JP2011044980A - Method of manufacturing film antenna - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a film antenna with which improvement in pattern accuracy and antenna element invisibility of a film antenna to be pasted or held on a window glass pane of an automobile or the like, simplification in a manufacturing process and work facilitation, improvement in efficiency of residual material discarding and the like can be achieved totally. <P>SOLUTION: An antenna pattern part 11 is screen-printed on one side of a film base material 10 by silver paste, a viscous layer 12 is screen-printed in an area corresponding to the pattern on another side by a viscous agent, and a release sheet 14 is pasted at a side of the viscous layer 12. Next, the film base material 10 is cut by a blade die using punched blades 21, 22 in a single blade shape to separate the film base material 10 in an area of the antenna pattern part 11 and in other area. After the unwanted film base material 10b is removed, a release sheet (26), to which a viscous layer (25) is applied is pasted to the side of the antenna pattern part 11. Since only the film base material 10 is cut, the antenna pattern part 11 is not almost deformed. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention is a film antenna that is attached to a window glass of an automobile or the like in order to receive radio waves used by an in-vehicle liquid crystal TV, a navigation system, or the like. Related to the manufacturing method.

  Recently, when an automobile is equipped with a liquid crystal TV, the automobile is used for receiving radio waves from TV broadcasts. When a navigation system is installed, the automobile is used for receiving radio waves from a GPS (Global Positioning System) satellite. Often, film antennas are attached to the window glass.

  This type of film antenna is installed by forming an antenna element and a power supply terminal with a conductor on the surface of an insulating transparent film base material and attaching the film base material to a window glass of an automobile. The antenna element itself is formed as a very narrow conductor while being pasted along the periphery of the window glass so as not to interfere.

  On the other hand, a laminated glass having a layer structure in which two glasses are bonded to each other with an intermediate film interposed therebetween is often applied to a window glass of a recent automobile in consideration of safety. As shown in (4) to (4), various proposals for sandwiching a film antenna in an interlayer film of laminated glass have been made and actually implemented.

By the way, in the type of film antenna in which the antenna element and the like are attached together with the film base as described above, the outer shape of the film base can be visually recognized when attached to the window glass even if the film base is transparent. In particular, in the case of the method of sandwiching the laminated glass, it becomes more prominent.
Moreover, in the window glass, the field of view of the sticking area of the film base material is naturally worse than that of other areas.
Therefore, in order to make the film antenna visually inconspicuous, it can be said that it is desirable that the film base material is cut in the same shape as the antenna element and the feeding terminal as much as possible.

And there exists the following method as a manufacturing method for mass-producing the film antenna which satisfy | fills such a request | requirement cheaply.
First, as shown in FIG. 25 (A), a foil-like conductive layer (Cu, Al, etc.) 202 is deposited on one surface of a film substrate 201 of a predetermined size by metal plating means or metal vapor deposition means, A laminated sheet 205 is formed by attaching a release sheet 204 to the surface of the material 201 opposite to the conductive layer 202 side through an adhesive layer 203.
Next, a Thomson blade die in which a band-shaped blade 208 formed by joining two double-blade shaped cutting blades 206 and 207 with the height of the blade edge aligned and bent along an antenna pattern and embedded in a plywood is used, as shown in FIG. ) And (C), only the portions of the conductive layer 202, the film base 201, and the adhesive layer 203 are cut, leaving the release sheet 204 in the laminated sheet 205, and the portion between the two cutting blades 206, 207 Only the antenna pattern portion 209 is used, and the other portions 210 and 211 are removed from the release sheet 204 and removed.
In the cutting process using the band-shaped blade 208, the antenna pattern portion 209 is pushed between the two blades 206 and 207 as shown in FIG. When it is removed upward, it springs back as shown in FIG. 25C, resulting in a half-moon-shaped or kamaboko-shaped cross section.

After the cutting / removing step, a release sheet 213 having an adhesive layer 212 is attached to the upper side of the antenna pattern portion 209 as shown in FIG. 26 (A), and a pressure roller (not shown) is attached in this state. By letting it pass, the antenna pattern portion 209 becomes a product sandwiched between the release sheets 204 and 213 as shown in FIG.
However, the adhesive force of the adhesive layer 212 to the conductive layer 202e is set to be larger than the adhesive force of the adhesive layer 203e to the release sheet 204 and the adhesive force of the adhesive layer 212 to the release sheet 204, and the adhesive layer 203e to the glass surface The adhesive strength is set larger than the adhesive strength of the adhesive layer 212 to the conductive layer 202e and the glass surface.

Therefore, for example, when the antenna pattern portion 209 is sandwiched between laminated glass of an automobile as a film antenna, the release sheet 204 is first peeled off as shown by an arrow in FIG. After attaching the antenna pattern part 209 by pressing it against the mating surface of one glass plate in the laminated glass with the part 209 attached, only the antenna pattern part 209 is removed by peeling the release sheet 213 together with the adhesive layer 212. It remains on the glass plate.
In addition, when the other glass plate is joined to the glass surface on which the antenna pattern portion 209 is bonded through an intermediate layer of a transparent resin in this state, the laminated glass 220 has two glass plates as shown in FIG. The antenna pattern portion 209 is sandwiched between the intermediate layers 223 between 221, 222.

