TW202330140A - Method for manufacturing laminate - Google Patents

Abstract

A method for manufacturing a laminate, the method comprising a step for cutting a laminate 1, which is formed by laminating a glass sheet 2 and a resin sheet 3, along a planned cutting line 5, wherein the cutting step includes: a resin layer cutting step P1 for irradiating the laminate 1 with a laser 6 from the resin-sheet 3 side along the planned cutting line 5, thereby cutting the resin sheet 3; a recess formation step P2 for moving a tip 8 that presses the surface of the glass sheet 2 along the planned cutting line 5, thereby forming a recess 2a, at which the surface of the glass sheet 2 plastically deforms, along the planned cutting line 5; a crack formation step P3 for forming a crack line 9 along the recess 2a; and a glass layer folding step P4 for folding and cutting the glass sheet 2 using the crack line 9 as a start point.

Description

Manufacturing method of laminated body

This disclosure relates to a method for manufacturing a laminate. Specifically, this disclosure relates to a method including the steps of: when manufacturing a laminate obtained by laminating a glass layer and a resin layer, the laminate to be the base body cut off.

While the glass plate is excellent in weather resistance, chemical resistance, and scratch resistance, it has a disadvantage of being easily damaged by physical shock or thermal shock. In order to eliminate the disadvantages of the glass plate, a laminate in which a glass layer formed of a glass plate and a resin laminate formed of a resin plate are laminated and integrated has been proposed.

Compared with glass plates, resin plates are inferior in weather resistance, chemical resistance, and scratch resistance. On the other hand, they have the advantages of having a smaller specific gravity than glass plates and strong physical impact resistance. Therefore, in the above-mentioned laminate, the advantages of each of the glass plate and the resin plate can make up for each of the disadvantages. Furthermore, in the laminated body, it is also possible to significantly reduce the weight compared with a glass plate having the same thickness as the laminated body.

The steps for producing the above-mentioned laminate often include a step of cutting the base laminate. Patent Document 1 discloses an example of a method of cutting a laminate.

In the same method, when cutting a laminate obtained by laminating a glass layer and a resin, first, the resin layer of the laminate is irradiated with laser light, thereby performing a step of cutting the resin layer. Thereafter, the step of cutting the glass layer is performed by irradiating the glass layer of the laminate with an ultrashort pulse laser. By performing these two steps, the total thickness of the laminate is cut. prior art literature patent documents

Patent Document 1: Japanese Patent Laid-Open No. 2019-122966

[Problem to be Solved by the Invention] In the case of cutting the laminated body by the above method, since an ultrashort pulse laser is used for cutting the glass layer, the end surface of the cut glass layer contains defects (cracks, etc.), which may cause the end surface of the glass layer to be damaged. Strength becomes insufficient. In particular, in a thin laminate used for a bendable flexible element, etc., the lack of end surface strength of the glass layer becomes conspicuous.

In view of the above, the technical problem to be solved is to raise the end surface of the glass layer after cutting when cutting the laminated body which is the base when manufacturing a laminated body obtained by laminating a glass layer and a resin layer. strength. [Means to solve the problem]

A method for producing a laminate for solving the above-mentioned problem includes a step of cutting a laminate formed by laminating a glass layer and a resin layer along a line to be cut, and the method for producing a laminate is characterized in that the step of cutting It includes: a step of cutting the resin layer, irradiating laser light on the laminate from the side of the resin layer along the planned cutting line, thereby cutting the resin layer; Line movement, thereby forming a concave portion formed by plastic deformation of the surface of the glass layer along the planned cutting line; a crack forming step, forming a crack line along the concave portion; and a glass layer breaking step, starting from the crack line, the glass layer To break off and cut off.

According to this method, by performing the concave portion forming step and the crack forming step, it is possible to avoid the generation of lateral cracks in the glass layer and to form crack lines. When the concave portion forming step is performed, a compressive stress layer in which compressive stress acts is formed on the surface layer portion of the concave portion formed by plastically deforming the surface of the glass layer. Furthermore, a tensile stress layer in which tensile stress acts is formed directly under the compressive stress layer. Thereafter, when the crack forming step is performed, crack lines are formed in the tensile stress layer. In this way, by forming the crack line using the concave portion that has undergone plastic deformation, it is possible to prevent the occurrence of lateral cracks in the glass layer accompanying the formation. Thereby, the end surface of the cut glass layer formed by performing the glass layer breaking step can be set as an end surface free of defects caused by side cracks. As a result, the end surface strength of the cut glass layer can be improved.

