprinkling means 38 may include a waste water tank 381, a filter 382, piping 383, a pump 384, and a shower head 385. Each structure of the water sprinkling means 38 can be made similar to each structure of the water sprinkling means 34.

Additionally, the water spraying means 34 and 38 may include heating equipment that heats the water flowing inside the pipes.

By having the water sprinkling means as described above in the manufacturing apparatus 150, it becomes possible to reuse the water sprinkled on the buff roll. This makes it possible to reduce the amount of wastewater and reduce environmental impact.

By combining the method for manufacturing a recycled material and the method for manufacturing a recycled material of this embodiment, for example, a used release film can be collected, and the functional layer can be removed from the collected release film to produce a recycled material. Furthermore, the obtained recycled material can be melt-processed to produce a base film as a recycled material, and a release layer (functional layer) can be formed on one surface of the film, so that the release film can be recycled and used. In this way, according to the present invention, it is possible to contribute to a recycling-oriented society.

Although preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to such examples. The various shapes and combinations of the constituent members shown in the above example are merely examples, and can be variously changed based on design requirements and the like without departing from the gist of the present invention.

The present invention will be explained below using Examples, but the present invention is not limited to these Examples.

<Examples 1 to 3>
In Examples 1 to 3, a release film having a release layer (functional layer) made of a silicone release agent on one side of a PET film was used as the laminated film. A small piece of 7 cm x 12 cm was cut out from the release film, and the base film side of the small piece was attached to a stainless steel plate to prepare a test piece.

Regarding the obtained test piece, the functional layer exposed on the side opposite to the stainless steel plate was removed using a test machine similar to the removal section 30 of this embodiment.

(Method of measuring residual rate)
The removal of the functional layer from the laminated film of the test piece was determined by measuring the amount of silicone using fluorescent X-rays using a wavelength-dispersive fluorescent X-ray analyzer (manufactured by Rigaku Corporation, ZSX Primus). . Perform fluorescent X-ray measurements on the laminated film before removing the functional layer, and create a calibration curve with the determined amount of silicone A as 100%, perform fluorescent X-ray measurements on only the PET film, and set the determined silicone amount B as 0%. Then, the residual rate (%) of the functional layer was roughly estimated from the silicone amount C determined by performing fluorescent X-ray measurements on the laminated film of the test piece from which the functional layer was removed.

Note that in all cases where the measured value of silicone amount C was smaller than the measured value of silicone amount B, the residual rate of the functional layer was evaluated as 0%.

[Examples 1-1 to 1-5]
In Examples 1-1 to 1-5, a test machine having the following configuration was used.
(Common configuration of test machine)
・Buff roll of first removal means: Count 320
・Buff roll of second removal means: count 600
・Buff roll rotation speed: 2000 rpm
・Rotation direction of buff roll: Reverse direction ・With watering means ・Distance of movement of center axis of buff roll from reference position: 0.2 mm
・Transportation speed of test piece: 4m/min

The temperature conditions were changed as shown in Table 1, and the residual rate of the functional layer was determined.

In the table, "pre-heating" corresponds to the immersion treatment in the heating section 20 of this embodiment. When performing "preheating", the test piece was immersed in warm water for 1 minute.

Furthermore, in the table, "shower temperature" means the temperature of water sprayed from the water spraying means in the removal section 30 of this embodiment.

As a result of the evaluation, it was found that the functional layer was removable in both cases. Furthermore, it has been found that the functional layer can be easily removed by heating the laminated film before removing the functional layer in the removal section.

[Examples 2-1 to 2-4]
In Examples 2-1 to 2-4, the test machine with the above configuration was used, and the rotation speed of the buff roll was set to 500 rpm (Example 2-1), 1000 rpm (Example 2-2), and 1500 rpm (Example 2-3). ), 2000 rpm (Example 2-4). In addition, preheating was performed at 80° C. in common for all.

FIG. 4 is a graph showing the results of Examples 2-1 to 2-4. As shown in FIG. 4, it can be seen that as the rotation speed of the buff roll increases, the residual rate of the functional layer decreases (the removal rate of the functional layer improves).

[Examples 3-1 to 3-24]
In Examples 3-1 to 3-24, a test machine having the following configuration was used. In addition, in common to all, preheating was performed at 80°C, and the shower temperature was set at 50°C.

