JP4192329B2 - Method for manufacturing electromagnetic wave shielding laminate - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method for manufacturing an electromagnetic wave shielding laminate, and in particular, is installed in front of a PDP in order to protect a plasma display panel (hereinafter abbreviated as PDP) body and to reduce electromagnetic waves generated from the PDP. The present invention relates to a method for manufacturing a protective plate for PDP.
[0002]
[Prior art]
Since the conventional PDP is composed of very precise electrical components, there is a high risk of damage if the user takes action that applies force to the surface when used as it is. it was high. Therefore, some protection was necessary to prevent it. In addition, it has become necessary to add electromagnetic wave shielding performance to the protective plate.
[0003]
As a conventional electromagnetic wave shielding laminate, for example, in JP-A-60-34099, a transparent conductive film is formed on the surface of a transparent resin plate, a copper fiber knitted fabric is placed on the surface, and glass is further formed thereon. It is described that an electromagnetic shielding body is formed by stacking plates and injecting an adhesive between an acrylic plate and a glass plate and solidifying the same. Japanese Patent Application Laid-Open No. 1-158799 describes a transparent electromagnetic wave shielding sheet obtained by laminating a woven fabric impregnated with a conductive paint and a transparent plastic. Further, JP-A-10-241578 discloses a PDP front plate formed by laminating and integrating a synthetic fiber network having a metallized filament surface on a transparent substrate.
[0004]
[Problems to be solved by the invention]
In the conventional electromagnetic wave shielding laminated body as described above, an adhesive or a pressure-sensitive adhesive is used for laminating each layer constituting them, and various pressing devices and laminators are used for the laminating. When laminating each layer with these press devices or laminators, the surface of each laminated member is not necessarily smooth, the surface of the laminated body may be insufficient, and fine voids may remain between the laminated members. . In addition, the adhesives and pressure-sensitive adhesives used often contain volatile components, and these volatile components cannot be completely removed during lamination, and air and other gases remain in the laminate. As a result, the quality of the obtained product, such as the transmittance, becomes uneven, and it is difficult to maintain a high yield rate.
[0005]
Moreover, when using an electromagnetic wave shielding laminated body as a front plate for PDP, there exists a problem of the heat | fever generate | occur | produced from PDP, and it is preferable to use a glass plate as 1 type of the structural material of a laminated body. In this case, in addition to the above problem of deaeration, when each laminated member is laminated by a press device or a laminator, when the resin layer is present on the outermost surface of the laminated body, the appearance quality of the resin layer is There exists a problem that it falls or a glass plate is damaged.
[0006]
Therefore, the object of the present invention is to solve the above-mentioned problems, and in the production of an electromagnetic wave shielding laminate, the appearance quality of the resin layer is not deteriorated even when the resin layer is present on the outermost surface of the laminate. The glass plate is not damaged even when air and other gases remaining in the laminate (particularly a laminate using a mesh-like conductive layer) are reduced and the glass plate is used as a laminate member. It is to provide a simple method for producing an electromagnetic wave shielding laminate, particularly a PDP protective plate.
[0007]
[Means for Solving the Problems]
The present invention is a method of laminating a plate-like body via an adhesive layer or an adhesive layer on at least one surface of a plate-like base material provided with a conductive layer on one surface, the laminated plate A surface of at least one of the substrate and the plate-like body that does not face the adhesive layer or the pressure-sensitive adhesive layer is made of a resin layer, and a rigid plate having a smooth surface is disposed on the surface of the resin layer via a breathable sheet. The electromagnetic wave shielding characterized in that the entire laminated member and rigid plate are accommodated in a sealed bag, the laminated member is laminated by degassing the bag, and the rigid plate and the breathable sheet are removed. A method for producing a laminate is provided.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Next, the present invention will be described in more detail with reference to preferred embodiments shown in the drawings.