Although a method similar to the method for manufacturing the film antenna is disclosed in Patent Document 5 below, in the invention of the same document, cutting including the release sheet 204 in the manufacturing method is performed, and the cut shape is obtained. The release sheet portion is peeled off, and the antenna pattern portion is attached to a new planar release sheet.
As for the cutting process, as shown in FIG. 5 of Patent Document 5, the upper die in which a square groove is formed and the arcuate tip that is pressed against the square groove, instead of cutting with a cutting edge of a band-shaped cutter. The antenna pattern portion is sandwiched between the lower mold having the.

On the other hand, in the following Patent Document 6, a transparent clear coating layer formed on the first release sheet, a conductive paste layer which is an antenna element printed on the clear coating layer, and the conductive paste layer There has been proposed a film antenna (antenna sheet) composed of a transparent adhesive layer formed on a substrate and a second release sheet adhered on the transparent adhesive layer so as to protect the adhesive layer.
In this film antenna, a clear coating layer is printed on the first release sheet, a conductive paste is printed on the clear coating layer to form an antenna pattern portion, and further covered with an adhesive layer. It is manufactured by covering the second release sheet.
When attaching to the window glass, the second release sheet is peeled off and the adhesive layer is attached to the glass surface, and then the first release sheet is peeled off so that the antenna pattern portion covered with the clear coating layer is placed on the glass surface. It will remain.

JP 2001-053524 A JP 2002-368514 A JP 2003-017920 A JP 2006-033525 A Japanese Patent No. 3746500 JP 2007-158940 A

By the way, according to the method for manufacturing the film antenna described with reference to FIGS. 25 and 26, the antenna pattern portion 209 after cutting with the band-shaped blade 208 has a half-moon-shaped or kamaboko-shaped cross section, and the conductive layer 202e is the film base layer 201e. In such a manner that the adhesive layer 203e is wrapped inside, the end portion of the conductive layer 202e appears on the release sheet 204 side.
Therefore, when the antenna pattern portion 209 is attached to the glass surface, the end corresponding to the cut portion of the conductive layer 202e comes into contact with the glass surface, but the light transmitted through the glass is otherwise at the end. Thus, the reflection condition is greatly different from that of the above portion, and as a result, the presence of the antenna pattern portion 209 tends to stand out. For example, each antenna pattern portion 209 sandwiched between the laminated glasses 220 in FIG. 27 has the ends of the two conductive layers 202e in contact with the glass plate 221 side, and each antenna pattern from the outside of the glass plate 221. It becomes easy to visually recognize the portion 209.

  Further, as described with reference to FIG. 25 (B), in the cutting process with the band-shaped blade 208, the portion corresponding to the antenna pattern portion 209 is pushed between the two blades 206 and 207, but the triangular shape formed by the blades 206 and 207 is formed. This groove does not have a sufficient space for the cut antenna pattern portion 209, and it may be relatively pressed into a state and may cause the banded blade 208 to bend laterally. There is a problem that distortion is likely to occur in the element shape of the antenna pattern portion 209 later.

  In addition, as shown by an arrow in FIG. 25 (C), after cutting the antenna pattern portion 209, the other portions 210 and 211 are peeled off from the release sheet 204 and removed, but the antenna element is bent at an acute angle, etc. Depending on the pattern shape, there may be many parts where the peeling operation becomes extremely difficult. In such a case, not only will the work efficiency be deteriorated, but the antenna pattern part 209 may be accidentally peeled off. Yield deteriorates.

In addition, when this film antenna manufacturing method is carried out, the parts other than the antenna pattern portion 209 are finally unnecessary, and the utilization rate from the viewpoint of the material is as low as about 1%.
Also, the copper foil 202 and the film base 201 are separated by chemicals so that they can be recycled, and the adhesive layer 203 adhering to the film base 201 needs to be removed by chemicals. Costs contribute to the product price.

On the other hand, according to the method for manufacturing a film antenna disclosed in Patent Document 6, since each layer is formed by screen printing, there is no problem as in the case of the band-shaped blade 208 described above.
However, since the adhesive layer is in direct contact with the conductive paste layer corresponding to the antenna element or the conductive paste layer is covered with the adhesive layer, there is a possibility that the antenna element may be altered due to oxidation or the like. is there.
In addition, since the three-layer lamination printing process is involved, when the width of the antenna element is set to 500 (μm) or less, it is difficult in terms of accuracy to laminate the clear coating layer and the adhesive layer with that width. In fact, as shown in the example drawings of Patent Document 6, the conductive paste layer is printed along the center of the surface of the clear coating layer, and the surface of the clear coating layer is covered with the conductive paste layer. Will print the adhesive layer.
Therefore, an antenna pattern that is considerably conspicuous when attached to a glass surface is obtained.

  Therefore, the present invention was created for the purpose of providing a method of manufacturing a film antenna that can rationally and comprehensively solve the problems associated with the above-described conventional film antenna and the manufacturing method thereof.

  The present invention relates to a method of manufacturing a film antenna that is attached to a window glass surface and used for receiving radio waves. In the method for manufacturing a film antenna, an antenna pattern comprising a conductive paste as a printing material and an antenna element and a feeder on one side of a film substrate. A first adhesive layer is formed by screen printing on a region corresponding to the antenna pattern portion on the other surface of the film base material, using a first step of screen printing the portion and a first adhesive as a printing material. The antenna pattern portion is formed by a second step, a third step of sticking a first release sheet on the first adhesive layer forming side of the film base, and a blade type using a single-edged blade. A fourth step of cutting only the film base material so as to divide the film base material in the region corresponding to the above and the film base material in the other region; and the fourth process 5th process which removes other than the area | region of the said antenna pattern part in the said film base material divided | segmented by the 1st side from the 2nd adhesive on the arrangement | positioning side of the said antenna pattern part in a said 1st peeling sheet And a sixth step of sticking a second release sheet composed of the second adhesive layer, and the adhesive force of the second adhesive layer to the antenna pattern portion is the first and second The first and second pressure-sensitive adhesives and the first pressure-sensitive adhesive are larger than the pressure-sensitive adhesive force of the pressure-sensitive adhesive layer on the first release sheet and smaller than the pressure-sensitive adhesive force of the first pressure-sensitive adhesive layer on the window glass surface. The present invention relates to a method for manufacturing a film antenna, wherein the smoothness of the release surface of the release sheet is selected.

