JP2021053682A - Method for manufacturing work-piece - Google Patents

Abstract

To provide a laser processing technique that can easily manufacture a work-piece while preventing coloration.SOLUTION: A method for manufacturing a work-piece, which manufactures the work-piece by laser-processing a laminate formed of polymer materials, includes: a first laser-processing step of irradiating the laminate with laser light at a first energy density to cut out an intermediate work-piece with a dimension larger than a design dimension of the work-piece; and a second laser-processing step of irradiating the intermediate work-piece with laser light at a second energy density to obtain the work-piece, where the second energy density is equal to 0.55 times or more and 0.90 times or less of the first energy density.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing a processed product, and more particularly to a method for producing a processed product by laser processing a laminate made of a polymer material.

In recent years, with the miniaturization of final products such as electric and electronic devices, the miniaturization and high definition of parts have been progressing. For this reason, high-definition processing technology for various materials used in the manufacture of parts is also required, and as a technology that enables high-precision and fine processing, laser light is used to process the workpiece. Laser processing technology is attracting attention.

However, in material processing using laser light, processing is performed by melting or decomposition reaction due to light absorption of the work piece, so the area around the laser processing part on the work surface side (laser light irradiation surface side) of the work piece. Decomposed products adhere to the laser, causing problems such as coloring.

Therefore, for example, Patent Document 1 proposes a laser processing method for reducing the adhesion of the decomposed product to the processed surface by performing laser processing of the workpiece while sucking and removing the decomposed product in the vicinity of the irradiated portion of the laser beam. ing.

Further, for example, Patent Document 2 discloses a technique for preventing contamination of a processed surface by performing laser processing on a workpiece in a state where the optical axis of the laser beam is inclined with respect to the workpiece at a predetermined angle. Has been done.

Japanese Unexamined Patent Publication No. 2008-284772 Japanese Unexamined Patent Publication No. 2008-302376

However, in the above-mentioned conventional technique, the processing apparatus is complicated because it is necessary to provide a suction mechanism for decomposed products, and the processing operation is complicated because it is necessary to control the angle of the optical axis of the laser beam. There was a problem of doing.

Therefore, an object of the present invention is to provide a laser processing technique capable of easily producing a processed product while preventing coloring.

The present inventor has conducted diligent studies for the purpose of solving the above problems. Then, the present inventor has a first laser processing step of cutting out an intermediate work piece having a size larger than a desired work piece size from the work piece in laser processing using a laminate made of a polymer material as a work piece. After that, a second laser processing step of converting the intermediate work piece into a work piece having a desired size is performed, and the energy density of the laser light of the first laser processing step and the energy of the laser light of the second laser processing step are performed. The present invention has been completed by finding that a processed product can be easily produced while preventing coloring if the density satisfies a predetermined relationship.

That is, the present invention aims to advantageously solve the above problems, and the method for producing a processed product of the present invention is a method for producing a processed product by laser processing a laminate made of a polymer material. The first laser processing step of irradiating the laminated body with a laser beam at a first energy density to cut out an intermediate work piece having a size larger than the design size of the work piece, and the intermediate work piece. The second energy density includes a second laser processing step of irradiating the object with a laser beam at a second energy density to obtain the processed product, and the second energy density is 0.55 times or more 0 than the first energy density. It is characterized by being 90 times or less. In this way, if an intermediate work piece having a size larger than the design size of the work piece is cut out and then laser-processed with a laser beam having a second energy density to obtain a work piece, the work piece can be produced while preventing coloring. It can be easily manufactured.
In the present invention, the "energy density" of the laser beam can be obtained by using the following formula.
Energy density [J / mm ³ ] = Laser light output [W] / (Laser light irradiation width [mm] x Work thickness [mm] x Laser light scanning speed [mm / sec])

Here, in the method for manufacturing a work piece of the present invention, it is preferable that the distance between the cut edge of the intermediate work piece and the design dimensional position of the work piece is 0.05 mm or more and 0.45 mm or less. When the distance between the cut edge of the intermediate work piece and the design dimensional position of the work piece is within the above range, it is possible to easily obtain a work piece having excellent dimensional accuracy while satisfactorily preventing coloring of the work piece. ..

