WO2016174956A1 - Method for producing flexible laminate - Google Patents

Abstract

This method for producing a flexible laminate 1 comprises a formation step, a lamination step, a cutting step, a grinding step and a separation step. In the formation step, a flexible laminate 1, which has a resin film 2 and a glass film 4 that is laminated on and bonded to the resin film 2, is formed. In the lamination step after the formation step, a laminate 7 with a sheet is formed by laminating and bonding the flexible laminate 1 onto a supporting sheet 5. In the cutting step after the lamination step, the laminate 7 with a sheet is cut. In the grinding step after the cutting step, the cut surface of the laminate 7 with a sheet is ground. In the separation step after the grinding step, the flexible laminate 1 is separated from the laminate 7 with a sheet.

Description

Method for producing flexible laminate

The present invention relates to a method for producing a flexible laminate.

As is well known, a laminated body in which a glass plate is laminated and integrated with a resin plate is derived from a resin and various properties such as high hardness, high durability, high air tightness, gas barrier properties and high-class feeling derived from glass. It has various characteristics such as light weight and high impact resistance.

Accordingly, this type of laminate is widely used in a wide range of fields, for example, flat panel displays (FPD) such as liquid crystal displays and plasma displays, portable electronic devices such as mobile phones and tablet PCs, solar cells, and electromagnetic cookers. -It is expected to be used as a panel material for electronic equipment or as a material for window panels of building structures and various vehicles (see, for example, Patent Document 1).

JP 2013-107245 A

By the way, such a laminated body becomes flexible by thinning. It is necessary to cut this flexible laminate (hereinafter referred to as a flexible laminate) into a shape and size according to the application. However, when the flexible laminate is cut, in particular, the cut surface of the glass portion may be formed on an uneven surface (rough surface) having minute defects such as cracks and chipping. If the cut surface having such a surface property is left as it is, the possibility of causing a fatal problem in terms of the quality of the product incorporating the flexible laminate, such as cracking of the glass portion starting from a minute defect, is remarkably increased. For this reason, after the flexible laminate is cut into a predetermined shape and size, it is necessary to remove the end portion including the cut surface of the flexible laminate by a grinding process.

However, when an attempt is made to grind the cut surface of the flexible laminate, because of the flexibility of the flexible laminate, when the grinding tool comes into contact with the flexible laminate, Since the situation that it moves violently and breaks occurs, the flexible laminate could not be ground.

Also, since the flexible laminate is rich in flexibility, the flexible laminate may be bent by its own weight when handling the grinding after the cutting process. Many end defects of the glass part after the cutting have many micro defects, and the bending stress concentrates on the micro defects on the cutting surface, so that the glass part of the flexible laminate may be broken.

SUMMARY OF THE INVENTION In view of the above circumstances, the present invention provides a technical problem of enabling a cut surface of a flexible laminate to be ground without being cracked after the cutting in the manufacturing process of the flexible laminate. And

A manufacturing method of a flexible laminate that has been invented in order to solve the above-described problems includes a production step of producing a flexible laminate having a resin film and a glass film laminated and bonded to the resin film, After the manufacturing process, the flexible laminated body is laminated and bonded to a support sheet to form a laminated body with a sheet, the cutting process for cutting the laminated body with the sheet after the laminating process, and the cutting process. A grinding process for grinding a cut surface of the laminate with sheet later and a peeling process for peeling the flexible laminate from the laminate with sheet after the grinding process are provided.

In the laminate with sheet, the flexible laminate is supported by the support sheet, and the flexibility is suppressed as compared with the case of the flexible laminate alone. Therefore, even if the grinding tool comes into contact with the laminated body with sheets in the grinding step, the vigorous movement of the laminated body with sheets is suppressed, and the flexible laminated body can be ground.

