WO2020075556A1 - 熱プレス用クッション材および熱プレス用クッション材の製造方法 - Google Patents

熱プレス用クッション材および熱プレス用クッション材の製造方法 Download PDF

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Publication number
WO2020075556A1
WO2020075556A1 PCT/JP2019/038541 JP2019038541W WO2020075556A1 WO 2020075556 A1 WO2020075556 A1 WO 2020075556A1 JP 2019038541 W JP2019038541 W JP 2019038541W WO 2020075556 A1 WO2020075556 A1 WO 2020075556A1
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Prior art keywords
layer
cushion material
core layer
hot
resin layer
Prior art date
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PCT/JP2019/038541
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English (en)
French (fr)
Inventor
吉田　晃
秀平 河野
Original Assignee
ヤマウチ株式会社
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Publication date
Application filed by ヤマウチ株式会社 filed Critical ヤマウチ株式会社
Priority to KR1020217006731A priority Critical patent/KR20210070268A/ko
Priority to EP19872130.0A priority patent/EP3865274A4/en
Priority to US17/281,469 priority patent/US11628637B2/en
Priority to CN201980062460.8A priority patent/CN112752641A/zh
Publication of WO2020075556A1 publication Critical patent/WO2020075556A1/ja

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Definitions

  • the present invention relates to a cushioning material for hot press. More specifically, the present invention relates to a printed circuit board such as a copper clad laminate, a flexible printed circuit board and a multilayer board, and precision equipment parts such as an IC card, a liquid crystal display panel and a ceramics laminated board (hereinafter referred to as “laminated board” in the present invention). (Hereinafter referred to as ”)) in the process of manufacturing the target product, and a method for manufacturing the cushion material for hot press and the cushion material for hot press used when press molding or thermocompression bonding the target product.
  • a printed circuit board such as a copper clad laminate, a flexible printed circuit board and a multilayer board
  • precision equipment parts such as an IC card, a liquid crystal display panel and a ceramics laminated board (hereinafter referred to as “laminated board” in the present invention). (Hereinafter referred to as ”)) in the process of manufacturing the target product, and a method for manufacturing the cushion material for hot
  • a laminated board 52 as a product to be pressed is sandwiched between heating plates 51 as heating / pressurizing means, A method of applying constant pressure and heat is used.
  • a method of applying constant pressure and heat is used.
  • hot pressing is performed with the flat cushion material 1 interposed between the hot platen 51 and the laminated plate 52.
  • a mirror surface plate 53 is interposed between the laminated plate 52 and the cushion material 1.
  • cushion material 1 general properties required for the cushion material 1 include cushioning property of absorbing unevenness of the heating plate 51 and the laminated plate 52, temperature and pressure from the heating plate 51 to the laminated plate 52 over the entire press surface. In-plane uniformity for uniformly transmitting heat, heat transferability for efficiently transferring heat from the heating plate 51 to the laminated plate 52, heat resistance capable of withstanding the press temperature, and the like.
  • a hot-press cushion material includes a plate-shaped cushion material body containing fibers and surface layers located on the upper and lower outermost surfaces of the cushion material body.
  • a technique is disclosed in Patent Document 1 (JP-A-2014-87999).
  • the surface layer is provided mainly for imparting releasability to the hot-press cushion material, and a synthetic resin film, a releasable resin coating film, or the like is used as the material of the surface layer. Is disclosed.
  • Patent Document 2 Japanese Unexamined Patent Publication No. 2004-344962
  • Patent Document 3 Japanese Unexamined Patent Publication No. 2011-116034 disclose surface layers of cushioning materials for hot pressing.
  • Patent Document 2 discloses a surface layer material including a sheet-shaped cushion material body and a release coating film formed on the cushion material body.
  • the base material of the surface layer material specifically, glass cloth is used.
  • Patent Document 3 includes a resin layer that covers one surface of the surface layer material, a rubber layer that covers the other surface of the surface layer material, and a woven fabric layer using bulky yarns arranged between the resin layer and the rubber layer.
  • the resin layer side of the woven fabric layer is a woven fabric-resin composite layer in which a resin constituting the resin layer is impregnated in a part of the woven fabric, and the rubber layer side of the woven fabric layer is a part of the woven fabric.