(Common configuration of test machine)
・Removal means buff roll: Count 320
・Buff roll rotation speed: 2000 rpm
・Rotation direction of buff roll: Reverse direction ・With watering means

As shown in Table 2, the survival rate of the functional layer was determined by changing (1) the moving distance of the central axis of the buff roll with respect to the reference position, (2) the number of times it passed through the test machine, and (3) the conveyance speed. (1) corresponds to the pressure applied from the buff roll to the laminated film. (2) corresponds to the number of removing means included in the removing section in the manufacturing apparatus 100 of this embodiment.

As a result of the evaluation, it was found that under conditions where the transport speed is high, the stronger the pressure applied to the laminated film from the buff roll, the easier it is to remove the functional layer.
It was also confirmed that increasing the number of buff rolls makes it easier to remove the functional layer.

Furthermore, as the transport speed increases, the functional layer tends to be difficult to remove, but it was found that the functional layer can be easily removed by adjusting the pressure applied to the laminated film from the buff rolls and the number of buff rolls.

The above results were obtained for a release film that has a release layer as a functional layer, but in the present invention, the functional layer is physically peeled off using a buff roll. It is expected that similar results will be obtained for laminated films.

<Examples 4 and 5>
In Example 4, a carrier film in which a residue of MLCC (Multi-Layer Ceramic Capacitor) was attached to one side of a PET film was used as the laminated film.
Further, in Example 5, a printed film in which a printed layer was formed on one side of a polyethylene film was used as the laminated film.

In Examples 4 and 5, the following test machine was used. Moreover, in common with Examples 4 and 5, preheating was not performed.
・Buff roll of first removal means: Count 240
・Buff roll of second removal means: None ・Rotation speed of buff roll: 2000 rpm
・Rotation direction of buff roll: Reverse direction ・Water spraying means available Shower temperature 50℃
・Movement distance of the center axis of the buff roll with respect to the reference position: 0.3mm

In Example 4, it was visually confirmed that the black MLCC residue had been removed. A release layer may be provided on the surface of the laminated film on which the MLCC is laminated. If the laminated film has a release layer, it is assumed that the release layer is also removed by polishing to the extent that the MLCC residue is removed.
In Example 5, it was visually confirmed that the printed layer had been removed.

As a result of the evaluation, in Example 4, the MLCC residue was completely removed by passing the test piece through the test machine once at a transport speed of 4 m/min. These conditions were the same as in Example 3-21 above, in which a portion of the release layer remained.

Furthermore, in Example 5, the printed layer was removed by passing the test piece through the test machine once at a transport speed of 1 m/min. These conditions were the same as in Example 3-13 above, in which a portion of the release layer remained.

From these results, it was confirmed that appropriate operating conditions differ depending on the structure of the laminated film.

<Examples 6 to 10>
In Examples 6 to 10, a manufacturing apparatus having the configuration shown in FIG. 2 was used.
(Configuration of manufacturing equipment)
・Winding diameter of raw fabric roll: Maximum diameter 300mm
・Transportation speed: 10m/min ・Hot water temperature in heating section: 90℃
・Immersion time in the heated part: 12 seconds per pass ・Buff roll of first removal means: No. 240
・Buff roll of second removal means: Count 240
・Swinging of buff roll: Yes (excluding Example 9)
・Swing width of buff roll: 10mm
・Swinging cycle of buff roll: 140 round trips/minute ・Shower temperature: 50℃
・Buff roll rotation speed: max. 2000rpm
・Film approach angle to buff roll: depression angle 30°, 50°, 70°
・Rotation direction of buff roll: Reverse direction

In Examples 6 to 10, as in Example 1, a release film (laminated film) having a release layer (functional layer) made of a silicone-based release agent on one side of a PET film was used. The release film was sequentially unrolled from a roll of rolled-up long release film, and the functional layer was continuously removed.

A 30 mm x 30 mm test piece was cut out from the film from which the functional layer had been removed, and the residual rate was determined for the obtained test piece according to the above (method for measuring residual rate).

