Roll press device and method of producing laminate structure

Abstract

A roll press device is provided and includes a pair of press rolls; and an auxiliary roll that is disposed on at least one of upstream and downstream of the pair of press rolls, wherein the roll press device is configured to press a laminate structure by allowing the laminate structure to pass between the pair of press rolls, and wherein a laminate structure contact surface of the auxiliary roll is positioned above or below a virtual plane that the laminate structure includes when the laminate structure passes between the pair of press rolls.

1 . A roll press device comprising:
 a pair of press rolls; and   an auxiliary roll that is disposed on at least one of upstream and downstream of the pair of press rolls,   wherein the roll press device is configured to press a laminate structure by allowing the laminate structure to pass between the pair of press rolls, and   wherein a laminate structure contact surface of the auxiliary roll is positioned above or below a virtual plane that the laminate structure includes when the laminate structure passes between the pair of press rolls.   
     
     
         2 . The roll press device according to  claim 1 ,
 wherein an angle of the laminate structure contact surface of the auxiliary roll with respect to the virtual plane is larger than zero degree and is equal to or less than 10 degrees.   
     
     
         3 . The roll press device according to  claim 1 ,
 wherein   the laminate structure includes   a substrate including a first surface and a second surface opposite to the first surface,   a first layer provided on the first surface of the substrate, and   a second layer provided on the second surface of the substrate,   the first layer includes a first end portion and a second end portion along a width direction of the substrate,   the second layer includes a third end portion and a fourth end portion along the width direction of the substrate,   the first end portion is opposite to the third end portion,   the second end portion is opposite to the fourth end portion,   the third end portion is positioned closer to a central portion side of the substrate than the first end portion,   an end surface of the third end portion includes an inclined surface or a stair shape or a combined shape of the inclined surface and the stair shape,   the laminate structure is configured to penetrate between the pair of press rolls, and   in a case where the second layer is positioned below the first layer, the laminate structure contact surface of the auxiliary roll is positioned below the virtual plane, and in a case where the second layer is positioned above the first layer, the laminate structure contact surface of the auxiliary roll is positioned above the virtual plane.   
     
     
         4 . The roll press device according to  claim 3 , wherein V 10  is an average volume density value of a region with a length of 1 mm in the first layer from one portion which is 2 mm apart outward from a portion of the first layer which is opposite to the third end portion to another portion which is 3 mm apart from the portion, and V 11  is an average volume density value of a region in the first layer which is sufficiently apart inward from the portion of the first layer which is opposite to the third end portion, and wherein V 10 /V 11 ≥0.94 is satisfied. 
     
     
         5 . The roll press device according to  claim 1 ,
 wherein
 the laminate structure penetrates between the pair of press rolls, and 
   in a case where the second layer is positioned below the first layer, the laminate structure contact surface of the auxiliary roll is positioned below the virtual plane, and in a case where the second layer is positioned above the first layer, the laminate structure contact surface of the auxiliary roll is positioned above the virtual plane.   
     
     
         6 . A method for producing a laminate structure comprising:
 pressing the laminate structure while passing between a pair of press rolls,
 wherein the laminate structure includes: 
   a substrate including a first surface and a second surface opposite to the first surface;   a first layer provided on the first surface of the substrate; and   a second layer provided on the second surface of the substrate,   wherein   the first layer includes a first end portion and a second end portion along a width direction of the substrate,   the second layer includes a third end portion and a fourth end portion along the width direction of the substrate,   the first end portion is opposite to the third end portion,   the second end portion is opposite to the fourth end portion,   the third end portion is positioned closer to a central portion side of the substrate than the first end portion, and   an end surface of the third end portion includes an inclined surface or a stair shape or a combined shape of the inclined surface and the stair shape.   
     
     
         7 . The method for producing a laminate structure according to  claim 6 ,
 wherein a radius of the pair of press rolls is r (m) and an optimal incline angle of the end surface of the third end portion is B opt  (degrees),   B opt =p×r+q is satisfied where −9≤p≤−5 and 6≤q≤10.   
     
     
         8 . The method according to  claim 6 , wherein V 10  is an average volume density value of a region with a length of 1 mm in the first layer from one portion which is 2 mm apart outward from a portion of the first layer which is opposite to the third end portion to another portion which is 3 mm apart from the portion, and V 11  is an average volume density value of a region in the first layer which is sufficiently apart inward from the portion of the first layer which is opposite to the third end portion, and wherein V 10 /V 11 ≥0.94 is satisfied. 
     
     
         9 . A method for producing a laminate structure comprising:
 using a roll press device,   wherein the roll press device includes
 a pair of press rolls, and 
 an auxiliary roll that is disposed on at least one of upstream and downstream of the pair of press rolls, 
 wherein a laminate structure contact surface of the auxiliary roll is positioned above or below a virtual plane that the laminate structure includes when the laminate structure passes between the pair of press rolls, and wherein the laminate structure is pressed wile passing between the pair of press rolls, and
 wherein the laminate structure includes: 
 
   a substrate including a first surface and a second surface opposite to the first surface;   a first layer provided on the first surface of the substrate; and   a second layer provided on the second surface of the substrate,   wherein   the first layer includes a first end portion and a second end portion along a width direction of the substrate,   the second layer includes a third end portion and a fourth end portion along the width direction of the substrate,   the first end portion is opposite to the third end portion,   the second end portion is opposite to the fourth end portion,   the third end portion is positioned closer to a central portion side of the substrate than the first end portion, and   an end surface of the third end portion includes an inclined surface or a stair shape or a combined shape of the inclined surface and the stair shape.   
     
     
         10 . The method according to  claim 9 , wherein V 10  is an average volume density value of a region with a length of 1 mm in the first layer from one portion which is 2 mm apart outward from a portion of the first layer which is opposite to the third end portion to another portion which is 3 mm apart from the portion, and V 11  is an average volume density value of a region in the first layer which is sufficiently apart inward from the portion of the first layer which is opposite to the third end portion, and wherein V 10 /V 11 ≥0.94 is satisfied.