  • a surface layer material which is a woven fabric-rubber composite layer in which rubber constituting a rubber layer is impregnated, and voids are provided inside the woven fabric layer.
  • woven fabric or paper made of aramid fiber may be used as the surface layer material.
  • fluff may be generated from the surface of the surface layer or a part of the surface layer may be damaged due to contact with a jig or impact during handling and repeated use. Further, when a synthetic resin film is used as the surface layer material, since the surface is highly smooth, the hot platen or mirror surface plate comes into close contact with the cushion material, and the work efficiency is reduced.
  • the present invention has been made to solve the above problems, and an object thereof is to prevent generation or damage of fluff from a surface layer material, and prevent contact with a hot platen or mirror surface plate.
  • a cushioning material for hot pressing and a method for manufacturing a cushioning material for hot pressing are provided.
  • the cushioning pad for hot pressing includes a cushioning material main body in a plate shape and surface materials provided on the front and back surfaces of the cushioning material main body, and the surface material is formed of a heat resistant fiber material having a non-woven structure.
  • the core layer is made of organic fiber.
  • the surface resin layer is too thick, it will adhere to the product to be pressed and work efficiency will decrease. Further, if the surface resin layer is too thick, the surface resin layer may crack and fall off.
  • the surface resin layer is preferably a thin film to the extent that the irregularities of the fibers of the heat resistant fiber material appear.
  • the front surface resin layer further includes a back surface rubber layer that covers the entire back surface of the core layer, and the cushion material body and the surface material are bonded via the back surface rubber layer.
  • the surface resin layer contains at least one resin selected from the group consisting of fluororesin, polyimide resin, polyamide resin, PTFE and PEEK.
  • the surface resin layer contains a conductive filler.
  • a method of manufacturing a cushioning material for hot pressing is a method of manufacturing a cushioning material for hot pressing, which includes a cushion material main body in a plate shape and surface materials provided on the front and back surfaces of the cushion material main body. .
  • the core layer formed of the non-woven heat-resistant fiber material has an air permeability of 5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 or less and a bulk density of 0.8 g / cm 3 or more.
  • the manufacturing process of the hot-press cushion material includes a step of attaching the surface material manufactured in the above step to the cushion material body.
  • the step of heating and pressing the surface material is calendering or hot pressing.
  • the hot-press cushioning material and the method for manufacturing the hot-pressing cushioning material of the present invention it is possible to prevent fluff from being generated or damaged from the surface layer material, and to prevent close contact with the hot platen or the mirror surface plate. it can.
  • FIG. 7 is a schematic sectional view of a surface layer material of Comparative Example 2.
  • FIG. 7 is a schematic sectional view of a surface layer material of Comparative Example 3.
  • FIG. 7 is a figure which shows a test jig typically. It is a graph which shows the relationship between air permeability and bulk density.
  • 3A and 3B are partial photographs of a vertical cross section including a surface portion of a cushion material, where (a) is a photograph of Comparative Example 1 and (b) is a photograph of Comparative Example 3. It is a photograph showing the surface of the cushioning material after the impact test, (a) is a photograph of the invention example 1, (b) is a photograph of the invention example 2, (c) is a photograph of the comparative example 1, d) is a photograph of Comparative Example 2, (e) is a photograph of Comparative Example 3, (f) is a photograph of Comparative Example 4, and (g) is a photograph of Comparative Example 5. It is a partial photograph of a longitudinal section including the surface portion of the present invention example 1 after the impact test.
  • 5 is a partial photograph of a vertical cross section including a surface portion of Comparative Example 2 after the impact test. 5 is a partial photograph of a vertical cross section including a surface portion of Comparative Example 3 after the impact test. It is a figure for demonstrating a hot press process.
  • FIG. 1 shows a cushioning pad 1 for hot pressing according to an embodiment of the present invention.
  • the hot-press cushion material 1 includes a plate-shaped cushion material main body 2 and surface materials 3 provided on the front and back surfaces of the cushion material main body 2.
  • the cushion material body 2 is, for example, a layer of a fiber-rubber composite material made of a woven cloth and rubber impregnated in the woven cloth.