In the method, it is preferable to perform the step of cutting the resin layer before performing the step of breaking the glass layer.

Thus, when the glass layer breaking step is performed, since the resin layer cutting step is performed before the same step, the resin layer of the laminate is already cut. Therefore, since the total thickness of the laminate is cut after the glass layer is cut in the glass layer breaking step, the end faces of the glass layers facing each other after cutting can be separated from each other immediately. Thereby, the possibility that the end surfaces of the cut glass layers may come into contact with each other and the strength of the end surfaces may be reduced can be eliminated as much as possible.

In the above method, it is preferable to interpose an adhesive layer connecting the two layers between the glass layer and the resin layer, and in the step of cutting the resin layer, a part of the thickness of the adhesive layer is cut in addition to the resin layer.

Accordingly, it is possible to avoid as much as possible that the thermal influence of the laser irradiated on the laminated body from the resin layer side not only the resin layer but also the glass layer is affected by the laser in the resin layer cutting step. In this way, it is possible to eliminate as much as possible the fear of defects in the glass layer due to the thermal influence of the laser.

In the above method, it is preferable to use a laser with a pulse width of 500 ps or less as the laser.

As a result, when the resin layer cutting step is performed, it is possible to almost certainly eliminate the possibility of defects in the glass layer due to the thermal influence of the laser.

In the method, preferably, the glass layer breaking step is performed successively after the crack forming step is performed.

In the case where the glass layer breaking step is performed without continuing the same step after the crack forming step (the case where other steps are performed between the crack forming step and the glass layer breaking step, etc.), before performing the glass layer breaking step, there is a glass Layers are at risk of being cut off accidentally. When such a situation occurs, the end face of the glass layer (the end face formed by accidental cutting) can be formed in a state detached from the crack line. As a result, a situation may arise where the manufactured laminate cannot be used as a product. However, if the glass layer breaking step is performed consecutively after the crack forming step, the above-mentioned concern can be almost certainly eliminated, and the quality of the laminate to be produced can be ensured. [Effect of the invention]

According to the method for producing a laminated body of the present invention, when the laminated body forming the base is cut when manufacturing a laminated body formed by laminating a glass layer and a resin layer, the end face strength of the cut glass layer can be increased. .

Hereinafter, the method of manufacturing the laminate according to the embodiment will be described with reference to the accompanying drawings.

This manufacturing method includes a step of cutting the laminate (hereinafter referred to as a cutting step). In this embodiment, the case where the part which becomes a product is excavated from this laminated body by cutting a laminated body in a cutting process is illustrated.

First, a laminate to be cut will be described.

As shown in FIG. 1 and FIG. 2, the laminated body 1 includes a glass sheet 2 as a glass layer, a resin sheet 3 as a resin layer, and an adhesive interposed between the two sheets 2 and 3. Layer 4. The laminated body 1 is formed by bonding and laminating two sheets 2 and 3 with an adhesive layer 4 . In this embodiment, the glass sheet 2, the resin sheet 3, and the adhesive layer 4 are all transparent bodies, but are not limited thereto.

A planned cutting line 5 indicated by a two-dot chain line in FIG. 2 is a line indicating a cutting position of the laminate 1 in a cutting step described below. The line to cut 5 forms a closed loop in plan view, and serves as a boundary line between the product portion 1 a and the discarded portion 1 b included in the laminate 1 . The product part 1a is a part that becomes a product later, and the discard part 1b is a part that is discarded without becoming a product. The product portion 1a has a rectangular shape with four corners bent in plan view. In addition, the shape of the product part 1a does not need to be a rectangular shape (for example, a circle, an ellipse, etc.). When the laminated body 1 is cut in the cutting step, the product portion 1a is dug out from the laminated body 1 .