Further, in the method for producing a processed product of the present invention, it is preferable to use at least one selected from the group consisting of a carbon dioxide gas laser, an excimer laser and a YAG laser as the laser light. If a carbon dioxide laser, an excimer laser, or a YAG laser is used, the laminated body and the intermediate work piece to be worked can be satisfactorily laser-machined.

Then, in the method for producing a processed product of the present invention, it is preferable to irradiate both surfaces of the intermediate processed product with the laser beam in the second laser processing step. By irradiating both sides of the intermediate work piece with laser light, the dimensional accuracy of the work piece can be further improved.

According to the present invention, a processed product in which coloring is prevented can be easily produced.

It is a figure explaining the process of manufacturing a processed product according to an example of the manufacturing method of the processed product of this invention, (a) is a plan view, and (b) is a sectional view. It is a top view explaining the relationship between the position of the cutting edge of an intermediate work piece and the design dimension position of a work piece in the case of manufacturing a plurality of work pieces according to another example of the work piece manufacturing method of this invention. It is a top view explaining the relationship between the position of the cutting edge of an intermediate work piece and the design dimension position of a work piece in the case of manufacturing a work piece according to another example of the work piece manufacturing method of this invention.

Hereinafter, the method for producing the processed product of the present invention will be described with reference to the drawings. In each drawing, the dimensions of some configurations are enlarged or reduced for ease of understanding.

(Manufacturing method of processed products)
The method for producing a processed product of the present invention is a method for producing a processed product by laser processing a laminate made of a polymer material, and is not particularly limited, and is an electric / electronic device such as a dye-sensitized solar cell. It can be used when manufacturing an optical element such as a polarizing plate and a processed product having a laminated structure such as an optical film such as a retardation film, a polarizing film, an antireflection film and a brightness improving film.

Then, in the method for manufacturing a work piece of the present invention, a laser beam is applied to a laminate to be a work piece at a first energy density, and an intermediate work piece having a size larger than the design size of the work piece is cut out. Laser light is applied at a second energy density of 0.55 times or more and 0.90 times or less of the first energy density with respect to the intermediate work piece obtained in the first laser processing step and the first laser processing step. It is characterized by including a second laser processing step of irradiating and obtaining a processed product.

Here, when a laminate made of a polymer material is usually cut by laser processing, the periphery of the cut portion on the processed surface side (laser light irradiation surface side) of the laminate is colored (for example, by adhesion of decomposition products). Yellowing, etc.). The degree of coloring increases as the energy density of the irradiated laser beam increases. However, in the method for manufacturing a workpiece of the present invention, after cutting out an intermediate workpiece having a size larger than the design dimension of the workpiece in the first laser machining step, the first laser machining step in the second laser machining step. Since the periphery of the cut portion (colored portion) is removed by using a laser beam having a lower energy density than that of the laser beam to obtain a processed product, it is possible to suppress the occurrence of coloring such as yellowing.

<First laser processing process>
In the first laser processing step, for example, FIG. 1 (a) shows a plan view, and FIG. 1 (b) shows a cross-sectional view along the thickness direction of the laminated body. The laminated body 10 formed by laminating 11 to 13 is irradiated with laser light at the first energy density, and the intermediate work piece 20 having a size larger than the design size of the work piece 30 is cut out. Specifically, in the first laser machining step, the laminate 10 is cut at the cutting position P1 located outside the design dimension position P2 of the workpiece 30 in FIG. 1, which is larger than the design dimension of the workpiece 30. Cut out the intermediate work piece 20.

