JP2000263698A - Method and apparatus for producing laminated structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a laminated structure wherein a two-dimensional pattern is formed on a substrate by fine projections with high dimensional accuracy. SOLUTION: A laminated plate 10 to be molded is constituted by forming a clayey coating layer on a substrate 11 and held on a table 31. A molded sheet 20 is a composite sheet wherein a surface layer 22 comprising hard rubber is bonded to the surface of a backup sheet 21 made of steel and a predetermined pattern is formed on the surface of the surface layer 22 by unevenness. The molded sheet 20 is attached to a sheet frame 25 at both ends thereof in the longitudinal direction thereof through a support sheet 27 and opposed to the laminated plate 10 through a slight interval so that the surface layer 22 is turned downwardly. By pressing a press roller 50 to the back surface of the molded sheet 20 to rotate the same, the pattern formed on the surface of the molded sheet 20 is transferred to the coating layer 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a laminated structure having a two-dimensional pattern formed by fine projections on a flat substrate.

[0002]

2. Description of the Related Art When manufacturing a structure in which a two-dimensional pattern is formed by fine projections on a flat substrate, such as a rear panel of a plasma display panel, the number of steps is relatively small and the cost is relatively low. As a quick alternative,
A manufacturing method applying press molding has been proposed (for example, JP-A-9-283017).

[0003] In the case of such a manufacturing method using press molding, a block-shaped (or cylindrical) mold is manufactured by using a high-precision processing method, and a clay-like coating layer coated on a substrate is formed. By molding using this mold, a laminated structure having a predetermined pattern formed on the surface is manufactured.

(Problems of the prior art) In the method of forming a coating layer by directly using a mold as described above, the flatness of the substrate is 10 μm or more, and the thickness of the coating layer coated on the substrate is reduced. When the difference is 100 μm or more, the difference in the distance between the mold and the substrate increases, or the difference in the press pressure applied to the coating layer increases. As a result, defects may occur in the cross-sectional shape of the coating layer after molding, or the mold may come into contact with the surface of the substrate and damage the surface of the mold.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the conventional method for forming a coating layer of a laminated board. Another object of the present invention is to provide a method and an apparatus capable of efficiently manufacturing a laminated structure having a two-dimensional pattern formed by fine projections with high dimensional accuracy at low cost.

[0006]

According to the present invention, there is provided a method for manufacturing a laminated structure, comprising the steps of preparing a molded sheet having a pattern formed on its surface by irregularities, and forming the molded sheet on both ends in a longitudinal direction by a sheet frame. Attaching, a step of preparing a laminate in which a clay-like coating layer is laminated on a substrate, a step of holding this laminated plate on the upper surface of a table with the coating layer facing upward, and A step of supporting the sheet frame in a state in which the surface is approached to the upper surface of the laminated plate with the surface facing downward, and pressing the roller with the press roller in the longitudinal direction on the back surface of the molded sheet to form the pattern. Transferring to a coating layer to obtain a laminated structure.

According to the method of the present invention, the surface layer can be pressed against the coating layer with a constant pressure using the press roller, so that the coating layer can be formed efficiently with high dimensional accuracy. be able to.

[0008] Preferably, a release agent is applied to the surface of the molded sheet prior to the step of supporting the sheet frame with the surface of the molded sheet approaching the upper surface of the laminated plate with the surface of the molded sheet facing downward. I do.

Preferably, a press roller whose trunk is covered with a rubber layer is used as the press roller.

[0010] Preferably, the molded sheet is constituted by a steel backup sheet and a surface layer portion which is adhered on the backup sheet, is made of hard rubber or resin, and has the pattern formed on a surface thereof.

The apparatus for manufacturing a laminated structure according to the present invention used in carrying out the above-mentioned method is characterized in that the laminated layer is formed by laminating a clay-like laminated layer on a substrate. An apparatus for manufacturing a body, comprising: a table for holding the laminated plate with the covering layer facing upward; and a sheet frame for supporting a formed sheet having a pattern formed by irregularities on its surface at both ends in the longitudinal direction. And, in a state where the surface of the molded sheet is directed downward and approached to the upper surface of the laminated plate, a gantry supporting the seat frame, and the seat frame, in a state where the seat frame is supported on the gantry, in the longitudinal direction. A reversing mechanism for reversing around one end, a release agent applying device for applying a release agent to the surface of the molded sheet in a state where the sheet frame is reversed, and supporting the sheet frame on the gantry. State, is rolled in the longitudinal direction on the back surface of the molded sheet, it is characterized in that and a press roller for transferring the pattern to the surface of the coating layer.

[0012]

FIG. 1 shows an outline of an apparatus for manufacturing a laminated structure according to the present invention. In the figure, 10 is a laminate, 11
Is a substrate, 12 is a cover layer, 20 is a formed sheet, 21 is a backup sheet, 22 is a surface layer, 25 is a sheet frame, 31 is a table, 33 is a holder, 34 is a stand, 35
Is a reversing mechanism, 37 is a support stand, 40 is a release agent coating device, 5
0 represents a press roller.