  • a bulky yarn (bulky yarn) made of glass fiber is used for at least one of the warp and the weft constituting the woven fabric.
  • the fiber-rubber composite layer has voids therein.
  • the thickness of the fiber-rubber composite material layer is about 0.5 mm to 5 mm, and is in the form of a sheet.
  • the rubber is impregnated into the gaps of the entire woven fabric so that the volume ratio of the rubber to the constituent fibers of the woven fabric is 5 to 50%. A more preferable volume ratio of the rubber is 5 to 35%.
  • the gap between the woven fabrics is not completely closed by the rubber, and has a certain degree of void.
  • the porosity of the fiber-rubber composite material layer is preferably 20 to 65%, more preferably 25 to 65%.
  • the rubber impregnated into the woven fabric is preferably made of fluororubber, EPM, EPDM, hydrogenated nitrile rubber, silicone rubber, acrylic rubber and butyl rubber. It is one or more materials selected from the group.
  • the cushion material main body 2 does not necessarily have to be a layer of a woven fabric-rubber composite material, and may have a structure conventionally used as a cushion material main body. That is, the cushion material main body 2 may have a single layer structure of any one of woven cloth, non-woven cloth, rubber and synthetic resin or a composite of two or more kinds, or a laminated structure of the same kind or different kinds of layers.
  • FIG. 2 shows the surface material 3.
  • the surface material 3 is provided mainly for imparting releasability to the hot-press cushion material 1.
  • the surface material 3 includes a core layer 31, a surface resin layer 32 that covers the entire surface of the core layer 31, and a back surface rubber layer 33 that covers the entire back surface of the core layer 31.
  • the core layer 31 is formed of a heat resistant fiber material having a non-woven structure.
  • the non-woven structure is meant to include a non-woven fabric and paper.
  • the core layer 31 is made of organic fiber.
  • the organic fiber for example, a fiber made of polypropylene, polyester, polyamide, polyvinyl alcohol (vinylon), aromatic polyamide (aramid), or the like can be used.
  • the core layer 31 is formed by heating and pressing a heat resistant fiber material having a non-woven structure.
  • the heating / pressurizing treatment is to apply pressure while heating, and specifically, it is calendering treatment or hot pressing treatment.
  • calendering treatment for example, a fibrous material having a non-woven structure is passed through a nip portion between a heat roll heated to 200 ° C. or more and a resin roll, and the thickness of the non-woven structure after the treatment is controlled by heating temperature and nip pressure. , Smoothness, etc. can be controlled.
  • the hot pressing process is a process of applying pressure while heating to, for example, 200 ° C. or higher.
  • the air permeability of the core layer 31 can be 5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 or less and the bulk density can be 0.8 g / cm 3 or more. If the air permeability of the core layer 31 is more than 5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 and the bulk density is less than 0.8 g / cm 3 , the resin coated on the surface will penetrate into the core layer 31. Since the entire surface of the core layer 31 cannot be covered with the surface resin layer 32, fluffing of the core layer 31 cannot be prevented. In addition, the fluff of the core layer 31 is flattened in the surface direction by the heat and pressure treatment.
  • the surface resin layer 32 is a thin film to the extent that the fibers of the core layer 31 show irregularities. Specifically, the thickness of the surface resin layer 32 is 0.5 ⁇ m to 200 ⁇ m, preferably 1 ⁇ m to 50 ⁇ m. Since the surface resin layer 32 has irregularities of the fibers of the core layer 31, the hot-press cushion material 1 does not adhere to the hot platen 51 or the mirror surface plate 53. If the surface resin layer 32 is too thin, the fibers cannot be sufficiently covered, so that fluff may be generated, and static electricity may be generated even when a conductive filler is mixed in the surface resin layer 32.
  • the surface resin layer 32 is too thick, the irregularities of the fibers of the core layer 31 do not appear on the surface resin layer 32, so that the surface resin layer 32 is in close contact with the hot platen 51 and the mirror plate 53, and the work efficiency is reduced.
  • the surface resin layer 32 permeates the surface portion of the core layer 31 and enters the voids between the fibers.
