JP6544855B2 - Method of manufacturing laminate - Google Patents

Description

  The present invention relates to a method of manufacturing a laminate including a metal pattern on a support such as plastic.

  As a laminate including a metal pattern on a support such as plastic, a wiring circuit, an electromagnetic wave shielding material, an electromagnetic wave transmission line, and the like are used. An example of these is a heat-generating sheet capable of generating heat by electric heat (Joule heat).

Patent Document 1 describes a heat generating sheet provided with an electrode by an adhesive on a substrate, coated with a heat generating resistance coating to form a planar heat generating layer, and further covered with a top coat.
Further, Patent Document 2 describes a flexible heating element in which a heating member and a strip electrode are each formed of a fibrous material, and a covering member is provided so as to include these.
Further, according to Patent Document 3, two conductive sheets are overlapped, a gap is formed at the edge, and a resin material is sandwiched at the center and formed into an integral sheet by heat and pressure bonding. A method of manufacturing a heat-generating sheet, which is placed and heat-pressed, is described.

Japanese Patent Laid-Open No. 5-326116 Japanese Patent Application Laid-Open No. 11-339934 Patent No. 5153472

  Although the method of forming an electrode and a heat generating layer in a base material is the mainstream as the manufacturing method of the conventional heat generating sheet, the electrode preparation cost was high. For example, when metal etching is used, high-speed production is also difficult, and a large amount of waste liquid in which gradual metal dissolves in the etching solution is generated, and processing cost also increases. In pattern deposition (deposition mask, lift-off, etc.), in addition to slowing the processing speed to obtain the adhesion amount (thick film) required for the electrode, an expensive vacuum device is required, and design customization also costs .

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for producing a laminate capable of producing a laminate having a metal pattern on a support at high speed. Further, the present invention provides a method for producing a laminate having good transportability of a support without scraping of a metal thin film in the production process of a metal pattern.

  In order to solve the above problems, the present invention forms a long thin metal film having a thickness of 1 to 50 μm on a long support having a thickness of 9 to 250 μm to form a long thin film. In the metal thin film forming step of forming a laminate, and while conveying the laminate under tension, a back roll having a convex portion formed is pressed against the support side of the laminate to make a part of the laminate It is brought into contact with the metal thin film side of the laminate while rotating a cutting roll having a convex shape and fine irregularities, leaving the metal thin film so that the support is exposed at the convex portion. And a cutting step of forming a metal pattern on the support by scraping.

It is preferable that the support is any plastic film selected from polyethylene terephthalate, polyethylene naphthalate, polyimide, polyamide and polyolefin.
The metal thin film is preferably any of aluminum, copper and stainless steel.
The metal thin film forming step is preferably a laminating step using an adhesive, and the adhesive is preferably any one of polyurethane, polyester, polyolefin, epoxy and ether.

It is preferable that the back roll is formed by winding a flat base having a pattern-like convex portion around a roll.
Assuming that the thickness of the metal thin film is T1, the thickness of the support is T2, the thickness of the adhesive layer made of the adhesive is T3, and the height of the convex portion of the back roll is T4, T1 ≦ T2. And T1 + T2 + T3 <T4 is preferably satisfied.

The manufacturing method is conductive on the laminate having the metal pattern on the support after the cutting process, on the two or more metal patterns and the support exposed to the periphery thereof. It can apply the paste which consists of powder and a binder, and can include the coating process of forming a conductive layer.
Moreover, the said manufacturing method can include the cutting process of cutting the said laminated body so that the said metal pattern may remain in both ends after the said coating process.
Moreover, the said manufacturing method can include the moisture-proof process which laminates a moisture-proof sheet on both surfaces of the said support body, the said metal pattern, and the said conductive layer after the said cutting process.
The conductive layer may be a heat generating layer that generates heat when current is supplied to the metal pattern, and the laminate may be a heat generating sheet.

  According to the present invention, after a metal thin film is uniformly formed on a support using an adhesive, the metal thin film is mechanically cut to form a metal pattern, so the adhesion strength of the metal pattern to the support is high. A laminate having a metal pattern on a long support can be manufactured at high speed. Since the metal thin film removed by cutting does not become waste liquid, recovery and processing can be easily performed.

