JP5342286B2 - シート接合体の製造方法及びシート接合体 - Google Patents
シート接合体の製造方法及びシート接合体 Download PDFInfo
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- JP5342286B2 JP5342286B2 JP2009069857A JP2009069857A JP5342286B2 JP 5342286 B2 JP5342286 B2 JP 5342286B2 JP 2009069857 A JP2009069857 A JP 2009069857A JP 2009069857 A JP2009069857 A JP 2009069857A JP 5342286 B2 JP5342286 B2 JP 5342286B2
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- Prior art keywords
- sheet
- joined body
- joining
- resin
- sheet member
- Prior art date
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
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Landscapes
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Description
また、このような場合に限らず、シート部材どうしの端部を接合してシート接合体を作製することが広く行われている。
このシート接合体は、その接合部の接合強度がシート部材自体の強度よりも低い状態に形成されやすく従来接合強度の向上が求められている。
この粘着テープを用いたシート接合体製造方法においては、一方のシート部材の端部と他方のシート部材の端部とを突き合せた状態にさせ、この突き合わせられた箇所を覆うようにして粘着テープをシート部材の表面に接着させることが行われている。
一方で、粘着テープは被着体に対して感圧接着されることから、通常、良好なる接着性を発揮させるために柔軟な粘着剤が用いられている。したがって、粘着テープの周囲に粘着剤をはみ出させやすく、この粘着剤は、常温で粘着性を有することから周辺の機器や部材に付着したり、はみ出した粘着剤にホコリ等が付着して美観を低下させたりするおそれを有する。
さらに、通常、粘着テープは、芯材に巻回されたものを外側から剥離して使用するようになっており、粘着面とは逆の面(背面)には剥離性を向上させる表面処理が施されている。
したがって、例えば、シート部材に塗工処理を施す場合においては、粘着テープを接着している箇所において塗工液をはじいてしまうおそれを有する。
この問題を防止すべく、被塗工面とは反対となる面においてのみ粘着テープを用いた接合を行うことが考え得るが、その場合には、十分な接合強度を確保できないおそれがある。
また、薬液中に浸す工程において粘着剤の成分が(例えば、継ぎ目部分から)染み出すなどして問題となる点については十分な解決がなされない。
このようなことから粘着剤の使用を制限しつつ優れた接合強度を有するシート接合体を製造する製造方法が近年検討されている。
この特許文献1記載のシート接合体製造方法においては、シート部材どうしの溶着によってシート接合体が作製されることから粘着剤の使用を抑制させ得る。
しかし、特許文献1記載のシート接合体の製造方法は、シート部材の端面という限られた領域を接着領域とすることから得られるシート接合体に優れた接合強度を付与することが困難であるという問題を有している。
しかも、シート部材の端部どうしが突き合わせられた部分を前記接合部材で被覆して、該接合部材で被覆されている箇所にレーザー光を照射して前記溶着を実施することから、接合部材での被覆面積を増大させて溶着領域を拡大させることができ、接合強度を向上させ得る。
すなわち、本発明によれば、溶着によってシート接合体に接合強度を付与することができ、しかも、その強度の向上も容易に実施させ得ることから粘着剤の使用を抑制しつつ優れた接合強度を有するシート接合体を製造することができる。
なお、図1(a)は、本実施形態のシート接合体製造方法における準備工程の様子を示す側面図である。
また、図1(b)は、前記準備工程後に実施される接合工程の様子を示す側面図であり、図1(c)は、前記接合工程後に実施される取出し工程の様子を示す側面図である。