In the above configuration, there is a laminating process before the cutting process, and the flexible laminate is supported by the support sheet from the cutting process to the grinding process, so after the cutting process and before the grinding process In addition, it is possible to avoid a situation in which the glass film of the flexible laminate breaks due to the micro defect of the cut surface due to the bending of the flexible laminate.

In the above configuration, in the laminate with sheet, it is preferable that the resin film is disposed closest to the support sheet in the flexible laminate.

In the peeling step, when the flexible laminate is peeled from the laminate with sheet, the flexible laminate may be bent so that the support sheet side is convex. In such a bent state, tensile stress is generated on the support sheet side of the flexible laminate, and compressive stress is generated on the opposite side of the flexible laminate from the support sheet. Glass is more susceptible to cracking when tensile stress is generated than when compressive stress is generated. If it is said structure, in a flexible laminated body, since a glass film will be arrange | positioned on the opposite side to a support sheet and will be arrange | positioned on the side which a compressive stress produces, it suppresses that a flexible laminated body is cracked. Can be expected.

In the above configuration, in the laminating step, the flexible laminate is laminated and bonded to the support sheet via an adhesive layer, and the adhesive layer has an adhesive force to the flexible laminate in the support sheet. It is preferable that it is smaller than the adhesive force with respect to.

If it is this structure, after peeling a flexible laminated body from a laminated body with a sheet | seat, an adhesive layer will remain on a support sheet instead of a flexible laminated body. Therefore, time and labor for peeling the adhesive layer from the flexible laminate can be eliminated.

In the above configuration, after the grinding step, it is preferable that a portion of the surface to be ground of the flexible laminate that is adjacent to the glass film in the laminating direction protrudes from the glass film. Here, the portion adjacent to the glass film in the laminating direction is formed with a layer (a layer for bonding the resin film and the glass film or a layer having other functions) interposed between the resin film and the glass film. If the glass film is directly laminated and bonded to the resin film, it is a resin film.

If it is this structure, after peeling a flexible laminated body from a laminated body with a sheet | seat, since the site | part of a glass film is not protruding among the grinding surfaces of a flexible laminated body, the site | part of a glass film is another member. It is possible to suppress cracking or damage due to contact with the like.

In the above configuration, it is preferable to bend the support sheet when the flexible laminate is peeled in the peeling step.

With this configuration, when the flexible laminate is peeled from the laminate with sheet, bending of the flexible laminate can be suppressed, so that the flexible laminate is prevented from being unduly loaded and cracked. it can.

As described above, according to the present invention, the cut surface of the flexible laminate can be ground without being cracked after the cutting in the manufacturing process of the flexible laminate. .

It is a flowchart which shows the manufacturing method of the flexible laminated body which concerns on embodiment of this invention. It is a schematic sectional drawing of the flexible laminated body produced at a production process. It is a schematic sectional drawing of the laminated body with a sheet | seat formed in a lamination process. It is a schematic sectional drawing of the laminated body with a sheet | seat cut | disconnected by the cutting process. It is a schematic sectional drawing of the laminated body with a sheet | seat ground by the grinding process. It is a schematic sectional drawing of the laminated body with a sheet in the middle of peeling a flexible laminated body at a peeling process. It is a schematic sectional drawing of the flexible laminated body peeled by the peeling process. It is an enlarged view of the A section of FIG. It is a figure which shows the modification of FIG. 8A. It is a figure which shows the modification of FIG. 8A.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

FIG. 1 is a flowchart showing a method for manufacturing a flexible laminate according to an embodiment of the present invention. This method for manufacturing a flexible laminate includes a production step S1, a lamination step S2, a cutting step S3, a grinding step S4, and a peeling step S5.

In the production step S1, the flexible laminate 1 shown in FIG. 2 is produced. The flexible laminate 1 has a resin film 2 and a glass film 4 laminated and bonded to the resin film 2 via a bonding layer 3. In the illustrated example, the glass film 4, the bonding layer 3, and the resin film 2 are large in this order, and are arranged so that the ends protrude in this order. This is to prevent the end of the glass film 4 from protruding because the glass film 4 is most easily broken.