In FIG. 1 a, 1 is a conductive layer (for example, a mesh pattern), 2 is a plate-like base material (for example, a resin film) that supports the conductive layer 1, and 3 is a plate-like body laminated on the surface of the conductive layer 1. Is an adhesive layer, 5, 5 'is a rigid plate, 6, 6' is a breathability inserted between the rigid plate 5 and the plate-like substrate 2, and between the plate-like body 3 and the rigid plate 5 '. A sheet, 7 is a sealed bag that accommodates the entirety of each of the laminated members, 8 is an exhaust port, and 16 is a net. In the above, at least one of the plate-like substrate 2 having the conductive layer 1 and the plate-like body 3 and the surface not facing the adhesive layer 4 (at least one outermost layer of the obtained laminate) has a resin layer. For example, the plate-like substrate 2 and / or the plate-like body 3 itself is a resin layer, or the plate-like substrate 2 and / or the plate-like body 3 has a resin layer on the surface not facing the adhesive layer 4. Have.
[0009]
In the present invention, as shown in FIG. 1 a, a laminated member of an electromagnetic wave shielding laminated body is arranged and exhausted from an exhaust port 8 of the sealing bag 7 by a vacuum pump (not shown). As a result of the exhaust, the bag 7 is depressurized or vacuumed. As a result, each laminated member receives atmospheric pressure from the entire periphery thereof, and the laminated members are brought into close contact with each other. By doing in this way, even if at least one outermost layer of the obtained laminate is a resin layer, the appearance quality of the resin layer does not deteriorate.
[0010]
The reduced pressure at this time varies depending on the type of adhesive used, but is usually about 760 to 400 mmHg. At this time, for example, when a film for laminated glass (for example, an interlayer film for lamination such as polyvinyl butyral) or a hot melt type sheet is used as the adhesive layer 4, the film or the hot melt sheet is softened. Further, heating is required to a temperature that does not adversely affect other laminated members, for example, a temperature of about 80 to 130 ° C. On the other hand, if a pressure-sensitive adhesive is applied as an adhesive layer 4 to either surface of the conductive layer 1 or the plate-like body 3, the above heating is unnecessary. After the lamination of each laminated member is completed, the exhaust port 8 is released to break the reduced pressure or vacuum, and the bag 7 is released to remove the rigid plates 5, 5 'and the breathable sheets 6, 6', as shown in FIG. An electromagnetic wave shielding laminate as schematically shown in FIG.
[0011]
In the above method, each laminated member is brought into close contact, but since this close contact is performed in a vacuum (reduced pressure) state, even when the outermost layer of the laminate is made of a resin layer, the surface smooth rigid body is formed on the surface of the resin layer. Are uniformly pressed, so that there are no scratches or irregularities on the surface of the resin layer. Furthermore, air or an adhesive layer is formed between the conductive layer 1 and the adhesive layer 4 and between the plate-like body 3 and the adhesive layer 4. The gas that volatilizes from 4 hardly remains between the laminated members. Further, since the air permeable sheets 6 and 6 ′ are inserted inside the rigid plates 5 and 5 ′, the rigid plates 5 and 5 ′ are not in close contact with the plate-like substrate 2 and the plate-like body 3. Can be easily peeled off and reused. Further, as described above, in the present invention, mechanical means such as a press device and a laminator are unnecessary, so that even if the rigid plates 5 and 5 ′ are glass plates, they are not damaged. A net 16 is placed on the surface of the rigid plate 5. The net is used for the purpose of uniforming the degree of vacuum in the sealing bag, and the net is used as appropriate.
[0012]
Next, each laminated member will be described. The conductive layer 1 having the mesh pattern is an example of the conductive layer in the present invention. The conductive layer 1 is not limited to the mesh pattern, and may have any shape such as a uniform layer as long as it is conductive. For example, as in the prior art, a transparent metal vapor-deposited layer, a transparent conductive metal oxide layer, a conductive fiber knitted fabric, a patterned conductive layer created by a photolithography method using a conductive paint, and printed with a conductive ink Examples include a patterned conductive layer. A preferred example is shown in FIG.
[0013]
FIG. 2 a is a schematic plan view of the plate-like substrate 2 having the conductive layer 1, and FIG. 2 b is a schematic cross-sectional view thereof. The conductive layer 1 is formed into a mesh pattern by forming a thin copper layer on the surface of the plate-like substrate 2 and etching the thin layer into a pattern by a known photolithography method. Since the conductive layer 1 needs to be translucent, the mesh pattern has an aperture ratio of about 60 to 90%. In the case of a mesh pattern, as shown in FIG. 2b, there are many irregularities on the surface of the conductive layer 1, but according to the present invention, air and other gases remain in the irregularities after lamination for the reasons described above. There is nothing. FIG. 2c shows a configuration in which another resin film 10 is laminated and coated with the adhesive 9 on the surface of the conductive layer 1 of FIG. 2b. The laminated film shown in FIG. 2c can be used in place of the plate-like substrate 2 having the conductive layer 1 shown in FIG. 2b.