According to the present invention, in the fourth step, which is a cutting step, only the film base material is cut by a blade mold using a single-edged blade, so that a large pattern is not generated in the antenna pattern portion without significant deformation or distortion. The antenna pattern portion can be configured with high accuracy.
Moreover, both sides of the antenna pattern portion do not wrap around to the release sheet side as in the cutting process in the prior art (FIG. 25), and the factor that hinders the invisibility of the antenna element can be eliminated.
In addition, the antenna pattern portion and the first adhesive layer can be formed by screen printing on the film substrate, and the region other than the antenna pattern portion in the cut film substrate can be easily removed because there is no adhesive layer. This simplifies the manufacturing process and facilitates work.
In addition, when an antenna pattern part is formed by punching from a film base material to which copper foil is pasted, most of the copper foil becomes a non-use part and is sent to a process for reuse. Thus, in the present invention, there is no waste in the conductive paste.
Furthermore, the film base material to be removed after cutting does not have an adhesive layer and can be reused as it is.

  In the fourth step of the present invention, there is a punching blade type in which two single-blade cutting blades are opposed to each other between the blade backs, and the facing distance between the blade backs is slightly wider than the width of the antenna pattern portion. If the cutting edge is fixed so that each cutting edge is along the both side surfaces of the antenna pattern portion while keeping the cutting edge, only the film base material is cut while leaving the first release sheet. The film substrate can be cut only by a single half-punch operation.

  Further, in the fourth step of the present invention, it is a punching blade type in which two single-blade cutting blades are opposed to each other at the back of the blade, and the back surface of each of the above-mentioned cutting blades is a fixed section on the blade tip side and the blade front side Each blade edge is arranged in the antenna pattern while keeping the gap between the blade back surfaces slightly narrower than the width of the antenna pattern portion and the gap between the blade edges slightly wider than the width of the antenna pattern portion. After fixing both corners of the upper surface of the antenna pattern portion with an inclined surface formed on the back surface of each blade, the first release sheet is used. If only the film base material is cut and left, it is possible to prevent the cutting blades from being cut inward and touching the first adhesive layer when cutting the film base material. Round both corners on top Peeling the second release sheet and the antenna pattern portion is improved to be molded.

  In addition, the fourth step of the present invention is a step of performing progressive die cutting with two blade dies using a single blade blade, and at least the antenna element portion has a blade back side as each blade die. A process in which the cutting edge is fixed so that the blade edge is along one side surface of the antenna element on the antenna element side, and only the film base material is cut while leaving the first release sheet. If it is executed sequentially on both sides of the element, only the film base on one side of the antenna element is cut each time, so that there is an appropriate dent on the film base on the first adhesive layer. It is ensured and the deformation of the film base material is suppressed, and disconnection of the antenna element can be prevented.

  Further, even in the case of the progressive die cutting process, the inclined surface formed on the blade back surface of the punching blade using each blade mold in which the blade back surface of the punching blade is inclined toward the blade surface side in a certain section on the blade edge side. After scraping the upper surface corner of the antenna pattern part with the surface, if the film substrate is cut only with the first release sheet, the cutting blade will cut into the first adhesive layer side. It is possible to prevent problems and to obtain an effect that both corners on the upper surface of the antenna pattern portion can be formed into a round shape.

In the case of using a blade type in which the blade back surface of the punching blade is inclined toward the blade surface side in a fixed section on the blade edge side, the height of the inclined surface formed on the blade back surface of the punching blade in the blade back surface direction is It is desirable to set it larger than the thickness of the first adhesive layer.
This is because when the film substrate is cut, the first adhesive layer is pressed from above, so that the side surface may bulge sideways. This is because the cutting edge of the blade can be prevented from coming into contact with the first adhesive layer.

  In addition, in the method for manufacturing a film antenna of the present invention, a printing reference mark is printed in advance on the film base, and the screen printing in the first step and the second step is based on the printing reference mark. In the screen printing in the first step, the cutting reference mark is printed together with the antenna pattern portion, and the blade shape is positioned in the fourth step based on the cutting reference mark. It is reasonable to do so.

  According to the method for manufacturing a film antenna of the present invention, improvement in pattern accuracy of the film antenna and invisibility of the antenna element, simplification of the manufacturing process, facilitation of work, and efficiency of disposal of the remaining material are comprehensively realized. can do.