(A) is a cross-sectional view for explaining a laminating process, (b) is a cross-sectional view for explaining a laminate obtained in the laminating process, (c) is a cross-sectional view for explaining a laminate subjected to a cutting process. It is a side view explaining a cutting process. It is a perspective view explaining the layered product which passed through the cutting process. It is a perspective view explaining a coating process. It is a perspective view explaining a cutting process. It is a perspective view explaining the layered product which passed through the cutting process. It is sectional drawing explaining the laminated body which passed through the cutting process. It is sectional drawing explaining the laminated body which passed through the moisture proof process.

  Hereinafter, the present invention will be described based on preferred embodiments with reference to the drawings. The drawings are schematic views, and the shape, dimensional ratio, etc. of each part may differ from the actual structure. In particular, the thickness direction of the laminate or the like is emphasized so as to be larger in scale than the plane direction.

  FIG. 1A shows an explanatory view of the laminating step. In the laminating step, the support 11 and the metal thin film 12 are laminated using an adhesive, and as shown in FIG. 1B, the support 11 and the metal thin film 12 are adhered via the adhesive layer 13. The laminated body 10 is manufactured.

As the support 11, a long film mainly made of plastic or the like is preferable. Specific examples of the support 11 made of plastic include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), other polyesters, polyimide (PI), polyamide (PA) such as nylon and aramid, polyethylene (PE), polypropylene (PP), other polyolefins, and any plastic film such as polycarbonate (PC). These plastic films are preferably oriented films such as biaxially oriented films. The thickness of the support 11 is preferably 9 to 250 μm, more preferably 10 to 200 μm, and most preferably 20 to 150 μm. When the support 11 is thin, a protective film may be laminated at the time of conveyance.
Further, for the support 11, a material that can be formed into a film, such as glass cloth or non-woven fabric, can also be used. Preferably, the support 11 is electrically insulating (insulator) or at least the surface is electrically isolated from the metal thin film 12.

The metal thin film 12 may be made of any conductive material because it uses the metal pattern 14 after cutting as an electrode, but a long metal thin film made of metal is preferable. As a specific example of the metal which comprises the metal thin film 12, either aluminum, copper, stainless steel etc. are mentioned. The preferred metal from the viewpoint of availability and price is aluminum. A preferred metal is copper in view of solderability and the like. The thickness of the metal thin film 12 is preferably 1 to 50 μm, and more preferably 5 to 45 μm. It is preferable that the metal thin film 12 can be conveyed in parallel with the support 11 alone or in a laminated state on another sheet, and a metal foil is preferable.
In addition, the metal thin film 12 can also be subjected to surface modification. An electrode formed of the metal pattern 14 after cutting can be connected to an external circuit. In this case, the bonding method of the electrodes is not particularly limited. Not limited to the application of the conductive paste described later and the contact type such as soldering described above, a non-contact charging method (non-contact type) such as Qi (wireless power supply) technology may be employed.

  The laminating method may, for example, be dry laminating, wet laminating, thermal laminating, extrusion laminating, hot melt laminating or the like. Among them, a dry laminate is preferable, in which an adhesive is coated on the support 11, and after drying, the adhesive is superposed on and adhered to the metal thin film 12. As the adhesive, any one of a polyurethane-based adhesive, a polyester-based adhesive, a polyolefin-based adhesive, an epoxy-based adhesive, an ether-based adhesive and the like is preferable. The thickness of the adhesive layer 13 is preferably, for example, 0.1 to 10 μm.

  The method of manufacturing the laminate 10 in which the metal thin film 12 is formed on the support 11 is not limited to the laminating step, and may be another metal thin film forming step. Examples of the method for forming a metal thin film include vapor deposition, plating, and lamination without using an adhesive.

  The obtained laminate 10 is long. In order to stabilize the adhesive strength, it is preferable that the laminate 10 be wound on a roll after the laminating step and stored (aged) at a predetermined temperature and then subjected to the cutting step.