[0014]
FIG. 3 shows a preferred example of the plate-like substrate 2 having the conductive layer 1 when the electromagnetic wave shielding laminate produced in the present invention is used as a protective plate for PDP. The example shown in FIG. 3 is a structure comprising a conductive layer 1, a plate-like substrate 2 thereof, and a resin film 12 (antireflection film) having an antireflection layer 11 laminated on the back surface thereof. As (11 + 12), for example, a resin film having an antireflection layer known as a trade name “ARKTOP” (manufactured by Asahi Glass Co., Ltd.) is useful. “Arctop” is an antireflection treatment in which a low-refractive index antireflection layer 11 made of an amorphous fluoropolymer is formed on one surface of a polyurethane resin film 12 having self-healing properties and scattering prevention properties. Is given.
The example shown in FIG. 4 is another example of the plate-like substrate 2 having the conductive layer 1, and the near-infrared shielding resin film 13 is interposed between the plate-like substrate 2 and the antireflection film (11 + 12). Are used in the same manner as the laminate shown in FIG. 3 described above, and the obtained laminate is given a near-infrared shielding effect in addition to the electromagnetic shielding effect.
[0015]
The plate-like body 3 used in the present invention is preferably a transparent resin film, a glass plate or a laminate thereof. As the resin film, for example, a resin film having excellent transparency such as polyester, polystyrene, polycarbonate, acrylic resin, or the like can be used. The glass plate may be a normal glass plate and is not particularly limited. When the electromagnetic wave shielding laminate obtained by the present invention is used as a protective plate for a PDP, in order to prevent the laminate from being deformed by heat released from the PDP, a glass plate or resin is used as the plate-like body 3. It is preferable to use a laminate of a film and a glass plate.
[0016]
One example of the structure of the plate-like body 3 preferable for the use of the protective plate for PDP is shown in FIG. The example shown in FIG. 5 has a configuration in which the resin film made of the “arc top” is laminated on the glass plate 15 having the transparent conductive layer 14 on the surface. Around the transparent conductive layer 14, there are provided an electrode of an arbitrary shape (not shown) and a colored ceramic layer. Examples of the transparent conductive layer 14 include a film containing zinc oxide as a main component (for example, a zinc oxide film doped with aluminum), a film containing indium-tin oxide (ITO) as a main component, and tin oxide as a main component. A single-layer transparent conductive film such as a film to be used. In particular, since a low sheet resistance value, a low reflectance, and a high visible light transmittance can be obtained, an oxide layer, a conductive metal layer, and an oxide layer are alternately measured on the glass plate 15 from the glass plate 15 side ( A multilayer film in which 2n + 1) layers (n is an integer of 1 or more) are preferable as the transparent conductive layer 14. These oxide layers are oxide layers mainly composed of ZnO, and the metal layer is preferably a metal layer mainly composed of Ag (refer to WO 98/13850 for details).
[0017]
Examples of the adhesive layer used in the present invention include acrylic, acrylic copolymer, silicone, rubber, and polyvinyl ether adhesives; ethylene-vinyl acetate copolymer, ethylene-acrylate ester copolymer Examples thereof include hot-melt adhesives such as coalesced, polyester-based, and polyamide, and thermosetting or ultraviolet-curable adhesives such as urethane-based, epoxy-based, amino resin-based, phenolic resin-based, and acrylate-based adhesives. These adhesives (adhesive layer or pressure-sensitive adhesive layer) may be used as a sheet or film having an appropriate thickness, or may be applied to the surface of a laminated member to be bonded.