The thickness of the laminated body 1 is not limited, and the laminated body 1 in this embodiment has a thickness to the extent that flexibility can be imparted. Thereby, the product part 1a excavated from the laminated body 1 can be used as a cover glass of the bendable flexible element (a portable terminal etc.), for example. Furthermore, from the viewpoint of imparting flexibility to the laminate 1, the thickness of the laminate 1 is preferably 500 μm or less, more preferably 250 μm or less, most preferably 125 μm or less.

The thickness of the glass sheet 2 is preferably not more than 200 μm, more preferably not more than 100 μm, most preferably not more than 50 μm. In this embodiment, the thickness of the glass sheet 2 is 100 μm. As the type of the glass sheet 2, it is preferable to use borosilicate glass, soda lime glass, or aluminosilicate glass, and it is most preferable to use non-alkali glass or chemically strengthened glass. In addition, as the kind of glass sheet 2, silicate glass, silica glass, etc. can also be used. In addition, when chemically strengthened glass is used, aluminosilicate glass can be chemically strengthened and used. In this embodiment, alkali-free glass is used as the glass sheet 2 .

When using alkali-free glass as the glass sheet 2, the transparency of the laminated body 1 improves. Here, the "alkali-free glass" is glass that does not substantially contain alkali components (alkali metal oxides), specifically, glass in which the weight ratio of alkali components is 3000 ppm or less. Furthermore, the weight ratio of the alkaline component is preferably less than 1000 ppm, more preferably less than 500 ppm, most preferably less than 300 ppm.

The glass sheet 2 can be formed by a float method, a rolling method, an orifice downdraw method, a redraw method, etc., and is preferably formed by an overflow downdraw method. By the overflow down-draw method, the glass sheet 2 can obtain high surface smoothness. Thereby, the adhesive force of the glass sheet 2 and the adhesive layer 4 can be improved, and the glass sheet 2 and the resin sheet 3 can be laminated|stacked accurately and precisely.

The thickness of the resin sheet 3 is preferably not more than 200 μm, more preferably not more than 100 μm, most preferably not more than 50 μm. In this embodiment, the thickness of the resin sheet 3 is 100 μm. As the kind of resin sheet 3, polyethylene terephthalate (polyethylene terephthalate, PET), polyethylene naphthalate (polyethylene naphthalate, PEN), polycarbonate (polycarbonate, PC), polyform Base methyl acrylate resin (polymethyl methacrylate, PMMA), polyimide (polyimide, PI) and so on. In this embodiment, polyethylene terephthalate is used as the resin sheet 3 .

The thickness of the subsequent layer 4 is preferably less than 100 μm, more preferably less than 50 μm, most preferably less than 25 μm. In this embodiment, the thickness of the adhesive layer 4 is 25 μm. As the adhesive layer 4 , for example, an adhesive sheet such as an acrylic type, a silicone type, or a urethane type, an ultraviolet curable resin, a thermosetting resin, or the like can be used. In this embodiment, an optical adhesive (Optical Clear Adhesive, OCA) is used as the adhesive layer 4 .

Hereinafter, the cutting step included in this production method will be described in detail.

In the cutting step, the laminated body 1 is cut along the planned cutting line 5 . The cutting steps are in chronological order, including the resin layer cutting step P1 (Fig. 3, Fig. 4), the recess forming step P2 (Fig. 5, Fig. 6), the crack forming step P3 (Fig. 7), and the glass layer breaking step P4 (Figure 8, Figure 9).

<Resin layer cutting procedure> As shown in FIGS. 3 and 4 , in the resin layer cutting step P1 , the resin sheet 3 is cut by irradiating the laminate 1 with laser light 6 from the resin sheet 3 side along the planned cutting line 5 . In addition, a laser irradiator 7 is used for irradiation of the laser beam 6 .

As a specific aspect of the resin layer cutting step P1 , as shown by arrows D1 to D4 in FIG. 4 , the laser beam 6 irradiated on the laminate 1 is circled along the line to cut 5 . Furthermore, in this embodiment, the closed loop formed by making the laser beam 6 surround the planned cutting line 5 multiple times. Furthermore, in the present embodiment, an ultrashort pulse laser is used as the laser 6, and the entire thickness of the resin sheet 3 is cut by ablation processing using the ultrashort pulse laser. Thereby, the cut part 3a which cut the resin sheet 3 is formed. In addition, on the planned cutting line 5, the point where irradiation of the laser beam 6 starts, and the point where irradiation ends can be set as arbitrary points. Furthermore, the speed (scanning speed) at which the laser beam 6 is moved along the line to cut 5 is, for example, 0.1 m/s to 5 m/s.