<Example 6>
The functional layer was removed under the following conditions. Table 3 shows the residual rate of the functional layer.
(conditions)
Temperature of hot water in heating section: 50℃ or 90℃
Buff roll rotation speed: 2000rpm
Passage count (processing count): 1 time

As a result of the evaluation, it was found that the functional layer was removable in both cases. Furthermore, it has been found that the functional layer can be easily removed when the approach angle of the film to the buff roll is large, that is, when the position of the buff roll is lowered and the pressure applied from the buff roll is large. Furthermore, it has been found that the functional layer can be easily removed by heating the laminated film before removing the functional layer in the removal section.

<Example 7>
The functional layer was removed under the following conditions. Table 4 shows the residual rate of the functional layer.
(conditions)
Temperature of hot water in heating section: 90℃
Buff roll rotation speed: 1000rpm, 1500rpm, 2000rpm
Passage count (processing count): 1 time

As a result of the evaluation, it was found that the functional layer was removable in both cases. It was also found that the higher the number of rotations of the buff roll, the easier it was to remove the functional layer.

<Example 8>
The functional layer was removed under the following conditions. The residual rate of the functional layer is shown in Tables 5 and 6. Table 5 shows the results when the heating part temperature was 90°C, and Table 6 shows the results when the heating part temperature was 50°C.
(conditions)
Temperature of hot water in heating section: 50℃, 90℃
Buff roll rotation speed: 1500rpm, 2000rpm
Passage count (processing count): 1 time, 2 times, 3 times

As a result of the evaluation, it was found that the functional layer was removable in both cases. Further, from the results in Table 6, it was found that under the condition where the heating part temperature is relatively low at 50° C., the results tend to vary if the approach angle of the film to the buff roll is small.

<Example 9>
The functional layer was removed under the following conditions, and the effect of the presence or absence of rocking of the buff roll was confirmed. Table 7 shows the residual rate of the functional layer.
(conditions)
Temperature of hot water in heating section: 90℃
Buff roll rotation speed: 1000rpm, 2000rpm
Passage count (processing count): 1 time

As a result of the evaluation, it was found that the functional layer was removable in both cases. It was also found that the higher the number of rotations of the buff roll, the easier it was to remove the functional layer when the buff roll was rocked.

From the above results, it was confirmed that the present invention is useful.

1... Recycled material, 2... Base film, 2a... One side, 3... Functional layer, 5... Laminated film, 33, 37... Buff roll

Claims (10)

1. The laminated film is fed out in the one direction from a roll wound up with a laminated film comprising a long base film extending in one direction and at least one functional layer formed on one surface of the base film. process and
   pressing a removal member for peeling off the functional layer on the one side of the laminated film to remove the functional layer;
   a step of winding up the laminated film from which the functional layer has been removed into a roll;
   A method for producing a recycled material in which the laminated film is not brought into contact with an organic solvent between the feeding step and the winding step.
2. The base film is made of polyester,
   2. The method for producing recycled materials according to claim 1, wherein the laminated film is not brought into contact with an alkaline solution between the feeding step and the winding step.
3. The method for producing recycled materials according to claim 1 or 2, wherein in the step of removing the functional layer, the functional layer is removed while sprinkling water on the entire surface.
4. The method for producing recycled materials according to claim 3, wherein in the step of removing the functional layer, warm water is sprinkled on the entire surface.
5. The method for producing recycled materials according to claim 1, further comprising the step of heating the laminated film prior to the step of removing the functional layer.
6. The method for producing recycled materials according to claim 5, wherein in the heating step, the laminated film is immersed in hot water.
7. A recycled material consisting of a long base film extending in one direction,
   The recycled material has a plurality of grooves extending along the one direction on one surface of the base film.
8. The base film is made of polyester,
   The recycled material according to claim 7, wherein the polyester has an intrinsic viscosity of 0.5 dL/g or more.
9. A method for producing recycled material, comprising the step of melting and molding the recycled material according to claim 7 or 8.
10. The laminated film is fed out in the one direction from a roll wound up with a laminated film comprising a long base film extending in one direction and at least one functional layer formed on one surface of the base film. A feeding section;
    a pretreatment unit that performs pretreatment to promote removal of the functional layer without using an organic solvent;
    a removal unit that presses a removal member that peels off the functional layer against the one surface of the laminated film to remove the functional layer;
    A recycling material manufacturing apparatus comprising: a winding section that winds up the laminated film from which the functional layer has been removed into a roll shape.

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