[0018]
The rigid plates 5 and 5 ′ used in the present invention are used as a push plate when the plate-like base material 2 and the plate-like body 3 are laminated, and may be a metal plate as long as the surface is smooth. However, a glass plate is usually used. As these glass plates, a certain level of strength is required, so that a glass plate of about 3 to 6 mm is generally used. In addition, the air-permeable sheets 6 and 6 ′ used in the present invention should be air-permeable so that the rigid plates 5 and 5 ′ can be easily peeled off after the laminated members are laminated under reduced pressure or vacuum as described above. Although not particularly limited, it is generally convenient to use a woven fabric or a non-woven fabric. Moreover, when performing pressure reduction or vacuum lamination, heating, it is preferable to use the polyester woven fabric with comparatively high heat resistance as a breathable sheet to be used. Also, if the texture of the woven fabric is rough, the texture may be transferred to the surface of the plate-like base material or the antireflection film (11 + 12). It is preferable to do. The sealing bag 7 used in the present invention is made of a plastic or rubber sheet that has good sealing performance under reduced pressure and has high durability, and has an exhaust port 8 and a content take-out means (not shown). That's fine.
[0019]
Next, a manufacturing method when the electromagnetic wave shielding laminate of the present invention is a protective plate for PDP will be described with reference to FIG. 6 uses a plate-like substrate 2 having a conductive layer 1 on which an antireflection film (11 + 12) shown in FIG. 3 is laminated, instead of the plate-like substrate 2 having the conductive layer 1 in FIG. Moreover, the laminated body of the glass plate 15 and the antireflection film (11 + 12) which have the transparent conductive layer 14 shown in FIG. 5 instead of the plate-like body 3 shown in FIG. 1 is used. By laminating the laminated members as described above in such a configuration, a protective plate for PDP as schematically shown in FIG. 6b is obtained. In addition, if it replaces with the laminated body of FIG. 3 in the above and uses the laminated body shown in FIG. 4, the protective plate for PDP which has a near-infrared shielding effect in addition to the electromagnetic wave shielding effect will be provided. The resistance value of the protective plate obtained as described above is 0.01 to 3.0Ω / □, particularly 0.01 to 0.5Ω / □, and more preferably 0.01 to 0.1Ω / □. preferable.
[0020]
As described above, the example in which the rigid bodies 5 and 5 ′ and the air permeable sheets 6 and 6 ′ are used on both sides of the laminate has been described, but in the present invention, the plate-like substrate 2 and the plate-like body 3 are used. When either one includes a rigid body such as a glass plate, the rigid body 5 or 5 'and the breathable sheet 6 or 6' can be used one by one on the laminated member side that does not include the glass plate. The object of the present invention is achieved. For example, in FIG. 6a, since the plate-like body 3 has the glass plate 15, the rigid body 5 ′ and the breathable sheet 6 ′ can be omitted.
[0021]
【Example】
Next, the present invention will be described more specifically with reference to examples.
Example 1 (see FIG. 1)
Each material used in this example is as follows.
(1) Plate-like substrate 2 having a conductive layer 1: A mesh film obtained by patterning a copper thin layer 1 (thickness 10 μm) formed on a polyethylene terephthalate film 2 (PET, thickness 100 μm) into a mesh pattern by a photolithography method ( As for the pattern, a pitch of 250 μm, a line width of 20 μm, a bias of 45 ° (hereinafter simply referred to as a mesh film) was cut into 300 × 300 mm. The mesh film is set on a suitable glass support plate, passed through a laminator, and an antireflection film “Arc Top” (manufactured by Asahi Glass Co., Ltd.) is bonded to the PET film surface having no mesh pattern. The “arc top” protruding from the bonded product was cut and removed from the glass support plate to obtain a plate-like substrate 2 having the conductive layer 1.
[0022]
(2) Plate-shaped body 3: “Arctop” is bonded to one surface of a glass substrate (300 × 300 mm, thickness 3 mm) by a laminator machine in the same manner as described above. The “arc top” was cut according to the glass substrate to obtain a plate-like body 3.
(3) Adhesive layer 4: A 0.4 μm thick embossed sheet made of hot melt adhesive EVA (ethylene-vinyl acetate copolymer) was cut into 296 × 296 mm to form an adhesive layer 4.
(4) Rigid plates 5, 5 ′: Two glass plates having a thickness of 3 mm and a size of 330 × 330 mm were used.
(5) Breathable sheets 6 and 6 ′: Two sheets of polyester fiber mesh (420 mesh) cut into a size of 300 × 300 mm were used.
