TW201702073A - Method for producing flexible laminate - Google Patents

Abstract

This method for producing a flexible laminate 1 comprises a formation step, a lamination step, a cutting step, a grinding step and a separation step. In the formation step, a flexible laminate 1, which has a resin film 2 and a glass film 4 that is laminated on and bonded to the resin film 2, is formed. In the lamination step after the formation step, a laminate 7 with a sheet is formed by laminating and bonding the flexible laminate 1 onto a supporting sheet 5. In the cutting step after the lamination step, the laminate 7 with a sheet is cut. In the grinding step after the cutting step, the cut surface of the laminate 7 with a sheet is ground. In the separation step after the grinding step, the flexible laminate 1 is separated from the laminate 7 with a sheet.

Description

Method for manufacturing flexible laminate

The present invention relates to a method of producing a flexible laminate.

As is well known, a laminated system in which a glass plate and a resin sheet are integrated into one layer has both high hardness, high durability, high airtightness, gas barrier property, and high-grade feeling from glass, and lightness derived from resin. Or high impact resistance and other characteristics.

Therefore, such a laminate can be expected to be used in a wide range of fields, such as a flat panel display (FPD) such as a liquid crystal display or a plasma display, a mobile electronic device such as a mobile phone or a tablet PC, a solar cell, an induction cooker, etc. A material for a panel of an electronic device, or a material for a window structure of a building structure or various vehicles (for example, refer to Patent Document 1).

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2013-107245

Further, such a laminate can be made flexible by thinning. The laminate having such flexibility (hereinafter referred to as a flexible laminate) must be cut into a shape and size for use in combination. However, when the flexible laminate is cut, in particular, the cut surface of the glass portion may be formed into a concave-convex surface (rough surface) having minute defects such as cracks or chipping. When the cut surface of the surface property is ignored, the crack of the glass portion starting from the minute defect is likely to cause a fatal problem for the product in which the flexible laminate is mounted. Therefore, after the flexible laminate is cut into a predetermined shape and size, it is necessary to remove the end portion of the cut surface including the flexible laminate by grinding to a predetermined size.

However, when the cut surface of the flexible laminate is to be ground, the flexible laminate may occur when the grinding tool contacts the flexible laminate due to the flexibility of the flexible laminate. The situation in which the body violently moves and ruptures, so that the flexible laminated body cannot be ground.

Moreover, since the flexible laminated body is flexible, when the grinding process is performed after the cutting process, the flexible laminated body may be bent by its own weight. A plurality of minute defects are present on the end surface of the cut glass portion, and the bending stress concentrates on the minute defects of the cut surface, so that the glass portion of the flexible laminate body is broken.

In view of the above circumstances, the present invention has been made to solve the technical problem of grinding a cut surface of a flexible laminated body without cracking after the cutting process in the manufacturing process of the flexible laminated body.

A method for producing a flexible laminate according to the above-mentioned problem, comprising: a manufacturing process for producing a flexible laminate having a resin film and a glass film laminated and bonded to the resin film; After the manufacturing process, the flexible laminated volume layer and the supporting sheet are formed to form a sheet laminated body; the cutting process is performed, and after the layering process, the sheet laminated body is cut; grinding In the process, after the cutting process, the cut surface of the sheet-form laminate is ground, and a peeling process is performed, and after the grinding process, the flexible laminate is peeled off from the sheet laminate.

In the case where the flexible laminate is supported by the support sheet, the thickness of the laminate is suppressed, and the flexibility is suppressed as compared with the case of the flexible laminate. Therefore, in the grinding process, even if the grinding tool contacts the sheet laminated body, the sheet laminated body can be prevented from moving violently, and the flexible laminated body can be ground.

Further, in the above configuration, the lamination process is performed before the cutting process, and the process from the cutting process to the grinding process is performed in a state in which the flexible laminate is supported by the support sheet, and after the cutting process, before the grinding process, It is possible to prevent the flexible laminate from causing a microscopic defect in the cut surface to cause the glass film of the flexible laminate to be broken.