The laminate 10 to be formed is shown in FIG.
As shown in FIG. 1, a clay-like coating layer 12 made of a glass paste is laminated on a substrate 11 to a predetermined thickness.
The laminated plate 10 is held on the upper surface of the table 31.

As shown in FIG. 3, the molded sheet 20 is composed of a backup sheet 21 made of a steel sheet and a surface layer 22 made of hard rubber adhered on the backup sheet 21. A predetermined two-dimensional pattern is formed by unevenness on the surface of.

As shown in FIG. 1, the molded sheet 20 is attached to a seat frame 25 via a support sheet 27 at both ends in the longitudinal direction (the left and right direction in FIG. 1) and stretched horizontally. The seat frame 25 is attached to a holder 33, and one end of the holder 33 is supported on a gantry 34. In this position, the formed sheet 20 is
The laminate 22 faces the laminated plate 10 on the table 31 with a slight gap with the surface portion 22 facing downward.

A press roller 5 is provided above the table 31.
0 is arranged. The body of the press roller 50 is covered with a rubber layer 51.

The holder 33 to which the one end of the seat frame 25 is attached is connected to a reversing mechanism 35 via a shaft 36.
It is connected to the. This shaft 36 is attached to the seat frame 25.
Is parallel to the one end. By driving the reversing mechanism 35, the seat frame 25 can be reversed around the axis 36, and the formed sheet 20 can be placed on the support 37 with the surface layer portion 22 facing upward.

Above the support table 37, a release agent coating device 4
0 is provided. The release agent applying device 40 is placed on the surface of the formed sheet 20 which is turned over and placed on the support table 37.
Is applied with a release agent.

FIG. 4 shows the structure of the main part of the release agent coating device 40. The release agent applying device 40 includes a nozzle 41 and a cleaner 42. The release agent is sprayed from the nozzle 41 toward the surface of the molded sheet 20 and then released from the cleaner 42.
As a result, the excess release agent is removed, and the film thickness is evenly distributed.

Next, a method of operating this apparatus will be described.

First, the molded sheet 20 attached to the seat frame 25 is placed on a support 37 with the surface layer portion 22 facing upward. In this state, a release agent (for example, silicone oil) is applied to the surface of the molded sheet 20 with a thickness of about 1 to 2 μm by using the release agent application device 40. In parallel with this, the laminate 10 (substrate 11
On which a clay-like coating layer 12 is laminated).

Next, the seat frame 25 is turned around the shaft 36 using the turning device 35, and the seat frame 2 is turned over.
The other end of 5 is placed on the gantry 34. In this state, as described above, the molded sheet 20 faces the laminated plate 10 on the table 31 with a slight gap, with the surface layer portion 22 facing downward.

Next, a press roller 50 is pressed against the back surface of the molded sheet 20 and rolled in the longitudinal direction of the molded sheet 20 (from the right end to the left end in the example shown in FIG. 1). As a result, the surface layer portion 22 of the molded sheet 20 is
The pattern formed on the surface of the surface layer portion 22 is transferred to the coating layer 12 as shown in FIG.

At this time, by controlling the pressing force of the press roller 50 to be constant, the entire surface of the formed sheet 20 can be pressed against the laminated board 10 with a substantially uniform pressure. As described above, since the rubber layer 51 is provided on the body of the press roller 50,
Of the upper surface, unevenness of the thickness of the substrate 11 and the thickness of the molded sheet 20, and the influence of poor roundness of the press roller 50 can be reduced. As a result, the molded sheet 2
The pattern formed on the surface of the surface layer 22 of No. 0 can be transferred to the coating layer 12 of the laminate 10 with high accuracy.

FIG. 6 (perspective view) and FIG.
As shown in (cross-sectional view), a laminated structure 10 in which a predetermined pattern is formed by fine projections on a substrate 11 is obtained.

[0026]

EXAMPLE Using the method of the present invention, a rear panel of a plasma display panel was manufactured under the following conditions.

The laminated substrate 11 (FIG. 2) has a thickness of 3 m.
A soda glass substrate measuring mx 560 mm in length and 970 mm in width was used. The coating layer 12 (FIG. 2) has an average particle size of 3
A glass paste obtained by adding and kneading a liquid additive (5 parts by weight) to a low-melting glass powder (100 parts by weight) of μm and alumina powder (3 parts by weight) having an average particle diameter of 2 μm was used. After applying the above-mentioned glass paste to the surface of the substrate 11 in a uniform thickness, the glass paste is dried under reduced pressure for 5 minutes, and the thickness is 18
A clay-like coating layer of 0 μm was formed.

As the molded sheet 20 (FIG. 3), a composite sheet in which a hard rubber surface layer portion 22 was stuck on a steel backing sheet 21 was used. The surface layer of this composite sheet was molded using a mold to produce a molded sheet having the cross-sectional shape shown in FIG.

After applying silicone oil to the surface of the molded sheet 20 to a thickness of 1 to 2 μm, the surface of the molded sheet 20 is pressed against the laminate 10 using a press roller 50 to form the surface layer portion 22. The pattern that covers
Transferred to No. 2. At this time, the moving speed of the press roller 50 was 20 mm / min.