In Embodiment 1 of this invention, it is the top view (A) of the antenna pattern part etc. which were screen-printed on the surface side of the film base material, and sectional drawing (B) of an antenna pattern part. It is sectional drawing of the antenna pattern part in the state which screen-printed on the back surface side of the film base material, and comprised the adhesion layer. It is sectional drawing of the antenna pattern part in the state which stuck the peeling sheet to the adhesion layer side. It is a top view which shows the formation line of the blade edge | tip of the extraction blade in a blade type | mold. It is sectional drawing which shows the state before cutting a film base material with a blade type | mold. It is sectional drawing which shows the state immediately after cutting a film base material with a blade type | mold. It is sectional drawing of the antenna pattern part in the state which removed the film base materials other than the area | region of an antenna pattern part from the peeling sheet. It is sectional drawing of the antenna pattern part in the state which stuck the peeling sheet on the upper side of the antenna pattern part. In Embodiment 2, sectional drawing (A) which shows the state before cutting a film base material with a blade type | mold, and expanded sectional view (B) which shows the relationship between the blade-tip part of a blade type | mold, and the upper side corner | angular part of an antenna pattern part. It is. It is sectional drawing which shows the state immediately after cutting a film base material with a blade type | mold. It is sectional drawing in the antenna pattern part in the state which stuck the peeling sheet on the upper side of the antenna pattern part. FIG. 6 is a plan view (A) showing a forming line of a cutting edge of a first cutting edge and a plan view (B) showing a forming line of a cutting edge of a second cutting edge in Embodiment 3. It is sectional drawing which shows the state before cutting a film base material with a 1st blade type | mold. It is sectional drawing which shows the state immediately after cutting a film base material with a 1st blade type | mold. It is sectional drawing which shows the state which raised the 1st blade type | mold after cutting the film base material with the 1st blade type | mold. It is sectional drawing which shows the state before cutting a film base material with a 2nd blade type | mold. It is sectional drawing which shows the state immediately after cutting a film base material with a 2nd blade type | mold. It is sectional drawing which shows the state which raised the 2nd blade type | mold after cutting the film base material with the 2nd blade type | mold. It is sectional drawing of the antenna pattern part in the state which stuck the peeling sheet on the upper side of the antenna pattern part. In Embodiment 3, sectional drawing (A) which shows the state immediately after cutting a film base material with the 1st blade type extraction blade, and the state immediately after cutting a film base material with the 2nd blade type extraction blade are shown. It is sectional drawing (B). It is sectional drawing of the antenna pattern part in the state which stuck the peeling sheet on the upper side of the antenna pattern part. It is sectional drawing in the antenna pattern part at the time of sticking the film antenna obtained in Embodiment 1 to 3 on a glass plate, (A) is a film antenna of Embodiment 1, (B) is a film of Embodiment 2. The antennas (C) and (D) correspond to the film antenna of the third embodiment, respectively. As Embodiment 4, while forming a black layer on the surface of an antenna element part, it is each sectional drawing equivalent to FIG. 22 at the time of applying a black thing as the adhesive of an adhesion layer. FIG. 10 is a plan view showing a printing mode of an antenna pattern portion and the like on a film base material when a film antenna is manufactured in a plurality of units as Embodiment 5. It is sectional drawing which shows the process of cutting only the part of a conductive layer, a film base material, and an adhesion layer, leaving the peeling sheet of a lamination sheet, and forming an antenna pattern part with the blade type | mold which concerns on a prior art. 25A is a cross-sectional view of a state in which a release sheet is pasted on the upper side of the antenna pattern portion formed in the process of FIG. 25, and a perspective view of a main part of the film antenna obtained after passing through the pinching roller (B) ). It is sectional drawing which shows the structure by which the antenna pattern part was inserted | pinched by the intermediate | middle layer of the laminated glass.

Hereinafter, embodiments of the “film antenna manufacturing method and film antenna” of the present invention will be described in detail with reference to FIGS. 1 to 24.
<Embodiment 1>
First, as shown in FIG. 1, an antenna pattern portion 11 having a predetermined planar shape [FIG. 1 (A)] is formed with silver paste on the surface side of a film substrate 10 made of PET (polyethylene terephthalate) and having a thickness of about 50 (μm). Screen print.
Here, the antenna pattern portion 11 includes antenna elements 11a, 11b, and 11c and power feeding portions 11d and 11e, and is printed with a thickness of about 13 to 15 (μm).
The width of the antenna elements 11a, 11b, and 11c is about 700 (μm).

Next, as shown in FIG. 2, the adhesive layer 12 is formed by screen-printing an adhesive with a thickness of about 20 (μm) on the area corresponding to the antenna pattern portion 11 on the back surface side of the film substrate 10.
When the antenna pattern portion 11 and the adhesive layer 12 are screen-printed, positioning is performed with reference to a printing reference mark (not shown) preliminarily printed on the film substrate 10.
In addition, when the antenna pattern portion 11 is screen-printed, cutting reference marks 13a and 13b as shown in FIG. 1A are also printed at the same time. Used when positioning.
And as shown in FIG. 3, in order to cover the adhesion layer 12, the peeling sheet 14 of the same plane shape as the film base material 10 is stuck, and it transfers to a cutting process in the lamination | stacking state.

In the cutting process of this embodiment, the broken lines 15 and 16 (cut lines) in FIG. 4 surround the region of the antenna pattern portion 11 with respect to the workpieces that are stacked as shown in FIG. The release sheet 14 is cut without cutting the release sheet 14 by the blade die having the cutting edge formed along the cutting edge so that only the film substrate 10 is divided into a region corresponding to the antenna pattern portion 11 and other regions.
In this case, the blade mold is positioned with high accuracy using the position information of the cutting reference marks 13a and 13b.