In the above-described configuration, in the above-mentioned sheet laminate, it is preferable that the resin film is disposed on the side of the support sheet which is the most in the flexible laminate.

In the peeling process, when the flexible laminate is peeled off from the sheet laminate, the flexible laminate may be bent so that the support sheet side is convex. In such a curved state, tensile stress is generated on the side of the support sheet of the flexible laminate, and compressive stress is generated on the side opposite to the support sheet of the flexible laminate. The glass is more susceptible to cracking in the case of generating tensile stress than in the case of generating compressive stress. According to the above configuration, since the glass film is disposed on the side facing the support sheet in the flexible laminate, that is, on the side where the compressive stress is generated, the effect of suppressing the crack of the flexible laminate can be expected.

In the above configuration, in the stacking process, the flexible build-up volume layer and the support sheet are connected to the support sheet via the adhesive layer, and the adhesion force ratio with respect to the flexible laminate is relative to the aforementioned It is preferred that the adhesion of the support sheet is smaller.

According to this configuration, after the flexible laminate is peeled off from the sheet laminate, the subsequent layer is not a flexible laminate and remains on the support sheet. Therefore, the time or labor for peeling off the adhesive layer from the flexible laminate can be eliminated.

In the above configuration, in the ground surface of the flexible laminate, the portion adjacent to the glass film in the lamination direction is more prominent than the glass film in the ground surface of the flexible laminate. Here, in the portion adjacent to the glass film in the lamination direction, a layer interposed between the resin film and the glass film (layer for bonding the resin film and the glass film or a layer having other functions, etc.) is formed. When it is a layer of the intermediate layer, when the glass film and the resin film are directly laminated and bonded, the resin is thin. membrane.

According to this configuration, since the flexible laminated body is peeled off from the laminated laminate, the portion of the glass film does not protrude in the ground surface of the flexible laminated body, so that the portion of the glass thin film can be prevented from coming into contact with other members or the like. Rupture or damage.

In the above configuration, when the flexible laminate is peeled off in the peeling process, it is preferable to bend the support sheet.

According to this configuration, when the flexible laminate is peeled off from the sheet laminate, the bending of the flexible laminate can be suppressed, and the flexible laminate can be prevented from being damaged by being subjected to an undue load.

As described above, according to the present invention, in the manufacturing process of the flexible laminate, after the cutting process, the cut surface of the flexible laminate can be ground without cracking.

1‧‧‧Flexible laminate

2‧‧‧Resin film

3‧‧‧bonding layer

4‧‧‧ glass film

5‧‧‧Support sheet

6‧‧‧Next layer

7‧‧‧With laminar laminate

7a‧‧‧ cut face

7b‧‧‧ground surface

S1‧‧‧Production Process

S2‧‧‧Laminated process

S3‧‧‧ cutting process

S4‧‧‧ grinding process

S5‧‧‧ peeling process

Fig. 1 is a flow chart showing a method of producing a flexible laminate according to an embodiment of the present invention.

Fig. 2 is a schematic cross-sectional view showing a flexible laminate produced in a manufacturing process.

Fig. 3 is a schematic cross-sectional view showing a laminated layered body formed in a lamination process.

Fig. 4 is a schematic cross-sectional view showing a laminated layered body cut by a cutting process.

Fig. 5 is a schematic cross-sectional view showing a laminated laminate body in a grinding process.

Fig. 6 is a schematic cross-sectional view showing a sheet laminate in the middle of peeling off the flexible laminate in the peeling process.

Fig. 7 is a schematic cross-sectional view showing a flexible laminate which is peeled off in a peeling process.

Fig. 8A is an enlarged view of a portion A of Fig. 7.

Fig. 8B is a view showing a modification of Fig. 8A.

Fig. 8C is a view showing a modification of Fig. 8A.

The form for carrying out the invention will be described below based on the drawings.

Fig. 1 is a flow chart showing a method of producing a flexible laminate according to an embodiment of the present invention. The manufacturing method of the flexible laminated body includes a manufacturing process S1, a build-up process S2, a cutting process S3, a grinding process S4, and a peeling process S5.

