JP2005319752A - Panel lamination method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a panel lamination method which can easily laminate a panel at normal temperatures using a comparatively small-sized suction device regardless of an installation site or sizes of panel. <P>SOLUTION: In this method, when sheet-like or plate-like panels A and B are laminated over each other through an adhesive sheet 1, a soft adhesive sheet 1 with an uneven pattern formed on the surface is used. Next, the panel B to be laminated is brought into contact with the projecting part of the adhesive sheet 1, then the periphery of the panel B is sealed leaving a part of the panel B unsealed, and the air in an internal void formed by the recessed part of the adhesive sheet 1 is sucked from the part left unsealed using the suction device 20. After that, the internal void is sealed in a vacuum state, and the panel B and the adhesive sheet 1 are bonded together by making the internal void vanish under atmospheric pressure. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention is a window for residential building materials, machine tool windows, vehicle windows, financial windows, showcases for precious metals and works of art, laminated glass such as laminated optical lenses, which are required for crime prevention, safety and disaster prevention. Flat type image devices such as liquid crystal display, plasma display (PDP) display, EL display and the like which require impact resistance, light weight, and visibility, and transparent protective panel laminates such as solar battery panels, panels having decorativeness and design properties It is related with the lamination | stacking method of the panel which comprises.

Conventionally, glass plates were mainly used for laminated glass and protective panels, but in recent years there has been a growing demand for crime prevention, safety, disaster prevention, lighter weight, and improved impact resistance, and acrylic as a material to replace glass plates. Different types of laminated glass combined with synthetic resin plates such as plates and polycarbonate (PC) plates have been widely used.
However, since the linear expansion coefficient of the glass plate and the synthetic resin plate is different, the conventional autoclave method using a thermoplastic resin or the method using a UV or thermosetting liquid adhesive warps, peels, cracks after the laminated glass is produced. There was a problem that caused.
In addition, when a protective panel is laminated on an image display device or the like, it is difficult to apply pressure and heat, and it is not possible to easily laminate.
In addition, crime prevention and safety performance of conventional window-laminated films are not enough for crimes that are becoming more and more severe year by year, so PC laminated glass, etc. for windows, showcases, etc. related to stores that handle vehicles, ordinary houses, finance and expensive goods. However, there are problems such as warping, peeling and cracking with increasing area, and replacement of existing windows.
In order to solve such problems, the present inventor has proposed a “double-sided pressure-sensitive adhesive sheet characterized in that a concavo-convex pattern is formed on a single-sided or double-sided adhesive surface by a release film having a concavo-convex pattern”. (Patent Document 1). According to the invention described in Patent Document 1, by applying uniform pressure to the pressure-sensitive adhesive surface on which the concavo-convex pattern is formed, the panels can be pressure-bonded while letting air escape from the concave portion, and a pressure bonding device is used. Panel manufacture is facilitated.
However, it cannot be said to be sufficient as a method for constructing existing panels on site. That is, since the size of the existing panel, the shape and location of construction are not constant, there is a problem that it is difficult to prepare a crimping device that can cope with such various conditions. In addition, a thin film such as a conventional anti-scattering film can be manually attached using a spatula or the like, but there is a problem that it is not easy to neatly laminate a sheet-like or plate-like panel.

JP 2003-336020 A

  The present invention has been made in consideration of the above-mentioned problems of the prior art, and can be easily laminated at room temperature using a relatively small suction device regardless of the construction site or the size of the panel. An object of the present invention is to provide a laminating method.

In order to achieve the above object, the method for laminating panels according to claim 1 of the present invention is a flexible pressure-sensitive adhesive sheet whose surface is subjected to uneven processing when the sheet-like or plate-like panels are laminated via the pressure-sensitive adhesive sheet. The panel to be laminated and the convex part of the pressure-sensitive adhesive sheet are brought into contact with each other, the air in the internal void formed by the concave part of the pressure-sensitive adhesive sheet is sucked to seal the internal void in a reduced pressure state, and then the interior is under atmospheric pressure. The gap is eliminated and the panel and the pressure-sensitive adhesive sheet are brought into close contact with each other.
In the present invention, the panel laminate immediately after sealing under reduced pressure has an internal gap formed by the concave portion of the pressure-sensitive adhesive sheet, but the internal gap gradually disappears due to atmospheric pressure, and the unevenness of the pressure-sensitive adhesive sheet is eliminated. The panel can be closely attached to.