Specifically, regarding the cross section taken along the line XX in FIG. 4, as shown in FIG. 5, the opposing distance between the blade backs of the single-blade extraction blades 21 and 22 is slightly smaller than the width of the antenna pattern portion 11. The cutting blades 21 and 22 are arranged side by side along the both sides of the antenna pattern portion 11, and the cutting edges of the cutting blades 21 and 22 are connected to the antenna pattern portion 11 as shown in FIG. The film is lowered along the side surfaces of the adhesive layer 12 to a position where it slightly bites into the release sheet 14, and the film substrate 10 is cut in the middle.
Therefore, this processing is a half cut (half punching).

  In this case, in this blade type, the blade back of each extraction blade 21, 22 is joined to both side surfaces of the spacer 23 so that each extraction blade 21, 22 and the spacer 23 are moved up and down integrally. Between each of the extraction blades 21 and 22 on the lower side, a fine sponge-made pressing portion 24 is attached. Further, as shown in FIG. 5, in a state where the extraction blades 21 and 22 are on the upper side of the workpiece, the lower surface of the pressing portion 24 is slightly protruded downward from the cutting edge positions of the extraction blades 21 and 22.

As shown in FIG. 6, in the stage where the cutting blades 21 and 22 are lowered and the film substrate 10 is cut, the pressing portion 24 is compressed immediately before the antenna pattern portion 11 to press the film substrate 10. Film substrate 10a and adhesive layer cut from antenna pattern portion 11 from between cutting blades 21 and 22 when cutting blades 21 and 22 are removed to the upper side after that. This is to prevent the laminated portion from being peeled off from the release sheet 14 by extruding the 12 laminated portions.
The material of the pressing portion 24 is not limited to a sponge, but is a material having a volume modulus of elasticity that causes an appropriate pressing force to the lower antenna element 11a when compressed as shown in FIG. I just need it.

When the cutting of the film substrate 10 is completed, the cutting blades 21 and 22 are raised, and the film substrate 10b (see FIG. 6) other than the region of the antenna pattern portion 11 after cutting is peeled off as shown in FIG. The laminated portion of the film substrate 10a and the adhesive layer 12 which are removed from above and cut with the antenna pattern portion 11 remains on the upper side of the release sheet 14.
In that case, the film substrate 10a in the region of the antenna pattern portion 11 is attached to the release sheet 14 via the adhesive layer 12, but the film substrate 10b in the other region is originally outside the region of the adhesive layer 12. It is extremely easy to remove because it does not stick anywhere.

Note that the blade type formed by the extraction blades 21 and 22 and the spacer 23 may be configured as a Thomson blade type, but an engraving blade type formed with a thin blade by cutting or an etching blade type formed with a thin blade by etching. Can be used.
According to the engraving blade type and etching blade type, if the width of the antenna elements 11a, 11b, and 11c is 500 (μm) or less, it is difficult to form the blade, but the pattern accuracy can meet extremely high requirements, and the temperature and humidity Since the error with respect to the change is far superior to that of the Thomson blade type, it can be said that it is optimal for manufacturing the antenna pattern in this embodiment.

When the film substrate 10 other than the area of the antenna pattern portion 11 is removed as described above, the area surrounded by the broken lines 15 and 16 in FIG. 4 (that is, the area of the antenna pattern section 11). In this state, the release sheet 26 having the adhesive layer 25 previously formed on the entire surface is pasted on the upper side of the antenna pattern portion 11 as shown in FIG. .
However, the adhesive force of the adhesive layer 25 to the antenna pattern portion 11 is greater than the adhesive force of the adhesive layers 12 and 25 to the release sheet 14 and smaller than the adhesive force of the adhesive layer 12 to the glass surface. The properties of the adhesive of the layers 12 and 25 and the smoothness of the release sheet 14 are selected.

Then, with the antenna pattern portion 11 sandwiched between the release sheet 14 and the release sheet 26, the whole is passed through a pinching roller (not shown), and a line dividing one antenna pattern (FIGS. 1 and 4). If the release sheets 14 and 26 (and the adhesive layer 25) are cut along the two-dot chain line, a film antenna supplied to the user as a product is completed.
When used in the mode of sandwiching the laminated glass, the release sheet 14 is peeled off and the adhesive layer 12 is pressed against the mating surface of one glass plate of the laminated glass in the same manner as described in the prior art (FIG. 26). After the antenna pattern portion 11 is adhered, if the release sheet 26 is peeled off together with the adhesive layer 25, only the antenna pattern portion 11 remains on the glass plate.

According to the method for manufacturing a film antenna and the film antenna of this embodiment, there are the following advantages compared with the prior art.
(1) The cutting blades 21 and 22 only cut the film substrate 10, and the antenna pattern portion 209 is not pushed into the triangular groove formed by the cutting blades 206 and 207 as in the prior art (FIG. 25). Therefore, the extraction blades 21 and 22 do not bend laterally, and the designed antenna pattern can be manufactured with high accuracy without distortion.
(2) The end of the conductive layer 202e wraps around the release sheet 204 as in the prior art processing (FIG. 25), and the antenna pattern portion 209 is easily visible from the outside of the glass plate 221. However, the invisibility of the antenna element 11a can be improved.

(3) The antenna pattern portion 11 and the adhesive layer 12 are planarly associated with each other and formed on the front and back of the film substrate 10 by screen printing, and in the cutting process by the cutting blades 21 and 22, the film substrate 10 as described above. Therefore, the degree of deterioration of the cutting edges of the extraction blades 21 and 22 is small.
(4) Since the adhesive layer 12 is not formed on the film base 10b other than the arrangement area of the antenna pattern portion 11, it can be easily removed after being cut as described above. In the prior art, in consideration of the difficulty of the peeling work, in addition to the extraction blades 21 and 22, there is also provided a scraping blade for forming a peeling white so that the peeling work can be performed without affecting the antenna pattern part 11 as much as possible. However, the yield rate is still lowered, and the improvement in this point greatly contributes to the simplification of the manufacturing process.