The flexible laminate 1 shown in Fig. 2 is produced in the manufacturing process S1. The flexible laminate 1 has a resin film 2 and a glass film 4 laminated and bonded to the resin film 2 via the bonding layer 3. Further, in the illustrated example, the glass film 4, the bonding layer 3, and the resin film 2 are enlarged in this order, and are arranged in this order as end projections. This is because the glass film 4 is most likely to be broken, so that the end portion of the glass film 4 is not protruded.

As the resin film 2, a thickness of 1 μm or more and 1000 μm or less is preferable, and a thickness of 5 μm or more and 500 μm or less is more preferable, and a thickness of 10 μm or more and 100 μm or less is preferable. Here, a resin film 2 having a thickness of 38 μm was used. Examples of the material of the resin film 2 include polycarbonate (PC), acrylic acid, polyethylene terephthalate (PET), polyether ether ketone (PEEK), polyamine (PA), and polyvinyl chloride. (PVC), polyethylene (PE), polypropylene (PP), polyethylene naphthalate (PEN), polyamine (PI), and the like.

As the bonding layer 3, a thickness of 1 μm or more and 1000 μm or less is preferable, and a thickness of 5 μm or more and 500 μm or less is more preferable, and a thickness of 10 μm or more and 100 μm or less is preferable. Here, a bonding layer 3 having a thickness of 25 μm is used. Examples of the material of the bonding layer 3 include an acrylic adhesive, a polyoxygen adhesive, a rubber adhesive, an ultraviolet curable acrylic adhesive, an ultraviolet curable epoxy adhesive, and a thermosetting epoxy. An adhesive, a thermosetting melamine-based adhesive, a thermosetting phenol-based adhesive, an ethylene/vinyl acetate (EVA) interlayer film, a polyvinyl butyral (PVB) interlayer film, or the like.

The glass film 4 is preferably 10 μm or more and 1000 μm or less, more preferably 10 μm or more and 500 μm or less, and most preferably 10 μm or more and 100 μm or less. Here, a glass film 4 having a thickness of 50 μm is used. The composition of the glass film 4 which can be used is not particularly limited, but a glass film 4 formed of an alkali-free glass containing no alkali component is particularly suitable. This is because in the case of the glass containing the alkali component in the composition, the alkali component in the glass is lost over time, and the bending stress acts on the flexible laminate. At 1 o'clock, the glass film 4 is easily broken by starting from the portion where the alkali component is lost.

In the build-up process S2 after the process S1 is produced, the flexible laminate 1 is laminated on the support sheet 5 via the adhesive layer 6 to form the sheet-like laminate 7 shown in FIG. In the present embodiment, the resin film 2 is disposed on the side of the flexible laminate 1 that is closest to the support sheet 5, but the glass sheet 4 can be disposed in the flexible laminate 1 Support sheet 5 side. Further, although not shown in the drawings, in the stacking process S2, the protective film for protecting the glass film 4 is laminated and fixed to the glass film 4. Further, in the example of the drawing, the resin film 2, the adhesive layer 6, and the support sheet 5 of the flexible laminate 1 are enlarged in this order, and are arranged in this order as end projections, which is also for protection. The glass film 4 of the flexible laminate 1.

As the support sheet 5, a thickness of 0.1 mm or more and 5 mm or less is preferable, and a thickness of 0.3 mm or more and 3 mm or less is more preferable, and a thickness of 0.5 mm or more and 1 mm or less is preferable. Here, a support sheet 5 having a thickness of 0.5 mm is used. That is, the thickness of the support sheet 5 is larger than the thickness of the flexible laminate 1.

The material of the support sheet 5 is not particularly limited as long as it can sufficiently support the rigidity of the flexible laminate 1 , and examples thereof include resin, glass, ceramics, etc., but the ease of peeling from the flexible laminate 1 is From the viewpoints of easiness of cutting, cost, and the like, a resin is preferable.

When a resin is used as the support sheet 5, the material of the resin is the same as that of the resin film 2.