Further, the invention according to claim 2 seals the periphery of the panel, leaving a part thereof, and sucking the air in the internal space from the remaining part using a suction device, and sealing the internal space in a reduced pressure state. The panel stacking method according to claim 1, wherein:
The invention according to claim 3 is characterized in that a pressure-sensitive adhesive sheet having a glass transition point of −20 ° C. or less and a holding power deviation length of 1.0 to 13 mm is used as the pressure-sensitive adhesive sheet. 3. A method for laminating panels according to 1 or 2.
Here, the displacement length of the holding force means that a 38 μm thick PET (polyethylene terephthalate) film is placed on a SUS plate (size 20 mm × 20 mm) with a hand roll through a concavo-convex adhesive sheet, and the concavo-convex shape disappears. This is a value obtained by measuring the shift length after applying a load of 4.9 N for 2 hours in an environment of 40 ° C. in accordance with JIS Z 0237 after contacting the state.

According to the first aspect of the present invention, a flexible adhesive sheet having a concavo-convex surface is used, the laminated panel and the convex part of the adhesive sheet are brought into contact with each other, and the internal void formed by the concave part of the adhesive sheet After sucking air and sealing the internal space in a reduced pressure state, the internal space sealed in the reduced pressure state is pressurized at atmospheric pressure and gradually disappears by leaving it under atmospheric pressure. The panel can be brought into close contact with the state where there is no more. And it becomes possible to laminate | stack simply at normal temperature using a comparatively small suction device irrespective of the magnitude | size of a construction place or a panel.
The invention according to claim 2 is particularly convenient when another panel is laminated on the existing panel.
According to the invention which concerns on Claim 3, the favorable panel laminated body of the quality which was excellent in the bonded external appearance can be obtained reliably.

The method for laminating panels according to claim 1 of the present invention is a panel that is laminated by using a flexible pressure-sensitive adhesive sheet having an uneven surface on the surface when laminating sheet-like or plate-like panels via pressure-sensitive adhesive sheets. And the convex part of the pressure-sensitive adhesive sheet are brought into contact, the air in the internal gap formed by the concave part of the pressure-sensitive adhesive sheet is sucked to seal the internal gap in a reduced pressure state, and then the internal gap disappears under atmospheric pressure, The adhesive sheet is closely attached.
As a device for sucking air, a vacuum pump, a vacuum cleaner, or the like can be used, but a vacuum pump capable of obtaining a large differential pressure from atmospheric pressure is particularly preferable.
The method of sealing under reduced pressure can seal the periphery of the panel, leaving a part thereof, and sucking the air in the internal gap from the remaining part using a suction device to seal the internal gap in a reduced pressure state. . For example, as shown in FIG. 1, the panel A on which the adhesive sheet 1 has already been attached to one panel B is in a state in which the convex portions and the panel B are brought into primary contact via the adhesive sheet 1, In the case of a rectangular panel, the three side end portions are pressure-bonded so as not to suck in air or sealed with a jig 10 such as a tape, and the pressure-sensitive adhesive sheet is used from the remaining end portion by using the suction device 20. This is carried out by sucking the air in the internal gap formed by the recesses and sealing the remaining end to form a vacuum-sealed state, and then placing it under atmospheric pressure. The time of keeping under atmospheric pressure is usually 1 to 7 days, preferably 2 to 4 days.

Also, for example, the entire panel is wrapped with a bag-shaped jig, sucked from the mouth of the bag using a suction device, sealed, and left to remove the air in the internal voids, and the panel is opened at atmospheric pressure through the bag. Pressurized, the internal void disappears.
In addition, as shown in FIG. 2, a jig 15 for closely adhering the periphery of the end of the panel is placed in the bag-shaped jig 13, and in this state, the suction is performed from the bag mouth, After the air in the internal space gradually escapes, if the bag is opened with the jig 15 crimped around the edge of the panel, the air does not enter from the edge of the panel and the atmospheric pressure outside the panel Direct pressure is applied and the internal void disappears.