In the resin layer cutting step P1 , a part of the thickness of the adhesive layer 4 is cut in addition to the resin sheet 3 . That is, as shown in the enlarged view of part A in FIG. 3 , when the resin layer cutting step P1 is completed, a part of the thickness of the adhesive layer 4 remains in an uncut state. The purpose of adopting such an aspect is to prevent the thermal influence of the laser beam 6 from inadvertently affecting the glass sheet 2 . Furthermore, the adhesive layer 4 remaining in the uncut state should also avoid hindering the smooth cutting of the laminated body 1 . Therefore, from the viewpoint of avoiding thermal influence on the glass sheet 2 and smooth cutting of the laminate 1, it is preferable to set the thickness t of the adhesive layer 4 remaining in an uncut state to 1 μm to 10 μm. μm. In the present embodiment, the number of turns of the laser beam 6 along the line to cut 5 is adjusted so that the value of the thickness t falls within the above range.

In addition, when breaking and cutting the glass sheet 2 in the glass layer breaking step P4 performed later, the adhesive layer 4 which remains in the uncut state is often cut together with the glass sheet 2. Moreover, even when the glass sheet 2 is not cut together, since the thickness of the remaining adhesive layer 4 is extremely thin, it can Can be easily cut off.

Here, as the type of the laser 6 , an ultraviolet (ultra violet, UV) laser, a CO ₂ laser, or the like can be used. In this embodiment, UV laser is used. Furthermore, the wavelength of the laser beam 6 is preferably 200 nm to 12000 nm, more preferably 300 nm to 8000 nm, most preferably 350 nm to 4000 nm. In this embodiment, the wavelength is set to 355 nm. Furthermore, as the pulse width of the laser 6, it is preferable to set it as a picosecond order or a femtosecond order, and specifically, to set it as 500 ps or less. Furthermore, it is more preferably below 300 ps, most preferably below 100 ps.

The width W of the cut portion 3 a formed by the resin layer cutting step P1 is preferably 0.005 mm˜0.5 mm. If the width W of the cut portion 3a is narrower than 0.005 mm, there is a possibility that the cut adhesive layer 4 may be improperly rejoined. On the other hand, if the width W of the cut portion 3 a is wider than 0.5 mm, there is a possibility that an abnormality may occur in the concave portion forming step P2 to be performed later. Specifically, if the width W of the cutting portion 3a is too large, as shown in FIG. There is a risk that the glass sheet 2 will bend and cannot be pressed smoothly.

<Concave forming step> As shown in FIGS. 5 and 6 , in the concave portion forming step P2, the glass sheet is formed along the line to cut 5 by moving the drill tip 8 pressing the surface of the glass sheet 2 along the line to cut 5 . The concave portion 2a formed by plastic deformation on the surface of the material 2. Here, in the present embodiment, when the concave portion forming step P2 is performed, the upper and lower sides (front and back) of the laminate 1 are reversed with respect to the time when the resin layer cutting step P1 is performed.

The drill tip 8 includes a shank 8a and a cutting edge 8b fixed to one end of the shank 8a. The shank 8a is made of metal, for example, and is formed in a cylindrical shape or a polygonal column shape. The blade tip 8 b includes, for example, single crystal or polycrystalline diamond, and may also include polycrystalline cubic boron nitride (PCBN), ceramics, cemented carbide, and other metals. The blade tip 8b is fixed to the shank 8a by an adhesive, a paste, or the like.