(5) Since the antenna pattern part 11 is formed by screen printing of silver paste, it is possible to use resources more efficiently compared to the method in which most of the copper foil as a material is discarded as in the prior art. . Further, it is not necessary to remove the adhesive layer from the cut and removed film base material 10b, and it is possible to proceed to the processing for recycling without taking any trouble.

<Embodiment 2>
In this embodiment, as shown in FIG. 9, the blades 31 and 32 having a cross-sectional shape in which the blade back side of the single-blade blades 21 and 22 used in Embodiment 1 is inclined toward the blade front side in a fixed section h of the blade edge. The blade spacing between the blade back surfaces of the extraction blades 31 and 32 is slightly narrower than the width W of the antenna pattern portion 11, and the distance S1 between the blade edges is set slightly wider than the width W of the antenna pattern portion 11. There is a feature in using.
Therefore, before the cutting blades 31 and 32 are lowered and the film substrate 10 is cut, the inclined surfaces 31a and 32a of the section h rub the upper surface corners C1 and C2 of the antenna pattern portion 11 to remove the portions. In addition to forming in a round shape, each of the extraction blades 31 and 32 slightly escapes outward to cut the film substrate 10.

  In the cutting with the cutting blades 21 and 22 of the first embodiment, since it is a normal single-edged shape, there is a tendency to warp to the blade back side when the film substrate 10 is cut. In this case, the cutting edge bites into the adhesive layer 12 and is appropriate. However, according to the extraction blades 31 and 32 in this embodiment, each of the extraction blades 31 and 32 slightly escapes to the outside and surely cuts only the film substrate 10, so that the above-described defects Does not occur.

In the case of Embodiment 1 and in this embodiment as well, since the force for compressing the flexible adhesive layer 12 from the upper side acts when the film substrate 10 is cut, the adhesive layer 12 bulges to the side, although slightly. Tend to.
In contrast to this state, in the case of the first embodiment, as shown in FIG. 6, the adhesive in the portion bulging to the side of the adhesive layer 12 adheres to the cutting edge portions of the cutting blades 21, 22, , 22 is interposed between the side surface of the film base material 10a, and the antenna pattern portion 11 (particularly the antenna element 11a), the film base material 10a, and the adhesive layer 12 are separated from the release sheet 14 There is a possibility that a problem of peeling from the substrate may occur.
On the other hand, in this embodiment, as shown in FIG. 9, the height h in the direction of the blade back surface of the section of the inclined surfaces 31a, 32a provided on the extraction blades 31, 32 is made larger than the thickness of the adhesive layer 12. In this case, even if the adhesive layer 12 bulges to the side, the adhesive can be prevented from adhering to the cutting edges of the extraction blades 31 and 32, and the above-described problems can be effectively prevented.

FIG. 11 is a cross-sectional view after a release sheet 26 having an adhesive layer 25 formed on one side is attached to the antenna pattern portion 11 after the film base material 10 is cut and removed by the cutting blades 31 and 32. is there.
In this state, the whole is passed through a pinching roller (not shown), and the release sheets 14 and 26 (and the adhesive layer) are separated by a line (corresponding to the two-dot chain line in FIGS. 25) is completed in the same manner as in the first embodiment, but the top corners C1 and C2 of the antenna pattern portion 11 are rounded according to the film antenna of this embodiment. Therefore, when the antenna pattern portion 11 is adhered to the glass plate and the release sheet 26 is peeled off, the adhesive layer 25 is easily peeled off from the surface of the antenna pattern portion 11.
Therefore, it is possible to effectively prevent a problem that the antenna pattern portion 11 is damaged when the release sheet 26 is peeled off.

<Embodiment 3>
In the first and second embodiments, a single blade having a cutting line formed along the two broken lines 15 and 16 shown in FIG. The film base material 10 corresponding to the antenna pattern portion 11 is cut with the mold leaving the release sheet 14, but in this embodiment, as shown in FIGS. The film base 10 is cut by a progressive feeding method while performing positioning using the cutting reference marks 13a and 13b separately for the first blade type and the second blade type related to the broken line 15.

Specifically, the antenna pattern portion 11 and the adhesive layer 12 are formed on the film base material 10 and the process is the same as in the first embodiment until the release sheet 14 is attached to the adhesive layer 12 side. 13 to 18 are performed.
First, as shown in FIG. 13, the workpiece is placed on the first processing table 41, and the cutting edge of the extraction blade 22-1 is along the broken line 16 in FIG. The first blade mold 42 that is continuously formed (along one side surface) is set at an accurate position based on the cutting reference marks 13a and 13b.

Then, as shown in FIG. 14, after the first blade mold 42 is lowered until the tip of the blade 22-1 reaches the surface of the release sheet 14 and the film substrate 10 is cut with the blade 22-1, When the first blade mold 42 is raised and the extraction blade 22-1 is returned to the upper side, only the film substrate 10b-1 on one side (the broken line 16 side) of the antenna pattern portion 11 is cut as shown in FIG. It becomes the state.
In this embodiment as well, the pressing portion 24-1 is provided under the same conditions as in the first and second embodiments, and the antenna pattern portion 11 immediately before the cutting blade 22-1 cuts the film substrate 10. Hold the top surface.