  An example of the laminated body 16 which passed through the cutting process in FIG.1 (c) is shown. In the laminate 16, a part of the metal thin film 12 is left together with the adhesive layer 13 to form the metal pattern 14, but the support 11 is exposed in the area other than the metal pattern 14 (the support exposed portion 15). The thin metal film 12 is scraped off as follows.

  FIG. 2 shows an explanatory view of the cutting process. In the cutting step, the laminated body 10 is conveyed between the cutting roll 30 and the back roll 32 while applying tension to the laminated body 10 obtained in the laminating step. The cutting roll 30 is disposed on the side of the metal thin film 12 of the laminate 10, and the back roll 32 is disposed on the side of the support 11 of the laminate 10. In addition, illustration of the adhesive bond layer 13 is abbreviate | omitted in FIG. 2 (FIG. 3-FIG. 6 is the same).

  A pattern of convex portions 33 and concave portions 34 is formed on the surface of the back roll 32. The position and shape of the convex portion 33 correspond to the support exposed portion 15, and the position and shape of the concave portion 34 correspond to the metal pattern 14. It is preferable that the convex part 33 of the back roll 32 is formed in the planar base material which can be isolate | separated from the main body (roll part) of the back roll 32. As shown in FIG. By forming the back roll 32 by winding the base material having the pattern-like convex portions 33 around the main body roll, the pattern of the convex portions 33 can be easily changed. The height of the convex portion 33 is, for example, 50 to 500 μm.

  By pressing the convex portion 33 against the laminate 10 from the support 11 side, a part of the laminate 10 is raised in a convex shape and contacts the cutting roll 30. Fine irregularities 31 are formed on the surface of the cutting roll 30, and when the cutting roll 30 is rotated at a high speed, the metal thin film 12 which has a convex shape and is in contact with the irregularities 31 due to the projections 33 is scraped off and laminated. It is removed from the body 10. At this time, the adhesive layer 13 is preferably removed together with the metal thin film 12. Chips can be collected timely by vacuum suction or the like.

  When the long laminate 10 is composed of the metal thin film 12, the adhesive layer 13 and the support 11, the thickness of the metal thin film 12 is T1, the thickness of the support 11 is T2, and the adhesive Assuming that the thickness of the layer 13 is T3 and the height of the convex portion 33 of the back roll 32 is T4, it is preferable to satisfy the expressions T1 ≦ T2 and T1 + T2 + T3 <T4. If generalization is carried out including the case where the adhesive layer 13 is not included, etc., the thickness of the long laminate 10 produced in the metal thin film forming step is T5, and the formulas of T1 ≦ T2 and T5 <T4 It is preferable to satisfy If T1 is too large compared to T2, it takes time to remove the metal thin film 12 until the support 11 is exposed, which lowers productivity. If T4 is too small compared to the thickness of T1 + T2 + T3 (or the thickness T5 of the entire laminated body 10), the surface undulation of the metal thin film 12 due to the presence or absence of the convex portion 33 becomes unclear, and the metal thin film 12 on the convex portion 33 It is difficult to selectively remove The laminated body 10 may or may not be in contact with the surface of the recess 34 on the support 11 side on the recess 34 of the back roll 32. It is preferable to adjust the tension of the laminate 10, the radius of the back roll 32, and the like so that the laminate 10 is easily curved along the surface of the convex portion 33.

  An example of the laminated body 16 which passed through the cutting process in FIG. 3 is shown. On the support 11, the metal patterns 14 are separated and regularly arranged in the longitudinal direction and the width direction of the laminate 16, and the periphery of the metal pattern 14 is a support exposed portion 15. In FIG. 3, a cross section in the width direction is shown on the front side of the support 11, a wavy line is shown on the back side, and both sides in the length direction are omitted (the same applies to FIGS. 4 and 5).

  The resulting laminate 16 has the metal thin film 12 formed on the entire surface of the support 11, and then a part of the metal thin film 12 is removed by cutting to form the metal pattern 14, so adhesion of the metal pattern 14 to the support 11 It has high sex and high strength. Compared to etching, the metal to be removed is recovered as dust without being a waste liquid, so that the processing cost is low and reutilization as waste metal becomes possible. Moreover, in the case of the method of etching the foil, the processing speed is not only slow as compared with the cutting step, but also the step of bonding the masking material for photolithography and it, the etchant and the waste liquid after use are generated, The pattern can be formed, but it takes time. In order to increase the processing speed, the initial investment for increasing the size of the etching solution tank is taken, so the etching is disadvantageously incomparable in comparison with the total production cost.