[0023]
As shown in FIG. 1, the laminated member has a rigid plate 5 ′ / breathable sheet 6 ′ / plate-like body 3 / adhesive layer 4 / conductive layer 1 and plate-like substrate 2 / breathable from the bottom to the top. The sheet 6 / the rigid plate 5 were superposed in this order. At this time, the “arc top” bonding plate-like body 3 has the surface on which the “arc top” is not bonded facing the adhesive layer 4, and the conductive layer 1 for the plate-like substrate 2 is used as the adhesive layer 4. Opposed. The superposed product was temporarily fixed with a heat-resistant adhesive tape (not shown) at eight locations around it. Furthermore, this temporarily fixed object was thrown into the sealing bag 7 made from PET, the exhaust port 8 was provided, the net | network 16 was installed in the position of illustration, and the opening | mouth of the bag into which the temporarily fixed object was thrown was sealed. The sealed bag was set in an oven, and the end of a vacuum rubber tube connected to a vacuum pump externally was connected to the exhaust port 8. The sealed bag 7 is heated to 80 ° C. over 1 hour in an oven, held at 80 ° C. for 20 minutes, then heated to 110 ° C. over 1 hour and held at that temperature for 20 minutes. And then cooled to 80 ° C. On the other hand, the vacuum was 760 mmHg until the vacuum was maintained at a temperature of 80 ° C., and the vacuum was 400 mmHg until the subsequent cooling.
[0024]
After cooling, the sealed bag was taken out of the oven and opened to take out the contents (laminate). The obtained laminate was set on an inspection table with a fluorescent lamp placed behind it, and the appearance was inspected by irradiating it with a fluorescent lamp from the back side. As a result, each glass was not damaged and air remained in the laminate. It was confirmed that there were no air bubbles due to, and there were no dents or scratches on the surface. Further, when the transmittance and the reflectance were measured with a spectrophotometer, the luminous average transmittance was 72.0%, the luminous average reflectance was 2.0%, and the transmittance at 900 nm was 3.5 as the near infrared shielding ability. %. Furthermore, when the facing electrode was provided and the resistance value was measured, it was 0.03Ω / □.
[0025]
Comparative Example 1
A laminate was obtained in the same manner as in Example 1 except that a breathable sheet made of polyester mesh was not used. As a result of visual inspection of the laminate, a large number of dents were observed on the surface of the “arc top”, particularly on the surface of the “arc top” laminated with the mesh film.
[0026]
Example 2 (see FIG. 6)
Each material used in this example is as follows.
(1) Plate-like substrate 2 having a conductive layer 1: A mesh film is cut into 980 × 580 mm, this is set on a suitable glass support plate, and “Arc Top” is bonded in the same manner as in Example 1. And the edge part of the "arc top" which protruded from the bonding product was cut, it removed from the glass support plate, and it was set as the plate-shaped base material 2 which has the conductive layer 1. FIG.
(2) Plate-shaped body 3: Same as Example 1 except that the size is 984 × 584 mm.
(3) Adhesive layer 4: Same as Example 1 except that the size is 976 × 576 mm.
(4) Rigid plates 5, 5 ′: A glass plate having a thickness of 5 mm and a size of 1040 × 620 mm and two glass plates having a thickness of 5 mm and a size of 980 × 580 mm were used. From the viewpoint of deaeration, it is preferable that the two rigid plates are the same size or one of which is a slightly smaller plate.
(5) Breathable sheet 6, 6 ′: Same as Example 1 except that the size is 980 × 580 mm.
[0027]
As shown in FIG. 6, the above laminated member has a plate-like substrate having a rigid plate 5 ′ (1040 × 620 mm) / breathable sheet 6 ′ / plate-like body 3 / adhesive layer 4 / conductive layer 1 from bottom to top. The material 2 / the breathable sheet 6 / the rigid plate 5 (980 × 580 mm) were superposed in this order. At this time, the “arc top” bonding plate-like body 3 has the surface on which the “arc top” is not bonded facing the adhesive layer 4, and the conductive layer 1 for the plate-like substrate 2 is used as the adhesive layer 4. Opposed. The superposed product was temporarily fixed with 14 heat-resistant adhesive tapes (not shown) at the 14 surrounding locations. Thereafter, a laminate was obtained in the same manner as in Example 1.