As a specific aspect of the concave portion forming step P2 , as shown in FIG. 6 , the point 5 a present on the planned cutting line 5 is used as the point where the surface pressing of the glass sheet 2 is started. Then, as indicated by arrows E1 to E4 , the drill tip 8 is moved along the planned cutting line 5 . Thereby, the drill tip 8 which has circled the planned cutting line 5 once again returns to the point 5a. Thereafter, while continuing to press the surface of the glass sheet 2 with the drill point 8 , the drill point 8 is moved to the end of the glass sheet 2 as indicated by the arrow E5 (point 2 e ). Thereby, not only along the planned cutting line 5 but also in the section from the point 5a to the point 2e, the concave portion 2a is formed. In addition, the position of the point 5a which is the point where pressing starts can be set to any point as long as it is on the planned cutting line 5. FIG. Furthermore, the speed (travel speed) at which the drill tip 8 is moved along the planned cutting line 5 is, for example, 1 mm/s to 500 mm/s.

Here, as a modified example of this embodiment, after the drill tip 8 that has circled the planned cutting line 5 once again returns to the point 5a, the drill tip 8 may be stopped midway between the point 5a and the point 2e, instead of The end of the glass sheet 2 is reached (point 2e). In this case, the recess 2 a is formed along the line to cut 5 , and the recess 2 a is formed in the middle of the section from the point 5 a to the point 2 e (hereinafter, the same modification will be referred to as a recess forming modification).

As shown in the enlarged view of part B in FIG. 5 (the drill tip 8 is omitted from the enlarged view), a compressive stress layer 2ax in which compressive stress acts is formed on the surface portion of the concave portion 2a. Furthermore, the tensile stress layer 2ay in which tensile stress acts is formed directly under the compressive stress layer 2ax.

＜Crack Formation Procedure＞ As shown in FIG. 7 , in the crack forming step P3 , a crack line 9 is formed along the concave portion 2 a.

In the present embodiment, when the drill tip 8 reaches the end (point 2 e ) of the glass sheet 2 in the concave portion forming step P2 described above, the crack line 9 is formed in the tensile stress layer 2ay along with it. At this time, the crack line 9 is formed in a direction opposite to the direction in which the drill tip 8 moves when forming the concave portion 2a. That is, the formation of the crack line 9 starts from the end (point 2 e ) of the glass sheet 2 , the crack line 9 develops in the order of the arrows E5 to E1 , and the formation of the crack line 9 stops at the point 5 a. Thereby, the crack line 9 is formed along the entire length of the line to cut 5 .

Here, in the case of applying the above-described recess forming modification in the recess forming step P2, in the crack forming step P3, as an example, the crack line 9 is formed in the following form. First, prepare the wheel cutter. Next, the wheel cutter is rolled on the surface of the glass sheet 2 so that it may intersect with the recessed part 2a formed in the middle of the section from the point 5a to the point 2e. Thereby, scratches are formed on the surface of the glass sheet 2 so as to cross the recessed part 2a. As a result, the formation of the crack line 9 starts from the point where the concave portion 2 a intersects the scratch, and the formation of the crack line 9 stops at the point 5 a. Thereby, the crack line 9 is formed along the entire length of the line to cut 5 .

＜Procedure for breaking the glass layer＞ As shown in FIGS. 8 and 9 , in the glass layer breaking step P4 , the glass sheet 2 is broken and cut starting from the crack line 9 . When the glass sheet 2 is broken, the laminated body 1 is bent so that the surface side of the glass sheet 2 on which the crack line 9 is formed protrudes as shown by the two-dot chain line in FIG. 8 . Thereby, the cut part 2x which cut the glass sheet 2 is formed. In addition, the breaking of the glass sheet 2 is performed in the order shown by arrow F1 - arrow F5 starting from the point 2e shown in FIG. 9 . And, let the point 5a shown in the same figure be the point where the breaking is completed. After the breaking of the glass sheet 2 is completed, the entire thickness of the laminate 1 is cut, and the product portion 1 a is dug out from the laminate 1 . Through the above, all the steps included in the cutting step are completed.

Here, the following modifications can also be applied to the above-described embodiment.

The order of performing resin layer cutting process P1 - glass layer breaking process P4 may differ from the said embodiment. Among the four steps P1 to P4, the three steps P2 to P4 need to be performed in the same order as in the above embodiment, but the timing of performing the resin layer cutting step P1 can be changed from the above embodiment. That is, the resin layer cutting step P1 can be performed at any timing between the recess forming step P2 and the crack forming step P3, between the crack forming step P3 and the glass layer breaking step P4, and after the glass layer breaking step P4.