Moreover, it is preferable that the bending elastic modulus of the support sheet 5 is 100 MPa or more and 5000 MPa or less. When the bending elastic modulus exceeds 5,000 MPa, the support sheet 5 becomes difficult to bend, and thus the flexible laminate 1 cannot be peeled off from the sheet laminate 7 . When the bending elastic modulus is less than 100 MPa, the rigidity of the sheet-like laminated body 7 is insufficient, and the grinding process may not be performed. From this viewpoint, the bending elastic modulus is preferably 500 MPa or more and 4000 MPa or less, and more preferably 1000 MPa or more and 3,000 MPa or less. Here, polycarbonate (PC) having a flexural modulus of 2300 MPa was used.

Next, the layer 6 is a layer in which the flexible laminate 1 and the support sheet 5 are peelably adhered. In the subsequent layer 6, the adhesion force with respect to the flexible laminate 1 is smaller than the adhesion force to the support sheet 5. As the adhesive layer 6, a thickness of 5 μm or more and 1000 μm or less is preferable, and a thickness of 20 μm or more and 500 μm or less is more preferable, and a thickness of 50 μm or more and 100 μm or less is preferable. Here, an adhesive layer 6 having a thickness of 80 μm is used.

In the present embodiment, the adhesive layer is formed of a resin layer having a self-adhesive resin layer and an adhesive layer applied to the resin layer, and the resin layer is a flexible laminate. The 1 side and the backing layer are the side of the supporting sheet 5. However, the adhesive layer 6 is not limited to such a configuration, and the flexible laminate 1 and the support sheet 5 may be peeled off.

Examples of the material of the self-adhesive resin layer constituting the adhesive layer 6 of the present embodiment include polyethylene (PE), polyethylene terephthalate (PET), polyvinyl chloride (PVC), and poly. Propylene (PP) Wait. Moreover, the material of the adhesive layer constituting the adhesive layer 6 of the present embodiment is the same as the material of the bonding layer 3.

In the cutting process S3 after the build-up process S2, the sheet-laminated body 7 is cut along the line indicated by the two-dot chain line in FIG. 3, and the sheet-laminated body 7 is made to have the size shown in FIG. . Examples of the cutting method include laser fusing, water jet cutting, laser cutting, and cutting cutting.

The cutting surface 7a of the sheet-layered laminated body 7 is ground by the grinding process S4 after the cutting process S3. Grinding is performed by pressing the grinding tool 8 having the V-shaped grinding surface 8a having the cross section shown by the chain line of Fig. 4, and pressing it to the cut surface 7a. In this grinding process S4, the portion to be removed by the grinding of the sheet laminated body 7 is mainly the lower end of the supporting sheet 5, and the maximum distance d of the ground surface (ground surface 7b) after grinding from the cut surface 7a For example, 0.8 to 1.2 mm.

When the cutting surface 7a of the sheet-like laminated body 7 is completely ground to complete the grinding process S4, the sheet-laminated layered body 7 is in the state shown in Fig. 5.

In the peeling process S5 after the S4 is ground, as shown in Fig. 6, the sheet-laminated body 7 is fixed to the adsorption stage 9, and the flexible laminated body 1 is peeled off from the sheet-layered laminated body 7. As described in detail, first, the sheet laminate body 7 is vertically inverted, and then placed on the adsorption stage 9, and the sheet laminate 7 is fixed by adsorption by the adsorption stage 9. In this state, the adsorption pad 10 is adsorbed to the support sheet 5 of the sheet-layered laminated body 7, and the support sheet 5 is stretched to support the sheet 5 to be peeled off from the flexible laminate 1. Moreover, when peeling off, the sheet laminate 7 is flexible The laminated body 1 is maintained in a flat shape by the adsorption stage 9, and the flexible laminated body 1 can be prevented from being improperly bent and broken.

When the entire support sheet 5 is peeled off from the flexible laminate 1 and the adsorption of the flexible laminate 1 by the adsorption stage 9 is stopped, and the flexible laminate 1 is vertically inverted, the flexible laminate 1 becomes the first The state shown in Fig. 7 (peeling process S5 is completed). This flexible laminated body 1 is subjected to grinding by the cut surface 7a. As shown in an enlarged view of Fig. 8A, in the ground surface 7b of the flexible laminate 1, the portion adjacent to the glass film 4 in the lamination direction (the bonding layer 3) protrudes more than the glass film 4. Further, in the ground surface 7b, the bonding layer 3 protrudes more than the resin film 2.