As for the flexible adhesive sheet which gave the uneven | corrugated process on the surface, the thing by which the uneven | corrugated pattern is formed in the adhesive sheet by sticking the release film which gave the uneven | corrugated pattern on the adhesive surface of one side or both surfaces is preferable. When the uneven pattern on the adhesive surface is a positive type, it can be obtained by a method of transferring the uneven pattern to the adhesive sheet by pasting a release film pre-formed with a negative uneven pattern on the adhesive sheet surface, and crosslinking In the transparent adhesive sheet that is a body, the adhesive sheet is crosslinked from the beginning with a concavo-convex pattern (cross-linking after applying a release film shaped with a concavo-convex pattern), and the concavo-convex pattern is formed after the adhesive sheet is crosslinked in a planar state. Either of the methods of transferring (attaching a release film having a concavo-convex pattern formed after cross-linking) is preferable, but the latter method of transferring the concavo-convex pattern after cross-linking the pressure-sensitive adhesive sheet is preferable.
A release film pre-shaped with a negative concavo-convex pattern is produced by using an embossing roll or the like, for example, by feeding a release film having an appropriate thickness between two concavo-convex rolls. can do. As the release film, a biaxially stretched polyester film, a biaxially stretched polypropylene film, or a paper coated with a silicone release agent is preferably used.

You may form an uneven | corrugated pattern in the single side | surface or both surfaces of an adhesive sheet depending on how to use. FIG. 3A shows an example in which a concavo-convex pattern is formed on one side of the pressure-sensitive adhesive sheet 1, and a release film 3 shaped with the concavo-convex pattern is laminated on one side of the pressure-sensitive adhesive sheet 1, and the concavo-convex pattern is formed on the other side. A flat release film 2 is laminated. FIG. 3B shows an example in which a concavo-convex pattern is formed on both surfaces of the pressure-sensitive adhesive sheet 1, and a release film 3 having a concavo-convex pattern formed thereon is laminated on both surfaces of the pressure-sensitive adhesive sheet 1.
The uneven pattern preferably has regularity. Moreover, the recessed part of an adhesive sheet is formed with the linear form connected so that the peripheral edge part of the adhesive sheet might be reached, and a recessed part becomes an escape route of air. As an uneven | corrugated pattern of the adhesive sheet in which air does not remain easily, continuous patterns, such as (a) rhombus, (b) hemisphere, (c) stripe shape as shown in FIG. In particular, a rhombus or stripe having a truncated pyramid-shaped convex pattern is preferable, and the depth, size, etc. of the uneven valley can be selected as appropriate.

The invention according to claim 3 is characterized in that as the pressure-sensitive adhesive sheet, a pressure-sensitive adhesive sheet having a glass transition point of −20 ° C. or lower and a holding power deviation length of 1.0 to 13 mm is used.
Here, the displacement length of the holding force means that a 38 μm thick PET (polyethylene terephthalate) film is placed on a SUS plate (size 20 mm × 20 mm) with a hand roll through a concavo-convex adhesive sheet, and the concavo-convex shape disappears. This is a value obtained by measuring the shift length after applying a load of 4.9 N for 2 hours in an environment of 40 ° C. in accordance with JIS Z 0237 after contacting the state. In order to be a flexible pressure-sensitive adhesive sheet in which the uneven pattern of the shaped pressure-sensitive adhesive sheet disappears at atmospheric pressure, it is necessary to be easily deformed at room temperature. For this purpose, the glass transition point is −20 ° C. or lower. Good. However, when the deviation length of the holding force is less than 1.0 mm, the concavo-convex pattern is difficult to be formed due to excessive crosslinking, or the formed concavo-convex pattern does not disappear. When the displacement length of the holding force exceeds 13 mm, the shape of the unevenness tends to collapse, the air is trapped while the air in the recess (internal void) is sucked, and a reduced pressure state cannot be obtained, and the recess disappears under atmospheric pressure. The problem of not doing arises.
The displacement length of the holding force that allows the air to be almost completely sucked and the uneven pattern (internal void) disappears under atmospheric pressure is more preferably 5 to 10 mm.

  In the method of the present invention, for example, a pressure-sensitive adhesive sheet laminated plate material previously peeled off from a release film on the pressure-sensitive adhesive surface opposite to the surface having a concavo-convex pattern and attached to a transparent plate material such as a glass plate or a synthetic resin plate is used in advance. The laminate can be easily obtained by making it and peeling it off from the release film on the surface of the pressure-sensitive adhesive sheet leaving the uneven pattern on a window material, a display panel or the like.