[Laminate]
Here, as the laminate to be processed, any laminate having two or more layers of a polymer material can be used. Specifically, the laminate includes two layers containing a polymer material such as a polycarbonate resin, a cyclic olefin resin, a natural rubber, a polyethylene naphthalate resin (PEN), an acrylic resin (PMMA), an epoxy resin, and a polystyrene resin. The laminate having the above can be used. Among them, as the laminate, it is preferable to use a laminate having a polycarbonate resin layer, and the laminate is formed by interposing one or more polymer material layers including an ultraviolet curable resin layer between the two polycarbonate resin layers. It is more preferable to use the body.
The laminated body may have an arbitrary member such as an electronic device interposed between the layers of the polymer material. The thickness of the laminated body is not particularly limited, but is preferably 0.5 mm or more and 2 mm or less.

[Laser light]
The laser light is not particularly limited as long as it can cut the laminated body, and any laser light can be used.
Above all, from the viewpoint of satisfactorily laser processing the laminated body, it is preferable to use at least one selected from the group consisting of carbon dioxide gas laser, excimer laser and YAG laser as the laser light.

Here, the output of the laser light is not particularly limited, and is preferably 100 W or more and 300 W or less, for example.
The oscillation frequency of the laser beam is preferably 1 kHz or more and 20 kHz or less.
Further, the irradiation width (laser light diameter) of the laser light is not particularly limited, and is preferably 0.1 mm or more and 2 mm or less, for example.
By using the laser beam having the above-mentioned properties, the intermediate work piece can be satisfactorily cut out from the laminated body.

The scanning speed of the laser beam is not particularly limited, and is preferably 100 mm / sec or more, more preferably 150 mm / sec or more, preferably 500 mm / sec or less, and 250 mm / sec. The following is more preferable. When the scanning speed of the laser beam is within the above range, the intermediate work piece can be satisfactorily cut out from the laminated body while suppressing coloring.
The direction of irradiating the laminated body with the laser beam can be any direction.

Then, the laser light energy density of the first laser processing step (the first energy density) is preferably 0.8 J / mm ³ or more, more preferably 0.9 J / mm ³ or more, It is preferably 2.0 J / mm ³ or less, and ^{more preferably 1.5 J / mm 3} or less. When the first energy density is equal to or higher than the above lower limit value, the intermediate work piece can be satisfactorily cut out from the laminated body. Further, when the first energy density is not more than the above upper limit value, coloring of the processed product can be sufficiently suppressed.

[Intermediate work]
The intermediate work piece cut out from the laminate has a size larger than the design size of the work piece.

Here, the dimensions of the intermediate workpiece are not particularly limited as long as the portion to be the workpiece (inside the design dimension position P2 in FIG. 1) is not colored. Above all, the distance between the cutting edge of the intermediate workpiece and the design dimensional position of the workpiece (in FIG. 1, the cutting position P1 which is the cutting edge of the intermediate workpiece 20 and the design dimensional position P2 of the workpiece 30 The distance d) between them is preferably 0.05 mm or more and 0.45 mm or less. When the above-mentioned distance is equal to or more than the above lower limit value, the colored portion when cutting out the intermediate workpiece in the first laser machining step can be reliably removed in the second laser machining step. Further, when the above-mentioned distance is equal to or less than the above upper limit value, it is possible to prevent the size of the work piece obtained through the second laser machining step from becoming larger than the desired design size, and to obtain a work piece having excellent shape accuracy. Obtainable.

Further, the shape of the intermediate work piece is preferably a shape in which the shape of the cut edge in a plan view and the design shape of the work piece (shape at the design dimension position) are similar to each other.

<Second laser processing process>
In the second laser machining step, for example, as shown in FIGS. 1 (a) and 1 (b), the energy density (second) of a predetermined magnitude is relative to the intermediate workpiece 20 obtained in the first laser machining step. (Energy density of) is irradiated with a laser beam to obtain a work piece 30.
Specifically, in the second laser machining step, at least a part of the intermediate workpiece 20 located between the cutting edge P1 and the design dimension position P2 of the workpiece is irradiated with laser light. The portion is removed to obtain the work piece 30. The laser light irradiation in the second laser processing step may be performed on only one surface of the intermediate work piece 20 or on both sides, but at least the first laser processing step. It is preferable to irradiate from the side irradiated with the laser beam.