[0028]
The obtained laminate was set on an inspection table with a fluorescent lamp placed behind it, and the appearance was inspected by irradiating it with a fluorescent lamp from the back side. As a result, each glass was not damaged and air remained in the laminate. It was confirmed that there were no air bubbles due to, and there were no dents or scratches on the surface. Moreover, this laminate was set on a PDP panel, and it was confirmed that there was no phenomenon that disturbed the image of the PDP. Furthermore, when the image device set on the PDP panel was set at an open site electromagnetic radiation level measurement place and the electromagnetic radiation level was measured, it was confirmed that the electromagnetic wave was shielded at a practical level.
[0029]
Comparative Example 2
A laminate was obtained in the same manner as in Example 1 except that a breathable sheet made of polyester mesh and a rigid plate were not used. When this laminate was inspected in the same manner as in Example 1, a large number of distortions were observed in which the wrinkles of the sealing bag were transferred to the surface of the “arc top”, particularly the “arc top” surface laminated with the mesh film.
[0030]
【The invention's effect】
According to the present invention as described above, in the production of an electromagnetic wave shielding laminate, the appearance quality of the resin layer does not deteriorate even when the resin layer is present on the outermost surface of the laminate, and the air remaining in the laminate To provide a simple method for producing an electromagnetic wave shielding laminate (particularly a protective plate for PDP) in which the glass plate is not damaged even when a gas plate is used as a laminated member while reducing gas and other gases. Can do.
[Brief description of the drawings]
FIG. 1 is a diagram schematically illustrating a production method of the present invention.
FIG. 2 is a diagram illustrating a plate-like substrate having a conductive layer used in the present invention.
FIG. 3 is a diagram illustrating another plate-like substrate having a conductive layer used in the present invention.
FIG. 4 is a diagram for explaining another plate-like substrate having a conductive layer used in the present invention.
FIG. 5 illustrates an example of a plate-like body used in the present invention.
FIG. 6 is a diagram schematically illustrating the manufacturing method of the present invention.
[Explanation of symbols]
1: Conductive layer 2: Plate-like substrate 3: Plate-like body 4: Adhesive layers 5, 5 ′: Rigid plates 6, 6 ′: Breathable sheet 7: Sealing bag 8: Exhaust port 9: Adhesive 10: Resin Film 11: Antireflection layer 12: Resin film 13: Near infrared shielding resin film 14: Transparent conductive layer 15: Glass plate 16: Net

Claims (8)

A method of laminating a plate-like body via an adhesive layer or a pressure-sensitive adhesive layer on at least one surface of a plate-like base material provided with a conductive layer on one side, the plate-like base material being laminated, A surface of at least one of the plate-like bodies that does not face the adhesive layer or the pressure-sensitive adhesive layer is made of a resin layer, and a rigid plate having a smooth surface is disposed on the surface of the resin layer via a breathable sheet, An electromagnetic wave shielding laminate comprising: a member and a rigid plate that are housed in a sealed bag; and the laminated member is laminated by degassing the bag; and the rigid plate and the breathable sheet are removed. Method.   The manufacturing method according to claim 1, wherein two rigid bodies are used and the laminated member is sandwiched between the two rigid bodies.   The manufacturing method according to claim 1, wherein the conductive layer is a copper mesh pattern formed by a photolithography method.   The manufacturing method of any one of Claims 1-3 with which the antireflection layer is provided in the surface which does not have a conductive layer of a plate-shaped base material.   The manufacturing method according to any one of claims 1 to 4, wherein the plate-like body is a resin film, a glass plate, or a laminate thereof.   The plate-like body is a laminate of a resin film layer and a glass plate having a transparent conductive layer, an antireflection layer is formed on the outer surface of the resin film layer, and the transparent conductive layer is a plate-like substrate. The manufacturing method of any one of Claims 1-5 currently formed in the surface facing a conductive layer.   The manufacturing method according to any one of claims 1 to 6, wherein the rigid plate is a glass plate, and the breathable sheet is a woven fabric or a non-woven fabric.   A protective plate for a plasma display panel, comprising the electromagnetic wave shielding laminate obtained by the method according to claim 1.

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