The thus-obtained laminated structure is dried and cured at a temperature of 120 ° C. for 40 minutes.
The resultant was fired at 10 ° C. for 30 minutes to obtain a rear panel of a plasma display panel having a sectional shape shown in FIG. In this example, the partition formed on the surface of the rear panel has a top width (W) of 50 μm and a height (H) of 160 μm.
m and the pitch (H) were 220 μm.

In the above example, the composite sheet is used as the molded sheet. When the pattern formed on the surface of the laminated structure is not so fine (for example, the pitch is 500 μm or more), a stainless steel sheet half-etched can be used.

[0032]

According to the method of manufacturing a laminated structure of the present invention, the pattern formed on the surface of the molded sheet is transferred to the surface of the laminated plate by using a press roller. Compared with the method using a mold, the shape accuracy of the pattern formed on the surface of the laminate can be increased. In addition, since a device having a relatively simple structure can be used, and the production efficiency is high, the laminated structure can be manufactured at low manufacturing cost.

[Brief description of the drawings]

FIG. 1 is a diagram showing a schematic configuration of an apparatus for manufacturing a laminated structure according to the present invention.

FIG. 2 is a perspective view showing an outline of a laminate used in the manufacturing method of the present invention.

FIG. 3 is a partial sectional view showing the shape of a molded sheet used in the production method of the present invention.

FIG. 4 is a cross-sectional view of a main part of the release agent applying device.

FIG. 5 is a partial cross-sectional view illustrating a state when a pattern formed on a surface of a molded sheet is transferred to a surface of a laminate.

FIG. 6 is a perspective view showing an example of a laminated structure manufactured by the manufacturing method of the present invention.

FIG. 7 is a partial cross-sectional view showing one example of a laminated structure manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

10: laminated board (laminated structure), 11: substrate, 1
2 ... coating layer, 20 ... molded sheet, 21 ... backup sheet, 22 ... surface layer, 25 ... seat frame, 27 ... support sheet, 31 ... table, 33 ..Holder, 34 ... Base, 35 ...
· Reversing mechanism, 36 ··· shaft, 37 ··· support base, 40 ·
··· Release agent application device, 41 ·· Nozzle, 42 ··· Cleaner, 50 ··· Press roller, 51 ··· Rubber layer.

 ──────────────────────────────────────────────────続 き Continued on the front page F-term (reference) 4F100 AA19B AG00A AG00B AR00B AT00A BA02 CA05B CA23B DD04 DD05 DD06 DD07 DE01B EC043 EH46B EJ083 EJ193 EJ483 EJ59B EJ86B EJ863 EK01 JK13B YY00B 5C020 MA1919 JA23 JA9

Claims (6)

[Claims] 1. A step of preparing a molded sheet having a pattern formed on the surface by irregularities; a step of attaching the molded sheet to a sheet frame at both ends in a longitudinal direction; and a step of coating a clay-like coating layer on a substrate. A step of preparing the laminated plate, a step of holding the laminated plate on the upper surface of the table with the covering layer facing upward, and a step of bringing the surface of the molded sheet downward to approach the upper surface of the laminated plate. In the state, a step of supporting the sheet frame, and a step of rolling a press roller in the longitudinal direction on the back surface of the molded sheet to transfer the pattern to the coating layer to obtain a laminated structure. A method for manufacturing a laminated structure, comprising: 2. A mold release agent is applied to the surface of the molded sheet prior to the step of supporting the sheet frame with the surface of the molded sheet facing down to the upper surface of the laminate. The method for manufacturing a laminated structure according to claim 1, wherein: 3. The method for manufacturing a laminated structure according to claim 1, wherein a press roller whose trunk is covered with a rubber layer is used as said press roller. 4. The molded sheet comprises: a backup sheet made of steel; and a surface layer portion which is adhered on the backup sheet, is made of hard rubber or resin, and has the pattern formed on a surface thereof. The method for producing a laminated structure according to any one of claims 1 to 3, characterized in that: 5. An apparatus for producing a laminated structure by forming a coating layer of a laminate in which a clay-like coating layer is coated on a substrate, and manufacturing the laminated structure with the coating layer facing upward. A table for holding, a sheet frame for supporting a formed sheet having a pattern formed by unevenness on the surface at both ends in a longitudinal direction thereof, and a surface of the formed sheet facing downward and approaching an upper surface of the laminated plate. In a state, a gantry supporting the seat frame, and a reversing mechanism for reversing the seat frame from the state of being supported on the gantry with one end in the longitudinal direction as an axis; A release agent application device for applying a release agent to the surface of the molded sheet; and a roller that rolls in the longitudinal direction on the back surface of the molded sheet while supporting the sheet frame on the gantry. And a press roller for transferring a pattern to the surface of the coating layer. 6. A backup sheet made of a steel sheet as the molded sheet, and a surface layer portion attached to the backup sheet, made of hard rubber or resin, and having the pattern formed on a surface thereof. The apparatus for manufacturing a laminated structure according to claim 5, wherein the composite sheet is used.