Next, as shown in FIGS. 16 to 18, the workpiece is moved to the second processing table 43, and the film substrate 10 is cut by the second blade mold 44 provided on the upper side of the second processing table 43. I do.
In this case, the cutting edge 21-2 of the second blade mold 44 is continuously formed along the broken line 15 in FIG. 12B (that is, along the opposite side surface of the antenna pattern portion 11). It is lowered after being set at an accurate position based on the cutting reference marks 13a and 13b of the workpiece.

The cutting of the film base material 10 at the second processing table 43 is performed in the same manner as in the case of the first processing table 41 except that the cutting line becomes a broken line 15 in FIG. 12B. As a result, FIG. As shown in FIG. 4, the laminated portion of the film substrate 10a and the adhesive layer 12 cut with the antenna pattern portion 11 remains on the surface of the release sheet 14, and the film substrate 10b-1,2 (10b-2) is the remaining cut portion. Are cut off at the second processing table 43).
Further, as shown in FIG. 19, after the release sheet 26 having the adhesive layer 25 applied is pasted on the upper side of the antenna pattern portion 11, the separation sheet 26 is passed through a pinching roller (see FIG. 19). The film antenna supplied to the user is completed by cutting the release sheets 14 and 26 (and the adhesive layer 25) with the two-dot chain line in FIG.

By the way, when the film substrate 10 is simultaneously cut along the side surfaces on both sides of the antenna pattern portion 11 as in Embodiments 1 and 2, the film substrate 10a remaining between the cutting blades 21 and 22 Therefore, a large internal stress is generated at the time of cutting, and even after cutting, as shown in FIGS. 7 and 11, both sides are low and the central part is bent into a high cross-sectional shape.
On the other hand, according to this embodiment, the film substrate 10 is cut for each side surface of the antenna pattern portion 11, and is attached to the flexible adhesive layer 12 when cutting with each of the cutting blades 21-2 and 22-1 Since the film base material 10 has a room to escape to the side appropriately, the internal stress generated in the film base material 10 is reduced.
Therefore, in this embodiment, as shown in FIG. 19, the antenna pattern portion 11 after cutting and the film base material 10a remain in a horizontal layer structure with almost no deflection, and have the effect of the first embodiment as it is. There is an effect that it is possible to prevent the occurrence of disconnection due to the deformation of the antenna pattern portion 11.

Also in the case of cutting by this progressive feeding method, as shown in FIG. 20, each of the cutting blades 32-1, 31-2 used in the second embodiment has a first blade mold 42 'and a second blade mold 44'. You may make it each comprise.
In that case, as shown in (A) and (B) of the figure, the cutting blades 32-1 and 31-2 are cut along the cutting lines 16 and 15 shown in (A) and (B) of FIG. The base film 10 is individually cut. The first blade mold 42 'and the second blade mold 44' have inclined surfaces 32a-1 and 31a-2 of the blades 32-1 and 31-2, respectively. It is set to a position where the upper surface corner of the antenna pattern portion 11 is rubbed.
In each of the blade dies 42 ′ and 44 ′ of this embodiment, the blade fixing portions 23-1 and 23-2 that move together with the blades 32-1 and 31-2 (the spacers 23 and 23 of the above embodiment). And the pressing portions 24'-1 and 24'-2 are provided.

  Therefore, the effect of this embodiment can be obtained together with the effect of Embodiment 2, and the laminated portion obtained after cutting the base film 10 as shown in FIG. 21 has a horizontal layer structure, and the laminated portion. The upper surface corner of the antenna pattern 11 is rounded.

<Embodiment 4>
The antenna pattern portion 11 when the film antenna obtained in each of the above embodiments is attached to the glass plate 221 is shown in FIG. 22 (A) [Embodiment 1], (B) [Embodiment 2], and (C). And (D) [Embodiment 3] as in the prior art (FIGS. 25 and 26), the end of the antenna pattern portion 209 does not appear on the glass plate 221 side. Although invisibility is improved, as shown in FIGS. 23A to 23D, the black layer 45 is formed by screen-printing black paint on the surface side of the antenna element portion 11a, and the adhesive layer 12x. If a black adhesive is applied to the adhesive, it will be difficult for light to be reflected on each surface, so it will be difficult to see from any glass surface side when sandwiched between laminated glass, further improving the invisibility It becomes possible.

<Embodiment 5>
In each of the above-described embodiments, the manufacturing process of a single film antenna is described. However, as shown in FIG.
First, printing reference marks 51a and 51b are preliminarily printed on a film substrate 50 having a large plane size. On the surface side of the film substrate 50, 24 marks are provided on the basis of the marks 51a and 51b. The antenna pattern portion 11 is screen-printed with a silver paste related to the antenna pattern, and the adhesive layer 12 is screen-printed with an adhesive in a region corresponding to the antenna pattern portion 11 on the back side.
Here, when the antenna pattern portion 11 is printed, the cutting reference marks 13a and 13b are also printed at the same time.
In addition, as will be described later, in the cutting process, the film base 50 is cut in units of groups (52 to 54), each of which is a set of 6 pieces, so that each set (52 to 54) is aligned and printed in an independent positional relationship. To do.