前記準備工程(図1(a))においては、平盤状のステージ40の上面中央部に、第一シート部材10の端部11と第二シート部材20の端部21とを位置させ、しかも、これら端部どうしが突き合わせられた状態となるようにして第一シート部材10と第二シート部材20とを配置し、さらに、この第一シート部材10の端部11と第二シート部材20の端部21とが突き合わせられている箇所を被覆するように前記接合部材30を配置させる。
すなわち、第一シート部材10の端部11から第二シート部材20の端部21に跨るようにしてこれらのシート部材上に前記接合部材30を載置する。
このように配置させた接合部材30の上方に透明ガラス板50を配置し、該透明ガラス板50を下方側(ステージ側)に向けて押圧し、該押圧力によって第一シート部材10、第二シート部材20、及び接合部材30の位置を固定させる。
このような緩衝シート材としては、例えば、シリコンラバーシート、ウレタンラバーシートなどを用いることができ、この緩衝シート材は、常温(例えば23℃)における硬度(JIS K6253に定められたタイプAデュロメータ硬さ)が、90°以下であることが好ましく、70°以下であることがさらに好ましい。
そして、照射したレーザー光Rを透明ガラス板50を通過させ、接合部材30と第一シート部材10が接触している界面、及び、接合部材30と第二シート部材20とが接触している界面に到達させ、主としてこの界面部で照射したレーザー光Rを吸収させて光エネルギーを熱エネルギーに変換し、接合部材30と第一シート部材10との溶着、及び接合部材30と第二シート部材20との溶着を実施する。
なお、この界面部におけるレーザー光Rの吸収が不十分となることが予測されるようであれば、予め前記準備工程において第一シート部材10と前記接合部材30との界面や前記第二シート部材20と前記接合部材30との界面などに染料、顔料、カーボンブラックといった光吸収剤を配し、光吸収性(発熱性)を向上させておくことも可能である。
この、界面に光吸収剤を配する態様としては、これらをシート部材10,20や接合部材30の表面に塗布する方法や、光吸収剤を含有させた接合部材を用いて、シート部材10,20と接合部材との界面に光吸収剤を存在させる方法が挙げられる。
または、溶着に要する時間の短縮を目的として、複数の光源からレーザービームを照射させることもでき、一箇所におけるレーザー光の照射時間を長くしつつ溶着に要する時間を短縮させるべく、スポットの形状が走査方向に伸びる楕円形状となるレーザービームを用いても良い。
また、この図2に示すような態様においても、緩衝シート材や光吸収剤の使用が可能である。
この場合には、例えば、上記に示した一連の工程で一面側に接合部材30を接着させて片面接合が行われたシート接合体1を一旦作製した後に、他面側に新たな接合部材を接着させる方法などを採用することができる。
また、例えば、図2(a)〜(c)に示すような方法によって下面側の片面接合がされたシート接合体1の突き合わせ箇所に新たな接合部材を上面側から被覆させて図1(a)〜(c)と同様にこの新たな接合部材の接着を実施する方法などが挙げられる。
あるいは、表面が金属材料のような熱によって軟化させることが実質困難な材料で形成されているものである場合には、少なくとも接合部材が溶着される端部の表面が粗化されていることが好ましい。
また、本実施形態においては、第一シート部材10と第二シート部材20との二枚のシート部材を用いる場合を例示しているが、三枚以上のシート部材を接合してシート接合体を作製することもできる。
さらには、一枚のシート部材の一端部と他端部とを接合して環状のシート接合体を作製することも可能である。
このシート状の接合部剤(以下「接合シート」ともいう)は、その厚みが薄過ぎる場合にはシート接合体の接合強度を十分向上させることが困難となるおそれがあり、逆に、厚過ぎる場合には、接合シートによって樹脂接合体に大きな段差が形成されてしまうこととなる。
このような点において、接合シートは、5〜500μmのいずれかの厚みであることが好ましく、10〜150μmのいずれかの厚みであることがさらに好ましい。
なお、要すれば、樹脂組成物中に粘着剤を含有させて接合シートの表面に粘着性(タック性)を付与したり、接合シートの表面に薄い粘着剤層を設けたりしてシート部材への仮接着性を接合シート付与させることも可能ではあるが、粘着剤の付着等の問題を防止し得る点において、樹脂組成物に粘着剤を含有させたり、粘着剤層を接合シートに設けたりしないことが好ましい。
すなわち、シート部材の接合には、粘着剤が用いられていないことが好ましく、前記接合シートは、非粘着性のものであることが好ましい。