Among them, preferably, after the crack formation step P3 is performed, the glass layer breaking step P4 is continuously performed without intervening the resin layer cutting step P1. The reason for this is to suppress the glass sheet 2 from being accidentally cut before the glass layer breaking step P4 is performed. Furthermore, it is preferable to perform the resin layer cutting process P1 before performing the glass layer breaking process P4. The reason is that after the glass sheet 2 is cut, as long as the end faces of the facing glass sheets 2 (the end faces formed by cutting) can be separated from each other immediately, the contact between the end faces will be avoided. It is advantageous in terms of the resulting reduction in the strength of the end faces.

Furthermore, in the case where the resin layer cutting step P1 is performed after the glass layer breaking step P4, the pulse width of the laser 6 used in the resin layer cutting step P1 does not need to be on the order of picoseconds or femtoseconds as in the above embodiment. Second level, can also be nanosecond level.

In addition, in the above-described embodiment, the line to cut 5 forms a closed loop and the product part 1a is dug out from the laminate 1, but the present invention is not limited thereto. For example, the laminated body 1 may be divided into two by cutting the laminated body 1 along the line to cut 5 extending linearly.

1: laminated body 1a: Products Department 1b: Abandoned Department 2: glass sheet 2a: concave part 2ax: compressive stress layer 2ay: tensile stress layer 2e, 5a: point 2x, 3a: cutting part 3: Resin sheet 4: Next layer 5: cut off the scheduled line 6:Laser 7:Laser irradiator 8: drill point 8a: Shank 8b: Knife tip 9: crack line A, B: Zoom in D1～D4, E1～E5, F1～F5: Arrows P1: Resin layer cutting step P2: concave part forming step P3: Crack formation step P4: Glass layer breaking step t: thickness W: width

FIG. 1 is a cross-sectional view showing a laminate. Fig. 2 is a plan view showing a laminate. Fig. 3 is a cross-sectional view showing a resin layer cutting step included in the method of manufacturing the laminate. 4 is a plan view showing a step of cutting a resin layer included in the method of manufacturing a laminate. Fig. 5 is a cross-sectional view showing a concave portion forming step included in the method of manufacturing the laminate. 6 is a plan view showing a concave portion forming step included in the method of manufacturing the laminate. 7 is a cross-sectional view showing a crack formation step included in the method of manufacturing the laminate. Fig. 8 is a cross-sectional view showing a glass layer breaking step included in the method of manufacturing the laminate. Fig. 9 is a plan view showing a glass layer breaking step included in the method of manufacturing the laminate.

1: laminated body

2: glass sheet

2a: concave part

2ax: compressive stress layer

2ay: tensile stress layer

3: Resin sheet

3a: cutting part

4: Next layer

5: cut off the scheduled line

9: crack line

B: Zoom in

P3: Crack formation step

Claims (5)

A method for manufacturing a laminate, comprising the step of cutting a laminate obtained by laminating a glass layer and a resin layer along a planned cutting line, The manufacturing method of the laminate is characterized in that the step of cutting includes: a resin layer cutting step of irradiating the laminate with laser light from the resin layer side along the planned cutting line, thereby cutting the resin layer; The step of forming a concave portion, moving a drill bit pressing the surface of the glass layer along the line to cut, thereby forming a concave portion in which the surface of the glass layer is plastically deformed along the line to cut; a crack forming step of forming a crack line along said recess; and In the step of breaking the glass layer, the glass layer is broken and cut starting from the crack line. The method for manufacturing a laminate according to claim 1, wherein the step of cutting the resin layer is performed before the step of breaking the glass layer. The method for manufacturing a laminate according to claim 2, wherein an adhesive layer for bonding the two layers is interposed between the glass layer and the resin layer, In the resin layer cutting step, a part of the thickness of the adhesive layer is cut in addition to the resin layer. The method of manufacturing a laminate according to Claim 2 or Claim 3, wherein a laser having a pulse width of 500 ps or less is used as the laser. The method for manufacturing a laminate according to any one of claim 1 to claim 4, wherein the step of breaking the glass layer is performed successively after the step of forming the crack.

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