[Laser light]
Here, as the laser light, any laser light can be used as long as it is possible to remove a part of the intermediate work piece to obtain a work piece.
Above all, from the viewpoint of satisfactorily laser processing the intermediate processed product, it is preferable to use at least one selected from the group consisting of carbon dioxide gas laser, excimer laser and YAG laser as the laser light.
The type of laser light used in the second laser processing step may be the same as or different from that in the first laser processing step.

Here, the output of the laser light is not particularly limited, and is preferably 100 W or more and 300 W or less, for example.
The oscillation frequency of the laser beam is preferably 1 kHz or more and 20 kHz or less.
Further, the irradiation width (laser light diameter) of the laser light is not particularly limited, and is preferably 0.1 mm or more and 2 mm or less, for example.
By using the laser beam having the above-mentioned properties, it is possible to satisfactorily process the intermediate processed product while suppressing the coloring of the processed product.

The scanning speed of the laser beam is not particularly limited, and is preferably 100 mm / sec or more, more preferably 250 mm / sec or more, preferably 500 mm / sec or less, and 350 mm / sec. The following is more preferable. When the scanning speed of the laser beam is within the above range, it is possible to obtain a work piece from the intermediate work piece satisfactorily while suppressing coloring.
The direction of irradiating the intermediate work piece with the laser beam can be any direction.

The energy density of the laser beam (second energy density) in the second laser processing step needs to be 0.55 times or more of the first energy density, and is 0.60 times or more. Is preferable, and it is necessary that it is 0.90 times or less, and it is preferable that it is 0.80 times or less. When the magnitude of the second energy density is equal to or higher than the above lower limit, the colored portion located between the cut edge of the intermediate workpiece and the design dimensional position of the workpiece is sufficiently removed to prevent coloring. Can be obtained. Further, when the magnitude of the second energy density is equal to or less than the above upper limit, it is possible to prevent the workpiece from being colored by the irradiation of the laser beam in the second laser machining step.

The second energy density is preferably at 0.55 J / mm ³ or more, preferably more preferably 0.60J / mm ³ or more and 1.0 J / mm ³ or less, 0 More preferably, it is 8.8 J / mm ^{3 or less.} When the second energy density is within the above range, coloring of the work piece can be prevented more reliably.

[Processed product]
The dimensions of the workpiece obtained in the second laser machining step are preferably the same as the design dimensions, but may be different from the design dimensions.
Specifically, for example, when the laser beam is irradiated from only one surface side of the intermediate workpiece in the second laser processing step, the workpiece is irradiated with the laser beam on the side opposite to the side irradiated with the laser beam. It may have a portion that cannot be completely removed by irradiation.
In the second laser processing step, intermediate processing is performed in the second laser processing step from the viewpoint of suppressing the occurrence of a portion that cannot be completely removed by irradiation with the laser light and obtaining a processed product having excellent shape accuracy. It is preferable to irradiate both sides of the object with laser light.
Further, the difference between the size of the work piece and the design size is preferably 100 μm or less.

Although the method for producing the processed product of the present invention has been described above with reference to FIG. 1, the method for producing the processed product of the present invention is not limited to the example shown in FIG. Specifically, in the method for producing a processed product of the present invention, for example, as shown in FIG. 2, a plurality of (two in the illustrated example) processed products may be produced from one laminated body. Further, in FIGS. 1 and 2, the case where the portion to be the workpiece is inside the design dimension position P2 is shown, but the portion to be the workpiece in the laminated body has the design dimensions as shown in FIG. 3, for example. It may be a portion outside the position P2. In this case, the cutting position P1 is located inside the design dimension position P2.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. The present invention is not limited to these examples. In Examples and Comparative Examples, the shape accuracy of the work piece and the presence or absence of coloring were evaluated as follows.