The film base 50 is cut by adhering a release sheet of almost the same size as the film base 50 to the adhesive layer 12 side, but it is punched in units of each set (52 to 54) in the cutting process. The blade base is positioned by using the cutting reference marks 13a and 13b for each group (52 to 54) in order, and the film base 50 is cut.
As described above, the screen printing in a plurality of units and the cutting process of the film substrate 50 are not limited to the method of simultaneously cutting the film substrate 10 with two cutting blades as in the first and second embodiments. The present invention can also be applied to a progressive system such as

  The present invention can be applied to a method of manufacturing a film antenna that is stuck or sandwiched on a window glass of an automobile or the like.

  10, 10a, 10b, 10b-1, 10b-2, 50 ... film substrate, 11 ... antenna pattern part, 11a, 11b, 11c ... antenna element, 11d, 11e ... feeding part, 12, 12x, 25 ... adhesive layer , 13a, 13b ... cutting reference mark, 14, 26 ... release sheet, 15, 16 ... broken line (cutting line), 21, 21-2, 22, 22-1, 31, 31-2, 32, 32-1 ... Extraction blade, 23,23 ', 23-1,23-2 ... Spacer, 24,24', 24-1,24-2 ... Pressing part, 31a, 32a ... Inclined surface, 41,41 '... First processing table 42,42 '... first blade type, 43,43' ... second processing table, 44,44 '... second blade type, 45 ... black layer, 51a, 51b ... printing reference mark, 52-55 ... cutting 201 in a process, 201 ... film base material, 202 ... foil-like conductive layer, 202e ... conductive layer constituting an antenna pattern part, 203, 203e ... adhesive layer, 204 ... release sheet, 205 ... laminated sheet, 206, 207 ... extraction blade , 208 ... strip-shaped blade, 209 ... antenna pattern part, 210, 211 ... other parts other than the antenna pattern part.

Claims (8)

In the method of manufacturing a film antenna that is attached to the window glass surface and used for receiving radio waves,
A first step of screen-printing an antenna pattern portion including an antenna element and a power feeding portion on one side of a film base material using a conductive paste as a printing material;
A second step of forming the first adhesive layer by screen printing in a region corresponding to the antenna pattern portion on the other surface of the film base material using the first adhesive as a printing material;
A third step of sticking the first release sheet to the first adhesive layer-forming side of the film substrate;
Only the film base material is cut so that the film base material in the region corresponding to the antenna pattern portion and the film base material in the other region are separated by a blade type using a single-blade type extraction blade. A fourth step;
A fifth step of removing the region other than the region of the antenna pattern portion in the film substrate divided in the fourth step;
It consists of the 6th process of sticking the 2nd exfoliation sheet where one side is constituted by the 2nd adhesion layer which consists of the 2nd adhesive on the arrangement side of the antenna pattern part in the 1st exfoliation sheet. ,
The adhesive force of the second adhesive layer to the antenna pattern portion is greater than the adhesive force of the first and second adhesive layers to the first release sheet, and the window glass surface of the first adhesive layer. The method for producing a film antenna, wherein the smoothness of the first and second pressure-sensitive adhesives and the first release sheet is selected so as to be smaller than the adhesive strength against the first adhesive sheet.   The fourth step is a punching blade type in which two single-blade cutting blades are opposed to each other between the blade backs, and the facing distance between the blade backs is kept slightly wider than the width of the antenna pattern portion. However, it is a step of cutting only the film base material using the one in which each cutting blade is fixed so that each blade edge follows both side surfaces of the antenna pattern portion, leaving the first release sheet. The manufacturing method of the film antenna of description.   The fourth step is a punching blade type in which two single-blade cutting blades are opposed to each other between the blade backs, and the blade back surface of each cutting blade is inclined toward the blade front side in a certain section on the blade edge side. In addition, the facing distance between the blade back surfaces is slightly narrower than the width of the antenna pattern portion, and the distance between the blade edges is kept slightly wider than the width of the antenna pattern portion, while each blade edge is on both sides of the antenna pattern portion. And the film base is left with the first release sheet remaining after rubbing both corners of the top surface of the antenna pattern portion with the inclined surface formed on the back surface of each blade. The method for manufacturing a film antenna according to claim 1, wherein the film antenna is a step of cutting only a material.   The fourth step is a step of performing progressive die cutting with two blade dies using a single blade type blade, and at least for the antenna element portion, the blade back side is the antenna element side as each blade die. Then, a process in which the cutting edge is fixed so that the blade edge is along one side surface of the antenna element, and only the film base material is cut while leaving the first release sheet is performed on both side surfaces of the antenna element. The method of manufacturing a film antenna according to claim 1, wherein the film antenna is sequentially executed.   The blade back surface of the extraction blade in each of the blade types is inclined toward the blade surface side in a fixed section on the blade edge side, and the upper surface corner portion of the antenna pattern portion is rubbed with the inclined surface formed on the blade back surface of the extraction blade 5. The method of manufacturing a film antenna according to claim 4, wherein only the film base material is cut after leaving the first release sheet.   The film antenna manufacturing method according to claim 3 or 5, wherein a height of the inclined surface formed on the blade back surface of the punching blade in the blade back surface direction is set larger than the thickness of the first adhesive layer. .   The printing base mark is printed in advance on the film base material, and the screen printing in the first step and the second step is performed by positioning based on the printing reference mark. The method for manufacturing a film antenna according to claim 2, claim 3, claim 4, claim 5, or claim 6.   In the screen printing in the first step, a cutting reference mark is printed together with the antenna pattern portion, and the blade shape is positioned in the fourth step based on the cutting reference mark. The method for manufacturing a film antenna according to claim 2, claim 3, claim 4, claim 5, claim 6, or claim 7.

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