  Depending on the application, the panel may be pasted not only on one side of the panel but also on both sides via an adhesive sheet. An example of the structure of the obtained laminate is shown in FIG. As shown in FIGS. 5A to 5E, the layer structure of the laminate is, for example, (a) synthetic resin plate 4 / glass plate 5, (b) synthetic resin plate 4 / Synthetic resin plate 4, (c) glass plate 5 / glass plate 5, (d) synthetic resin plate 4 / glass plate 5 / synthetic resin plate 4, (e) glass plate 5 / synthetic resin plate 4 / glass plate 5, etc. There are various possibilities, but there is no problem even if the synthetic resin plate 4 and the glass plate 5 are arbitrarily combined depending on the application. In addition, not only glass plates and synthetic resin plates, but also suitable materials of the same or different types are selected from metal plates, ceramic plates, fiber (paper, wood) plates, etc. By using the pressure-sensitive adhesive sheet, various laminated panels can be obtained by applying the method of the present invention.

  Hereinafter, although an example is described, the present invention is not limited to this.

Smooth silicone mold release with a thickness of 75 μm and 38 μm by adding 0.05 parts by weight of 1,9 nonanediol diacrylate and 0.15 parts by weight of benzophenone to 100 parts by weight of acrylic ester copolymer, followed by melting and stirring. After a PET (polyethylene terephthalate) film is formed into a sheet having a thickness of 500 μm, a light amount of 1000 mJ / cm ² is irradiated from the front and back (integrated light amount 2000 mJ / cm ² ) using a high-pressure mercury lamp through a release PET film. As a result, an ultraviolet-crosslinked pressure-sensitive adhesive sheet was obtained.
The release PET on the 38 μm side of this pressure-sensitive adhesive sheet is peeled off, and the “ND processed embossed silicone release 38 μm PET” film (a diamond-shaped uneven pattern processed product having a truncated pyramid) made by Dynic Co. is attached with a nip roll, and single-sided uneven adhesive A sheet was obtained.
As a method of laminating, first, a smooth 75 μm side release PET film of the single-sided uneven pressure-sensitive adhesive sheet is peeled off from one side of a polycarbonate (PC) plate having a thickness of 5 mm × width of 500 mm × length of 500 mm, and laminated with a nip roll to form uneven adhesive. A PC board with a sheet was prepared.
Subsequently, the release film on the uneven surface of the PC plate with the uneven pressure-sensitive adhesive sheet was peeled off and brought into contact with a glass plate having a thickness of 5 mm, a width of 500 mm, and a length of 500 mm by its own weight through the uneven pressure-sensitive adhesive sheet surface.
After sealing the glass plate and the PC plate 3 side edges (end face) with tape so that air is not sucked in, the remaining one side edge is recessed with a vacuum pump (internal gap formed by the recess) Was sucked with a vacuum manometer until the pressure was 5 kPa, the suction end was sealed, sealed under reduced pressure, and allowed to stand at room temperature for 1 week to obtain a panel laminate.
The composition of the acrylic acid ester copolymer is obtained by copolymerizing n-butyl acrylate: 78.4% by weight, 2-ethylhexyl acrylate: 19.6% by weight, and acrylic acid: 2.0% by weight. The molecular weight and molecular weight distribution measured by GPC of the acrylate copolymer were weight average molecular weight (MW): 2.27 × 10 ⁶ , weight average molecular weight / number average molecular weight (MW / MN): 3.6. .
Further, the uneven shape of the adhesive surface formed by the 38 μm-thick release PET film processed with the uneven pattern has a mesh pattern, and the convex portion has a base of 2 mm and an apex angle of 70 °. It was rhombus in plan view, the groove width of the recess was 0.2 mm, and the maximum unevenness difference (Rmax) was 20 μm (see FIG. 6).

The same raw materials used in Example 1 were melted and stirred in the same composition, and a smooth release PET film having a thickness of 75 μm used in Example 1 and “ND processed embossed silicone release 38 μm PET” manufactured by Dynic Co., Ltd. After forming into a sheet having a thickness of 500 μm between the films, a single-sided concavo-convex pressure-sensitive adhesive sheet was obtained by irradiating a light amount of 2000 mJ / cm ² through a 75 μm release PET film using a high-pressure mercury lamp.
Thereafter, a panel laminate was obtained by the same lamination method as in Example 1.

To 100 parts by weight of the same uncrosslinked acrylate copolymer as in Example 1, 0.5 parts by weight of acetylacetone zinc and 0.7 parts by weight of acetylacetone aluminum were added, melted and stirred, and a smooth separation having a thickness of 75 μm was performed. A single-sided uneven pressure-sensitive adhesive sheet was obtained by forming a sheet having a thickness of 500 μm between a mold PET film and a “ND processed embossed silicone release 38 μm PET” film manufactured by Dynic. Thereafter, a single-sided uneven pressure-sensitive adhesive sheet that was UV-crosslinked by irradiating light of 2000 mJ / cm ² through a 75 μm release PET film using a high-pressure mercury lamp was obtained.
Thereafter, a panel laminate was obtained by the same lamination method as in Example 1.