また、透明ガラス板に代えて、円柱状、円筒状、球状などといった各種形状の透明ガラス材を接合部材の押圧に用いることができる。
また、要すれば、これらに代えて透明な樹脂によって形成された部材で接合部材の押圧を実施することも可能である。
なかでも、半導体レーザー、ファイバーレーザーなどの赤外線レーザーが接合部材とシート部材との界面における発熱性に優れ好適である。
また、上記以外に用い得る成分としては、例えば、ポリメチン系吸収剤、ジフェニルメタン系吸収剤、トリフェニルメタン系吸収剤、キノン系吸収剤、アゾ系吸収剤などが挙げられる。
800〜1200nmの波長を有するレーザー光を用いる場合、例えば、米国Gentex社から商品名「Clearweld」として市販のものを用いることが出来る。
これらの光吸収剤を塗布する手段としては、例えばディスペンサー、インクジェットプリンター、スクリーン印刷、2流体式、1流体式または超音波式スプレー、スタンパーなどの一般的な手法を用いることが出来る。
実施例1のシート接合体を下記のような部材を使用して作製した。
(使用部材)
・シート部材A:ポリエチレンテレフタレート樹脂(PET)製シート材(長さ50mm×幅50mm×厚み50μm)
・シート部材B:ポリエチレンテレフタレート樹脂(PET)製シート材(長さ50mm×幅50mm×厚み50μm)
・接合シートC:ポリエチレンテレフタレート樹脂(PET)製シート材(長さ50mm×幅3mm×厚み50μm)
(使用レーザー光照射装置)
・レーザー光源:半導体レーザー
・レーザー光波長:940nm
・出力:20W
・レーザー光スポット径:2mmφ
・走査速度:100mm/s
まず、シート部材Aとシート部材Bとをその端部どうしを突き合せた状態でステージ上に並べ、接合シートCを、この突き合わせられたシート部材Aの端部からシート部材Bの端部に跨るようにしてこれらのシート部材上に載置した。
すなわち、この幅3mmの接合シートCがシート部材Aの端部とシート部材Bの端部の上面をそれぞれ約1.5mmずつ被覆する状態となるようにシート部材Aとシート部材Bとの境界線に沿って接合シートCを配した。
なお、シート部材A及びシート部材Bと接合シートCとの界面にはレーザー光の吸収性を向上させるべく染料(光吸収剤)液の塗布を実施した。
このようにセットされたシート部材A、シート部材B、及び接合シートCの上部に透明ガラス板を載置して、接合シートCに加わる圧力が約0.1MPaとなるように前記透明ガラス板で接合シートCを押圧しつつこの接合シートCによって被覆されている箇所に出力20Wのレーザー光を照射した。
このとき直径2mmのレーザー光スポットの中心部がシート部材Aとシート部材Bとの境界線に沿って移動するようにレーザー光の照射位置を100mm/sで走査し接合シートとシート部材A、及び接合シートとシート部材Bとを一度に溶着させて実施例1のシート接合体を製造した。
この長手方向中央の溶着箇所を介して一端側がシート部材Aで、他端側がシート部材Bで形成されている短冊状試料の両端部をそれぞれ引張り試験機(島津製作所社製、「オートグラフ AG−5000A」)のチャックに挟んで、シート部材Aとシート部材Bとが離間する方向に50mm/minの速度で引張り試験を実施したところ、その接合強度(接合体が破断した時の応力(N)を試料幅(1cm)で除した値)が約100N/cmであることがわかった。
上記のことからも、本発明によれば粘着剤を用いることなく優れた接合強度を有するシート接合体を製造し得ることがわかる。
接合する2枚のシート部材を、ポリエチレンテレフタレート樹脂(PET)製シート材に代えて、25μm厚みのステンレス(SUS)層と25μ厚みのポリイミド樹脂(PI)層とが積層された積層シート材(長さ50mm×幅50mm×厚み50μm)とし、SUS層側に接合シート(長さ50mm×幅3mm×厚み50μmのPET製シート)を接着させたこと、及びレーザー光スポットの走査速度を50mm/sとした以外は、実施例1のシート接合体と同様に実施例2のシート接合体を作製した。
また、この接合部の断面観察を行ったところ、SUS層の背面側に位置するPI層には、SUS層からの熱伝達による溶融が見られ、PI層どうしの溶着が生じていることが確認された。
さらに、突き合わせられているシート部材の端部にわずかな間隙が生じている箇所においては、接合シートのPETが流入していることも確認できた。
そして、この実施例2のシート接合体の接合強度を実施例1のシート接合体と同様に測定したところ約210N/cmであることがわかった。