The resin film 2 preferably has a thickness of 1 μm to 1000 μm, more preferably 5 μm to 500 μm, and most preferably 10 μm to 100 μm. Here, a resin film 2 having a thickness of 38 μm is used. Examples of the material of the resin film 2 include polycarbonate (PC), acrylic, polyethylene terephthalate (PET), polyether ether ketone (PEEK), polyamide (PA), polyvinyl chloride (PVC), polyethylene (PE), and polypropylene ( PP), polyethylene naphthalate (PEN), polyimide (PI) and the like.

The bonding layer 3 preferably has a thickness of 1 μm to 1000 μm, more preferably a thickness of 5 μm to 500 μm, and most preferably a thickness of 10 μm to 100 μm. Here, the bonding layer 3 having a thickness of 25 μm is used. Examples of the material of the bonding layer 3 include acrylic adhesives, silicone adhesives, rubber adhesives, ultraviolet curable acrylic adhesives, ultraviolet curable epoxy adhesives, thermosetting epoxy adhesives, and heat. Examples thereof include a curable melamine adhesive, a thermosetting phenol adhesive, an ethylene vinyl acetate (EVA) interlayer, and a polyvinyl butyral (PVB) interlayer.

The glass film 4 preferably has a thickness of 10 μm to 1000 μm, more preferably 10 μm to 500 μm, and most preferably 10 μm to 100 μm. Here, a glass film 4 having a thickness of 50 μm is used. Although there is no special limitation in the composition of the glass film 4 which can be used, the glass film 4 formed with the alkali free glass which does not contain an alkali component is used especially suitably. This is because, in the case of a glass containing an alkali component in the composition, the alkali component in the glass is released with time, and when the bending stress is applied to the flexible laminate 1, the portion from which the alkali component is removed starts. This is because the glass film 4 is easily broken.

In the lamination step S2 after the production step S1, the flexible laminate 1 is laminated on the support sheet 5 via the adhesive layer 6 to form a laminate with sheet 7 shown in FIG. In this embodiment, in the laminate with sheet 7, the resin film 2 is disposed closest to the support sheet 5 in the flexible laminate 1, but the glass film 4 is in the flexible laminate 1. It may be arranged on the most support sheet 5 side. Moreover, although illustration is abbreviate | omitted, in the lamination process S2, the protective film for protecting the glass film 4 with respect to the glass film 4 is laminated | stacked and fixed. In the illustrated example, the resin film 2, the adhesive layer 6, and the support sheet 5 of the flexible laminate 1 are large in this order, and are arranged so that the ends protrude in this order. This is also for protecting the glass film 4 of the flexible laminate 1.

The support sheet 5 preferably has a thickness of 0.1 mm to 5 mm, more preferably a thickness of 0.3 mm to 3 mm, and most preferably a thickness of 0.5 mm to 1 mm. Here, a support sheet 5 having a thickness of 0.5 mm is used. That is, the thickness of the support sheet 5 is larger than the thickness of the flexible laminate 1.

The material of the support sheet 5 is not particularly limited as long as the rigidity capable of supporting the flexible laminate 1 is obtained, and examples thereof include resin, glass, ceramics, and the like. Resins are preferred from the viewpoints of ease of processing, ease of cutting, cost, and the like.

When a resin is used as the support sheet 5, the resin material may be the same as that of the resin film 2.

Further, the flexural modulus of the support sheet 5 is preferably 100 MPa or more and 5000 MPa or less. When the flexural modulus exceeds 5000 MPa, the support sheet 5 becomes difficult to bend, and thus the flexible laminate 1 may not be peeled from the laminate with sheet 7. When the bending elastic modulus is less than 100 MPa, the rigidity of the laminated body 7 with sheet becomes insufficient, and there is a possibility that grinding cannot be performed. In this respect, the flexural modulus is more preferably 500 MPa to 4000 MPa, and most preferably 1000 MPa to 3000 MPa. Here, polycarbonate (PC) having a flexural modulus of 2300 MPa is used.