<Shape accuracy of the work piece>
The actual size D1 of the obtained work piece was measured, and the absolute value of the difference from the design size D2 was calculated. Then, it was evaluated according to the following criteria.
〇: Absolute value of difference is 0.1 mm or less Δ: Absolute value of difference is more than 0.1 mm ×: The laminate could not be cut and a work piece could not be obtained <Presence or absence of coloring>
The surface of the obtained processed product was visually observed, and the presence or absence of coloring (yellowing) was evaluated according to the following criteria.
〇: No yellowing ×: With yellowing

(Example 1)
As a work piece, a layer made of a polycarbonate resin having a thickness of 350 μm, a layer made of a polyethylene naphthalate resin having a thickness of 300 μm, and a layer made of a polycarbonate resin having a thickness of 350 μm are laminated in this order in a rectangular shape in a plan view. A body (total thickness: 1 mm) was prepared. Then, the laminated body was irradiated with laser light under the conditions shown in Table 1, and an intermediate work piece having a plan view shape as shown in FIG. 1A was cut out (first laser processing step).
Next, the obtained intermediate work piece was irradiated with laser light under the conditions shown in Table 1 to obtain a work piece having a plan view shape as shown in FIG. 1 (a) (second laser processing step). .. Specifically, a work piece was obtained by irradiating a laser beam between the cutting edge P1 of the intermediate work piece and the design dimension position P2 of the work piece.
Then, the shape accuracy of the work piece and the presence or absence of coloring were evaluated. The results are shown in Table 1.
In the first laser processing step and the second laser processing step, a CO ₂ laser irradiation device (laser wavelength: 10.6 μm, laser scanning method: galvano scanner and stage, maximum output: 300 W, frequency: ~ 200 kHz) is used. used.

(Examples 2 to 5)
A workpiece was produced in the same manner as in Example 1 except that the laser beam irradiation conditions of the first laser machining step and / or the second laser machining step were changed as shown in Table 1. Then, the evaluation was performed in the same manner as in Example 1. The results are shown in Table 1.

(Comparative Examples 1-2)
A processed product was produced in the same manner as in Example 1 except that the laser beam irradiation conditions in the second laser processing step were changed as shown in Table 1. Then, the evaluation was performed in the same manner as in Example 1. The results are shown in Table 1.

(Comparative Example 3)
The laser beam irradiation conditions of the first laser machining step were changed as shown in Table 1, and the workpiece was manufactured in the same manner as in Example 1 except that the second laser machining step was not carried out. Then, the evaluation was performed in the same manner as in Example 1. The results are shown in Table 1.

From Table 1, it can be seen that in Examples 1 to 5, a processed product in which coloring is prevented can be easily obtained. Further, it can be seen that in Examples 1 to 4, a work piece having a shape accuracy superior to that in Example 5 having a large distance d can be obtained. Further, from Table 1, Comparative Example 1 in which the ratio of the second energy density to the first energy density is large, Comparative Example 2 in which the ratio of the second energy density to the first energy density is small, and the second laser. It can be seen that in Comparative Example 3 in which the processing step was not carried out, coloring of the processed product could not be prevented.

According to the present invention, a processed product in which coloring is prevented can be easily produced.

10 Laminates 11 to 13 Polymer material layer 20 Intermediate work piece 30 Work piece P1 Cutting position (cutting edge of intermediate work piece)
P2 Design dimension position

Claims (4)

It is a method of manufacturing a work piece by laser processing a laminate made of a polymer material.
A first laser processing step of irradiating the laminate with a laser beam at a first energy density and cutting out an intermediate work piece having a size larger than the design size of the work piece.
A second laser processing step of irradiating the intermediate work piece with laser light at a second energy density to obtain the work piece, and
Including
A method for producing a processed product, wherein the second energy density is 0.55 times or more and 0.90 times or less the first energy density. The method for manufacturing a work piece according to claim 1, wherein the distance between the cut edge of the intermediate work piece and the design dimensional position of the work piece is 0.05 mm or more and 0.45 mm or less. The method for producing a processed product according to claim 1 or 2, wherein at least one selected from the group consisting of a carbon dioxide gas laser, an excimer laser, and a YAG laser is used as the laser light. The method for producing a processed product according to any one of claims 1 to 3, wherein in the second laser processing step, both surfaces of the intermediate processed product are irradiated with the laser beam.

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