このことからも、本発明によれば粘着剤を用いることなく優れた接合強度を有するシート接合体を製造し得ることがわかる。
接合する2枚のシート部材を、ポリエチレンテレフタレート樹脂(PET)製シート材に代えて富士フイルム社製の80μm厚みのトリアセチルセルロース樹脂(TAC)製長尺シート材(幅1330mm)とし、接合シートとして、同じくTACシート(1330mm長さ×5mm幅×80μm厚み)を用意した。
この接合シートの一面中央部に約3mm幅となるように光吸収剤(Gentex社製、商品名「Clearweld LD120C」)を10nL/mm2となる量で塗布し、上記実施例1と同様にレーザー溶着を実施した。
なお、接合シートの加圧は、約0.1MPaに代えて15kgf/cm2となるようにして行った。
また、出力を20Wに代えて30Wとした以外の、940nmの波長のレーザー光(スポット径2mmφ)を100mm/sで走査させた点については実施例1と同じ条件で溶着を実施した。
得られたシート接合体(長尺シート)を300Nの張力をかけて、一方のロールから送出して他方のロールに巻き取る“ロールトゥロール搬送”をしたところ、この接合部における切断が生じることなく良好に搬送することができた。
接合する2枚のシート部材を、日本ゼオン社製の70μm厚みのノルボルネン樹脂製長尺シート材(商品名「ゼオノア」、幅1000mm)とし、接合シートとして、同じくノルボルネン樹脂シート(1000mm長さ×5mm幅×70μm厚み)を用意した。
この接合シートの一面中央部に約3mm幅となるように光吸収剤(Gentex社製、商品名「Clearweld LD120C」)を15nL/mm2となる量で塗布し、上記実施例3と同様にレーザー溶着を実施した。
なお、接合シートの加圧は、15kgf/cm2に代えて10kgf/cm2となるようにして行った。
また、出力を30Wに代えて50Wとした以外の、940nmの波長のレーザー光(スポット径2mmφ)を100mm/sで走査させた点については実施例3と同じ条件で溶着を実施した。
得られたシート接合体(長尺シート)を300Nの張力をかけて、“ロールトゥロール搬送”したところ、この接合部における切断が生じることなく良好に搬送することができた。
実施例3と同じTAC製長尺シートを用意し、この長尺シートの端部どうしを突き合わせ、この突き合わせ箇所に対して延伸ポリプロピレンフィルム基材の50mm幅の粘着テープ(日東電工社製、商品名「ダンプロンテープ」、厚み70μm(基材厚み40μm+粘着剤層厚み30μm))を接着させて実施例3と同様に長尺のシート接合体を作製した。
この粘着テープを突き合わせ部の両面に接着させることで300Nの張力をかけて、実施例3と同様にロールトゥロール搬送が可能なシート接合体を得ることができたが、このシート接合体は、粘着剤の使用によって埃などの付着による美観の低下や一部の成分がアルカリ溶液などに対して溶出する懸念があるとともに50mm幅のテープを両面に接着させていることで“ロールトゥロール搬送”において二本のローラでニップされた箇所を接合部が通過する際の衝撃が大きいものであった。
実施例3と同じTAC製長尺シートを用意し、この長尺シートの端部どうしを突き合わせ、この突き合わせ箇所に対して光吸収剤(Gentex社製、商品名「Clearweld LD120C」)を塗布し、先の特許文献1(特開平5−278112号公報)に記載の方法のごとくレーザー光を照射して端面どうしを溶着させた。
具体的には、透明ガラス板にて10kgf/cm2の圧力で加圧しつつ、突き合わせ箇所に対して、940nmの波長のレーザー光(スポット径1mmφ、出力50W)を50mm/sで走査させて溶着を実施した。
得られたシート接合体に対して実施例1、2と同様に引張り試験機で接合強度の測定を行ったところ、10N/cmの接合強度しかなく、300Nの張力をかけて“ロールトゥロール搬送”したところ、この接合部に沿ってシート接合体の破断が生じる結果となった。
Claims (4)
- 帯状のシート部材の端部どうしを突き合わせ、この突き合わせられた部分を熱可塑性樹脂が含有されてなる接合部材で被覆し、前記接合部材で被覆されている箇所にレーザー光を照射して前記シート部材と前記接合部材とを溶着させることにより前記端部どうしを粘着剤を用いることなく接合させてロールトゥロール搬送されるシート接合体を作製することを特徴とするシート接合体の製造方法。
- 前記接合された箇所が薬液に浸漬されるシート接合体を作製する請求項1記載のシート接合体の製造方法。