The adhesive layer 6 is a layer that releasably bonds the flexible laminate 1 and the support sheet 5. In the adhesive layer 6, the adhesive force to the flexible laminate 1 is smaller than the adhesive force to the support sheet 5. The adhesive layer 6 preferably has a thickness of 5 μm to 1000 μm, more preferably 20 μm to 500 μm, and most preferably 50 μm to 100 μm. Here, an adhesive layer 6 having a thickness of 80 μm is used.

In this embodiment, the adhesive layer 6 is composed of a self-adhesive resin layer and an adhesive layer formed by applying an adhesive to the resin layer. It arrange | positions so that the flexible laminated body 1 side and an adhesive material layer may become the support sheet 5 side. However, the adhesive layer 6 is not limited to such a configuration, and any adhesive layer 6 may be used as long as the flexible laminate 1 and the support sheet 5 are detachably bonded.

Examples of the material of the self-adhesive resin layer constituting the adhesive layer 6 of the present embodiment include polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polypropylene (PP), and the like. . Further, the material of the adhesive layer constituting the adhesive layer 6 of the present embodiment may be the same as the material of the bonding layer 3.

In the cutting step S3 after the laminating step S2, the laminated body with sheet 7 is cut along a line indicated by a two-dot chain line in FIG. 3 so that the laminated body with sheet 7 has a desired size shown in FIG. Examples of the cutting method include laser cutting, water jet cutting, laser cleaving, dicing cutting and the like.

In the grinding step S4 after the cutting step S3, the cut surface 7a of the laminate with sheet 7 is ground. Grinding is performed by pressing the grinding tool 8 having a grinding surface 8a having a V-shaped cross section indicated by a two-dot chain line in FIG. 4 against the cut surface 7a. In this grinding step S4, the most part removed by grinding in the laminated body 7 with the sheet is the lower end of the support sheet 5, and the maximum distance d from the cut surface 7a of the ground surface (surface to be ground 7b) is, for example, 0.8 to 1.2 mm.

When all the cut surfaces 7a of the laminate with sheet 7 are ground and the grinding step S4 is completed, the laminate with sheet 7 is in the state shown in FIG.

In the peeling step S5 after the grinding step S4, as shown in FIG. 6, the flexible laminate 1 is peeled from the laminated body 7 with the sheet 7 fixed on the suction stage 9. Specifically, first, the laminated body 7 with sheet is turned upside down and placed on the suction stage 9, and the laminated body 7 with sheet is fixed by suction of the suction stage 9. In this state, the suction pad 10 is adsorbed to the support sheet 5 of the laminated body 7 with sheet, and the support sheet 5 is pulled so that the support sheet 5 is bent, and is peeled from the flexible laminate 1. In addition, since the flexible laminated body 1 of the laminated body 7 with a sheet | seat is maintained in flat form by the adsorption | suction stage 9 in the case of peeling, it can prevent that the flexible laminated body 1 bends and breaks unjustly.

After peeling the entire support sheet 5 from the flexible laminate 1, when the suction of the suction stage 9 to the flexible laminate 1 is stopped and the flexible laminate 1 is turned upside down, the flexible laminate 1 is in the state shown in FIG. 7 (the peeling step S5 is completed). The flexible laminate 1 is obtained by grinding the cut surface 7a. As shown in an enlarged view in FIG. 8A, a portion of the ground surface 7 b of the flexible laminate 1 that is adjacent to the glass film 4 in the laminating direction (bonding layer 3) protrudes from the glass film 4. In addition, the bonding layer 3 protrudes from the resin film 2 in the surface 7b to be ground.