[Comparative Example 1]
The 500 μm pressure-sensitive adhesive sheet produced in Example 1 was formed into a planar double-sided pressure-sensitive adhesive sheet without shaping (transferring) the uneven pattern, and a panel laminate was obtained in the same manner as in Example 1 using this. . In addition, about the shift | offset | difference length of holding force, in the adhesive sheet which has not performed this uneven | corrugated process, it was set as the measurement made to contact with the same pressure as the case of the adhesive sheet which gave the said uneven | corrugated process.

[Comparative Example 2]
In the same manner as in Example 2, after molding into a sheet having a thickness of 500 μm between a smooth release PET film having a thickness of 75 μm and a “ND processed embossed silicone release 38 μm PET” film made by Dynic, a high pressure mercury lamp was formed. Using a high pressure mercury lamp through a “ND processed embossed silicone release 38 μm PET” film made by Dynic, in addition to irradiating a light amount of 2000 mJ / cm ² through a 75 μm release PET film, the light amount is 1000 mJ / cm ^2. To obtain a single-sided uneven pressure-sensitive adhesive sheet which was UV-crosslinked. Thereafter, a panel laminate was obtained by the same lamination method as in Example 1.

[Comparative Example 3]
As a method of laminating using the single-sided uneven pressure-sensitive adhesive sheet obtained in the same manner as in Example 1, first, the uneven pressure-sensitive adhesive sheet was smoothed to a thickness of 75 μm on one side of a PC plate having a thickness of 5 mm × width of 500 mm × length of 500 mm. The release PET film was peeled off and laminated with a nip roll to prepare a PC board with an uneven pressure-sensitive adhesive sheet.
Next, the release film on the concavo-convex surface of the PC board with the concavo-convex adhesive sheet is peeled off entirely and brought into contact with a glass plate having a thickness of 5 mm × width 500 mm × length 500 mm by its own weight through the concavo-convex adhesive sheet surface at room temperature. A panel laminate was obtained by leaving for 1 week.

About the panel laminated body of PC board / glass board obtained by the above Example and comparative example, while measuring the shift | offset | difference length of the holding force of the adhesive sheet used, the bonded external appearance (matching external appearance) was observed visually. And evaluated. The results are shown in Table 1.
Appearance observation (combined appearance): “O” indicates the disappearance of the uneven pattern, no bubbles, and no peeling.
As shown in the results of Table 1, according to the method for laminating panels according to the present invention, a panel laminate having an excellent bonded appearance can be obtained.

It is explanatory drawing which illustrates the lamination method of the panel which concerns on this invention. It is explanatory drawing which illustrates the lamination method of the panel which concerns on this invention. It is sectional drawing which illustrates the structure of an adhesive sheet. It is a top view which illustrates the uneven | corrugated pattern of an adhesive sheet. It is sectional drawing which illustrates the structural example of a panel laminated body. The structure of the uneven | corrugated pattern of an adhesive sheet is demonstrated, (a) is sectional drawing of an uneven | corrugated pattern, (b) is a top view of an uneven | corrugated pattern.

Explanation of symbols

A, B Panel 1 Adhesive sheet 2 Smooth release film 3 Release film shaped uneven pattern 4 Synthetic resin plate 5 Glass plate 10 Jig such as tape 20 Suction device

Claims (3)

When laminating sheet-like or plate-like panels via an adhesive sheet,
Using a flexible pressure-sensitive adhesive sheet with an uneven surface, the laminated panel and the convex part of the pressure-sensitive adhesive sheet are brought into contact with each other, and the internal voids formed by the concave parts of the pressure-sensitive adhesive sheet are sucked to reduce the internal gap. A method for laminating a panel, comprising sealing the panel in a state and then causing the internal gap to disappear under atmospheric pressure to bring the panel and the adhesive sheet into close contact.   2. The panel is sealed by leaving a part of the periphery of the panel, and suctioning air from the remaining part using a suction device to seal the internal cavity in a reduced pressure state. A method for laminating the panel as described.   The method for laminating panels according to claim 1 or 2, wherein the pressure-sensitive adhesive sheet is a pressure-sensitive adhesive sheet having a glass transition point of -20 ° C or lower and a holding force deviation length of 1.0 to 13 mm. .

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