- レーザー光の前記照射を前記接合部材を透明な部材で前記シート部材に押圧しつつ実施し、且つ該透明な部材を通じて前記押圧されている箇所にレーザー光を照射する請求項1又は2記載のシート接合体の製造方法。
- 透明な部材による前記押圧を1kgf/cm 2 以上50kgf/cm 2 以下の圧力で実施する請求項3記載のシート接合体の製造方法。
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JP2009069857A JP5342286B2 (ja) | 2008-05-16 | 2009-03-23 | シート接合体の製造方法及びシート接合体 |
TW098112478A TWI478807B (zh) | 2008-05-16 | 2009-04-15 | 板狀接合體的製造方法及板狀接合體 |
KR1020090035906A KR20090119691A (ko) | 2008-05-16 | 2009-04-24 | 시트 접합체의 제조 방법 및 시트 접합체 |
EP20090006406 EP2119552A1 (en) | 2008-05-16 | 2009-05-12 | Method of producing sheet joined body and sheet joined body |
US12/466,022 US20090286035A1 (en) | 2008-05-16 | 2009-05-14 | Method of producing sheet joined body and sheet joined body |
CNA2009101404798A CN101579924A (zh) | 2008-05-16 | 2009-05-15 | 片接合体的制造方法以及片接合体 |
US13/211,769 US20110297312A1 (en) | 2008-05-16 | 2011-08-17 | Method of producing sheet joined body |
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JP5427434B2 (ja) * | 2009-02-26 | 2014-02-26 | 日東電工株式会社 | シート接続体の製造方法 |
US20110072854A1 (en) * | 2009-09-25 | 2011-03-31 | Hideto Nikkuni | Method for joining members to be joined and joining apparatus used therefor |
KR101718169B1 (ko) * | 2010-01-13 | 2017-03-20 | 닛토덴코 가부시키가이샤 | 시트 접합체의 제조 방법, 시트 접합체, 롤체, 광학용 필름, 및 편광 필름 |
JP5548593B2 (ja) * | 2010-01-13 | 2014-07-16 | 日東電工株式会社 | シート接合体の製造方法、シート接合体、ロール体、光学用フィルム、及び偏光フィルム |
JP5608376B2 (ja) * | 2010-01-14 | 2014-10-15 | 日東電工株式会社 | シート接合体作製方法 |
CN102189683A (zh) * | 2010-02-04 | 2011-09-21 | 日东电工株式会社 | 树脂部件的激光接合方法以及树脂部件的激光接合体 |
JP5555613B2 (ja) * | 2010-02-04 | 2014-07-23 | 日東電工株式会社 | 樹脂部材のレーザー接合方法および樹脂部材のレーザー接合体 |
JP5798795B2 (ja) * | 2010-06-23 | 2015-10-21 | 日東電工株式会社 | 高分子フィルムの接合方法、及び、偏光フィルムの製造方法 |
JP5830233B2 (ja) * | 2010-09-17 | 2015-12-09 | 日東電工株式会社 | シート接合体の製造方法及びシート接合体の製造装置 |
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KR20090119691A (ko) | 2009-11-19 |
US20110297312A1 (en) | 2011-12-08 |
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TWI478807B (zh) | 2015-04-01 |
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