In the present invention, the portion of the ground surface 7b of the flexible laminate 1 that is adjacent to the glass film 4 in the laminating direction only has to protrude from the glass film 4, for example, as shown in FIG. The resin film 2 may protrude from the bonding layer 3 in the ground surface 7b. Moreover, as shown to FIG. 8C, the to-be-ground surface 7b may have a curved shape instead of a linear cross section.

In the manufacturing method of the flexible laminate of the present embodiment configured as described above, the following effects can be enjoyed.

In the laminate with sheet 7, the flexible laminate 1 is supported by the support sheet 5, and the flexibility is suppressed as compared to the case of the flexible laminate 1 alone. Therefore, even if the grinding tool 8 comes into contact with the laminated body 7 with the sheet in the grinding step S4, it is possible to suppress the vigorous movement of the laminated body 7 with the sheet, and the flexible laminated body 1 can be ground.

Further, in the present invention, there is a lamination step S2 before the cutting step S3, and since the flexible laminate 1 is supported by the support sheet 5 from the cutting step S3 to the grinding step S4, after the cutting process, Prior to the grinding process, it is possible to avoid a situation in which the glass film 4 of the flexible laminate 1 is broken due to minute defects in the cut surface 7a.

The present invention is not limited to the above embodiment, and various modifications are possible within the scope of the technical idea. For example, in the above embodiment, the grinding surface 8a of the grinding tool 8 used in the grinding step S4 has a V-shaped cross section, but the cross section may be a linear shape or the cross section may be a curved shape. Good.

Moreover, in the said embodiment, although the flexible laminated body 1 is laminated | stacked and adhere | attached on the support sheet 5 via the contact bonding layer 6 in the laminated body 7 with a sheet | seat, a contact surface shall be smooth and clean, for example The flexible laminate 1 may be directly laminated and bonded to the support sheet 5 by means such as adhesion.

Moreover, in the said embodiment, although the glass film 4 is laminated | stacked and couple | bonded with the resin film 2 via the bonding layer 3 in the flexible laminated body 1, the glass film 4 is obtained by means, such as welding, for example. The resin film 2 may be directly laminated and bonded. Further, a layer having a function other than bonding the glass film 4 and the resin film 2 may be interposed between the glass film 4 and the resin film 2. Moreover, in the flexible laminated body 1, although the glass film 4 and the resin film 2 were each one piece, multiple pieces may be sufficient respectively.

DESCRIPTION OF SYMBOLS 1 Flexible laminated body 2 Resin film 3 Bonding layer 4 Glass film 5 Support sheet 6 Adhesive layer 7 Laminated body 7a Cut surface 7b Surface to be ground S1 Production process S2 Lamination process S3 Cutting process S4 Grinding process S5 Peeling process

Claims (5)

A production process for producing a flexible laminate having a resin film and a glass film laminated and bonded to the resin film;
After the production step, a lamination step of laminating and bonding the flexible laminate to a support sheet to form a laminate with a sheet;
After the laminating step, a cutting step of cutting the laminate with sheet,
After the cutting step, a grinding step of grinding the cut surface of the laminate with sheet,
The manufacturing method of a flexible laminated body provided with the peeling process of peeling the said flexible laminated body from the said laminated body with a sheet | seat after the said grinding process. 2. The method for manufacturing a flexible laminate according to claim 1, wherein in the laminate with sheet, the resin film is disposed closest to the support sheet in the flexible laminate. . In the laminating step, the flexible laminate is laminated and bonded to the support sheet via an adhesive layer,
The method for producing a flexible laminate according to claim 1, wherein the adhesive layer has an adhesive force with respect to the flexible laminate that is smaller than an adhesive force with respect to the support sheet. The portion of the surface to be ground of the flexible laminate that is adjacent to the glass film in the laminating direction protrudes from the glass film after the grinding step. The manufacturing method of the flexible laminated body as described in a term. The method for producing a flexible laminate according to any one of claims 1 to 4, wherein the support sheet is bent when the flexible laminate is peeled in the peeling step.

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