Further, in the present invention, in the ground surface 7b of the flexible laminate 1, the portion adjacent to the glass film 4 in the lamination direction may be protruded more than the glass film 4, for example, as shown in Fig. 8B. In the ground surface 7b, the resin film 2 can protrude more than the bonding layer 3. Further, as shown in Fig. 8C, the cross section of the ground surface 7b may not be linear but curved.

In the method for producing a flexible laminate according to the embodiment configured as described above, the following effects can be obtained.

In the state in which the flexible laminated body 1 is supported by the support sheet 5, the flexible laminated body 7 is restrained from the case where the flexible laminated body 1 is single. Therefore, in the grinding process S4, even if the grinding tool 8 contacts the sheet laminated body 7, the sheet-forming layered body 7 can be prevented from moving violently, and the grinding of the flexible laminated body 1 can be performed.

Further, in the present invention, there is a product before the cutting process S3. The layer process S2, from the cutting process S3 to the grinding process S4, is in a state in which the flexible laminated body 1 is supported by the support sheet 5, so that the cut surface 7a can be avoided from the cutting process to the grinding process. The microscopic defect causes the glass film 4 of the flexible laminate 1 to be broken.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the technical idea. For example, in the above embodiment, the grinding surface 8a of the grinding tool 8 used in the grinding process S4 has a V-shaped cross section, but the cross section may be linear, and the cross section may be curved.

Further, in the above-described embodiment, the flexible laminate 1 is laminated on the adhesive layer layer 7 via the adhesive layer 6 and then on the support sheet 5, but it may be adhered, for example, by making the contact surface smooth and clean. By means of the method, the flexible laminate 1 is directly laminated and then supported on the sheet 5.

Further, in the above-described embodiment, in the flexible laminate 1 , the glass film 4 is laminated and bonded to the resin film 2 via the bonding layer 3, but the glass film 4 may be directly laminated by, for example, welding. Bonded to the resin film 2. Further, between the glass film 4 and the resin film 2, a layer having a function other than bonding the glass film 4 and the resin film 2 may be interposed. Further, in the flexible laminate 1, the glass film 4 and the resin film 2 are each one, but they may be a plurality of sheets.

1‧‧‧Flexible laminate

2‧‧‧Resin film

3‧‧‧bonding layer

4‧‧‧ glass film

5‧‧‧Support sheet

6‧‧‧Next layer

7‧‧‧With laminar laminate

Claims (5)

A method for producing a flexible laminated body, comprising: a manufacturing process for producing a flexible laminate having a resin film and a glass film laminated and bonded to the resin film; and a lamination process after the manufacturing process Forming the flexible laminate layer and subsequently supporting the sheet to form a sheet laminate; the cutting process, after the layering process, cutting the sheet laminate; the grinding process, in the cutting process Thereafter, the cut surface of the sheet-form laminate is ground; and a peeling process is performed, and the flexible laminate is peeled off from the sheet laminate after the grinding process. In the method for producing a flexible laminate according to the first aspect of the invention, the resin film is disposed on the side of the support sheet which is disposed on the side of the support sheet. The method for producing a flexible laminate according to the first or second aspect of the invention, wherein the flexible laminated volume layer and the support sheet are bonded to the support sheet via the adhesive layer in the stacking process In the subsequent layer, the adhesion force with respect to the flexible laminate is smaller than the adhesion force with respect to the support sheet. The method for producing a flexible laminate according to the first or second aspect of the invention, wherein, after the grinding process, the surface of the flexible laminate is ground in the lamination direction and the glass Adjacent to the film The portion is more prominent than the aforementioned glass film. The method for producing a flexible laminate according to the first or second aspect of the invention, wherein, in the peeling process, the support sheet is bent when the flexible laminate is peeled off.