  An example of a coating process is shown in FIG. The coating process can be performed after the cutting process. A conductive paste is applied from a coating device 40 onto the laminate 16 having the metal pattern 14 on the support 11, on the two or more metal patterns 14 and on the support exposed portion 15 between and around the same. , And the conductive layer 17 is formed. The conductive paste contains conductive powder (particles) as a conductive material, and contains a binder as a binder of the conductive powder. As the conductive powder, metal powder such as silver or carbon powder is preferable. The binder includes a composition containing a resin. You may implement the drying process of an electroconductive paste, a sintering process, etc. after application.

  The laminate 18 which has undergone the coating process has a conductive layer 17 so as to connect two or more metal patterns 14. When the conductive layer 17 is continuously formed in the length direction (conveying direction) of the support 11, the productivity is excellent and it is preferable.

  An example of a cutting process is shown in FIG. Moreover, an example of the laminated body 19 which passed through the cutting process in FIG. 6 is shown. In the cutting step, the long laminate 18 having the metal pattern 14 and the conductive layer 17 on the support 11 is cut to produce a sheet-like laminate 19 having the metal pattern 14 at both ends. In the example shown in FIG. 5, a cutting line 51 extending in the width direction of the support 11 and a cutting line 52 extending in the length direction of the support 11 are set. The cutting line 51 in the width direction is provided at a position where the metal pattern 14 is cut off, and the cutting line 52 in the length direction is provided at a position where the metal pattern 14 and the conductive layer 17 are not formed on the support 11. ing.

  The laminated body 19 which passed through the cutting process has the metal pattern 14 in two opposing sides, respectively. As shown in the cross-sectional view of FIG. 7, the metal patterns 14 at both ends are not directly continuous, and in the meantime, the conductive layer 17 is formed on the exposed support portion 15. For this reason, when it supplies with electricity between the metal patterns 14 of both ends, an electric current can be sent through the conductive layer 17. FIG. If the conductive layer 17 has a sufficiently large electric resistance as compared with the metal pattern 14, it can generate heat as a heat generating layer by energization of the metal pattern 14. Thereby, the laminated body 19 can be used as a heat generating sheet. The heat-generating sheet thus obtained can be used in various applications such as agriculture, snow melting, condensation prevention, heating, heat retention, interior and the like.

  Since the metal pattern 14 is exposed to the cut surface of the laminate 19 that has undergone the cutting step, it is preferable to perform a moisture-proof step in order to suppress metal corrosion, deterioration, and the like. The moisture proofing step can be carried out also by applying a moisture proofing paint or the like, but as shown in FIG. 8, a method of laminating moisture proofing sheets 21 and 22 on both sides of the laminate 19 is preferable. As a material of the moisture-proof sheets 21 and 22, a plastic having heat fusion property is preferable. In the laminated body 20 that has undergone the moisture-proof step, the moisture-proof sheets 21 and 22 are joined to each other at the peripheral portion 23 of the support 11, so that the entry of moisture can be effectively suppressed. In order to energize the metal pattern 14 as an electrode from the outside of the moistureproof sheets 21 and 22, a method of exposing a part of the metal pattern 14 or drawing out a conducting wire from the metal pattern 14 may be mentioned.

Although the present invention has been described above based on the preferred embodiments, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the present invention.
Each process that handles a long film such as a metal thin film forming process, a laminating process, and a cutting process starts from a state in which the long film is wound in a roll, and processes during transport of the film drawn from the roll. It is preferable to carry out by the method of so-called rolling-up of the processed film on a roll, so-called roll-to-roll.
The thin film material formed on the support and formed into a pattern by the cutting process may be a material other than metal. The coating material applied on the pattern in the coating step may be a material other than the conductive paste.
The laminate of the present invention can be used for a wiring circuit, an electromagnetic wave shielding material, an electromagnetic wave transmission line, and the like.

(Lamination process)
A metal foil (metal thin film) described in Table 1 and a plastic film (support) are laminated using the adhesive described in Table 1, and a long sheet is a laminate of the metal foil and the plastic film (support) The laminates A-1 to A-6 were produced.

(Cutting process)
The long laminates A-1 to A-6 obtained in the "lamination process" were drawn out and transported, and the metal thin film side cutting process was performed. As a cutting roll, a wheel having a ridge-like unevenness of about 2 mm × 2 mm × 2 mm in height, width and height was used, and as a back roll, the surface of a metal plate was patterned to have a height of 300 μm. The metal thin film was cut using the base on which the photoresin layer was formed, to produce laminates B-1 to B-6 having a metal pattern as shown in FIG. 3 on the support. The evaluation in the cutting process is shown in Table 2.

(Evaluation of transportability in cutting process)
The transportability in the cutting step was evaluated based on the following criteria.
○: Processing was possible without problems from the start to the end of the raw fabric roll.
Fair: Minor wrinkles sometimes occurred from the start to the end of the roll, but processing was possible while adjusting.
X: Wrinkles occurred from the start to the end of the original roll, and breakage occurred at least once.

(Evaluation of scraping of metal thin film in cutting process)
From the laminate which was cut through the cutting process and wound into a roll shape, an arbitrary portion of 10 m ² was visually observed and evaluated based on the following criteria.
:: The amount of uncut-off is smaller than the amount of uncut-off generated in the laminate B-2.
Δ: Amount of uncut portion generated in the laminate B-2.
X: The amount of the uncut portion is larger than the amount of the uncut portion generated in the laminate B-2.

(Coating process)
While conveying the laminates B-1 to B-6 obtained in the "cutting step", carbon paste (JELCON CH-made by Jujo Chemical Co., Ltd.) is formed on the support film and the metal pattern as shown in FIG. 10) was applied to manufacture a laminate having a strip-like carbon paste layer formed thereon.

(Cutting process)
The substrate film obtained in the "coating step" is cut in the lengthwise direction with the slit while being conveyed in the lengthwise direction of the support film, and then cut in the width direction by the cutter, as shown in FIG. It was set as such a sheet-like laminated body.

(Dampproof process)
A 100 μm thick polyethylene film (moisture-proof sheet) was laminated on both sides of the sheet-like laminate obtained in the “cutting process” to produce heat-generating sheets C-1 to C-6 subjected to moisture-proof processing . The relationship with the laminates B-1 to B-6 obtained in the "cutting step" and the evaluation of the heat generating sheet are shown in Table 3.

(Comparative example 1)
Conductive silver nanopaste was applied in a plurality of patterns on a part of the long PET film using a screen printing method to produce a long laminate D-1. The layered product D-1 was subjected to the coating process, the cutting process, and the moistureproof process in the same manner as the layered product C-1 to produce a heat-generating sheet E-1. Table 3 shows the evaluation of the heat generating sheet E-1.

(Comparative example 2)
Apply a carbon paste (JELCON CH-10) manufactured by Tojo Chemical Co., Ltd. on a long PET film, laminate conductive silver nanopaste in a plurality of patterns on a part of the plane, and use the electrode To form a sheet-like laminate D-2. A heat-generating sheet E-2 was manufactured from the laminate D-2 through the moisture-proof step. Table 3 shows the evaluation of the heat generating sheet E-2.

(Evaluation of heat generation efficiency)
The heat generation efficiency of the obtained heat generating sheet was evaluated based on the following criteria.
○: Heat generation efficiency is high.
Δ: Heat generation efficiency is slightly low.
X: Heat generation efficiency is very low.

The heat generation efficiency of the heat generating sheets E-1 and E-2 is not good because it is estimated from the resistivity (reciprocal of conductivity) of the material used for the electrode, but the aluminum foil is on the order of 10 ^-8 Ωm and the silver paste is 10 ^Since it is considered to be in the order of ^-4 Ωm, it is considered as Δ because it is considered to be a difference that can not be ignored when considering use on a yearly basis, although this is not a large difference.

(Evaluation of productivity)
The speeds at which the electrode patterns were formed were compared at processing speeds.
:: cutting having a desired level difference was able to be performed by cutting of 30 m / min or more.
Fair: Cutting having a desired level difference could be performed by cutting at 10 m / min or more and less than 30 m / min.
X: It was possible to perform cutting having a desired level difference by cutting less than 10 m / min.

  For example, the method of forming the electrode patterns of the laminates A-1 to A-6 is a step of bonding a PET film and an aluminum foil at a speed of 60 m / min, and then performing cutting at 60 m / min, twice As it is processed, the processing speed is substantially 30 m / min. However, in the case of the laminate A-2, since the thickness of the aluminum foil is 50 μm, a cutting time is required, and hence the cutting speed is lower than 60 m / min.

  Since the method of forming the electrode patterns of the laminates D-1 and D-2 uses the screen printing method, the paste must be dried sufficiently, even if the processing speed is increased by increasing the oven length. The processing speed is about 2 to 10 m / min, and it is obvious that processing can be performed at high speed if processing is performed by the method of the present invention.

DESCRIPTION OF SYMBOLS 10 ... Laminated body obtained by the lamination process, 11 ... Support body, 12 ... Metal thin film, 13 ... Adhesive layer, 14 ... Metal pattern, 15 ... Support body exposed part, 16 ... Laminated body which passed through the cutting process, 17 ... Conductive layer, 18: laminate subjected to coating process, 19: laminate subjected to cutting process, 20: laminate subjected to moisture proofing step, 21, 22 moisture proof sheet, 23: peripheral portion, 30: cutting roll, 31 ... Irregularities, 32 ... Back rolls, 33 ... Convex parts, 34 ... Concave parts, 40 ... Coating devices, 51, 52 ... Cutting lines.

Claims (10)

Forming a long thin metal film having a thickness of 1 to 50 μm on a long support having a thickness of 9 to 250 μm to form a long thin laminate;
While conveying the above-mentioned layered product under tension, the back roll in which a convex part was formed was pressed against the above-mentioned support side of the layered product, and a part of the layered product was made convex, and it had fine unevenness. The cutting roll is brought into contact with the metal thin film side of the laminate while being rotated, and the metal thin film is scraped off so that the support is exposed at the convex portion, so that on the support A cutting process for forming a metal pattern,
A method of manufacturing a laminate, comprising:   The method for producing a laminate according to claim 1, wherein the support is any plastic film selected from polyethylene terephthalate, polyethylene naphthalate, polyimide, polyamide and polyolefin.   The method according to claim 1 or 2, wherein the metal thin film is any of aluminum, copper, and stainless steel.   The metal thin film forming step is a laminating step using an adhesive, and the adhesive is any one of polyurethane, polyester, polyolefin, epoxy and ether. The manufacturing method of the laminated body of any one of these.   The method for producing a laminate according to any one of claims 1 to 4, wherein the back roll is formed by winding a flat base having a pattern-like convex portion around a roll.   Assuming that the thickness of the metal thin film is T1, the thickness of the support is T2, the thickness of the adhesive layer made of the adhesive is T3, and the height of the convex portion of the back roll is T4, T1 ≦ T2. And a method of manufacturing a laminate according to claim 4, satisfying the following equation: T1 + T2 + T3 <T4.   After the cutting process, on the laminate having the metal pattern on the support, conductive powder and a binder are formed on two or more of the metal patterns and the support exposed to the periphery thereof. The method for producing a laminate according to any one of claims 1 to 6, further comprising a coating step of applying a paste to form a conductive layer.   The method according to claim 7, further comprising a cutting step of cutting the laminate so that the metal pattern remains at both ends after the coating step.   The method for manufacturing a laminate according to claim 8, further comprising a moisture-proof step of laminating a moisture-proof sheet on both sides of the support, the metal pattern and the conductive layer after the cutting step.   The said electroconductive layer is a heat generating layer which generates heat by electricity supply to the said metal pattern, The said laminated body is a heat generating sheet, The manufacturing of the laminated body of any one of Claims 7-9 characterized by the above-mentioned. Method.

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