  • the surface resin layer 32 includes, for example, at least one resin selected from the group consisting of fluororesin, polyimide resin, polyamide resin, PTFE and PEEK. Further, the surface resin layer 32 preferably contains a conductive filler.
  • the conductive filler is, for example, conductive zinc oxide, conductive titanium oxide, carbon black, carbon resin, carbon nanotube, or the like.
  • the back surface rubber layer 33 plays a role of adhering the cushion material body 2 and the surface material 3 to each other.
  • the back rubber layer 33 is, for example, a fluororubber adhesive.
  • the rubber is one rubber or a mixture of two or more rubbers selected from the group consisting of fluororubber, EPM, EPDM, hydrogenated nitrile rubber, silicone rubber, acrylic rubber and butyl rubber.
  • the back surface rubber layer 33 permeates the back surface portion of the core layer 31 and enters the voids between the fibers.
  • the cushion material main body 2 in the form of a plate is prepared (step S1).
  • a fiber-rubber composite material layer is used as the cushion material body 2
  • the woven cloth is impregnated with the rubber solution and dried to remove the solution.
  • the vulcanization of the rubber impregnated in the woven fabric can be performed at this stage, but it can also be performed at the step S3 described later without performing at this stage.
  • step S2 the surface material 3 provided on the front surface and the back surface of the cushion material body 2 is prepared (step S2).
  • step S2 in order to manufacture the surface material 3 shown in FIG. 2, the non-woven heat-resistant fiber material that becomes the core layer 31, the resin that becomes the surface resin layer 32, and the adhesive that becomes the back surface rubber layer 33. Prepare the agent.
  • the prepared core layer 31 is heated and pressed (step S21). Specifically, the fibers of the heat resistant fiber material of the core layer 31 are calendered or hot pressed. Thereby, the air permeability is 5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 or less and the bulk density is 0.8 g / cm 3 or more.
  • step S22 a step of covering the entire surface of the core layer 31 with the surface resin layer 32 is performed (step S22).
  • the surface resin layer 32 is formed by applying a resin on the entire surface of the core layer 31 so that the core layer 31 has a thin film in which irregularities of the fibers appear. Further, an adhesive that forms the back rubber layer 33 is applied to the entire back surface of the core layer 31.
  • a step of attaching the surface material 3 to the front surface and the back surface of the cushion material body 2 is performed (step S3).
  • the cushion material body 2 and the surface material 3 are laminated so that the back surface rubber layer 33 side of the surface material 3 is in contact with the cushion material body 2, and the back surface rubber layer 33 is vulcanized by heat and pressure treatment.
  • the cushion material body 2 and the surface material 3 are integrated. If the cushion material body 2 is not vulcanized in the step S1, the rubber material is vulcanized by heat and pressure when the cushion material body 2 and the surface material 3 are bonded and integrated. It can be performed simultaneously with the vulcanization of the rubber layer 33.
  • the air permeability is 5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 or less
  • the bulk is increased by the step of heating and pressing the core layer 31 (step S21).
  • the density of 0.8 g / cm 3 or more and the step of covering the entire surface of the core layer 31 with the surface resin layer 32 (step S22) can prevent the surface material 3 from fuzzing.
  • the surface resin layer 32 is a thin film to the extent that unevenness of the fibers of the heat resistant fiber material of the core layer 31 appears, the hot press cushion material 1 does not adhere to the hot platen 51 or the mirror surface plate 53, and the work efficiency is improved. To do.
  • Table 1 shows the evaluation results of the experiments performed on the present invention examples 1 and 2 and the comparative examples 1 to 5.
  • a cushion material body was prepared (step S1).
  • a glass woven fabric “T860” manufactured by Unitika Ltd.
  • This woven fabric is a bulky yarn obtained by bulk-processing a ply-twisted yarn having a count of 305 tex and made of 3200 E glass fibers (fiber diameter 6 ⁇ m), and a warp having a count of 135 tex made of 1600 E glass fibers (fiber diameter 6 ⁇ m). It is a plied yarn that has not been bulked, and is a double-woven weft yarn and a warp yarn.
  • This woven fabric has a weight of 850 g / m 2 , a thickness of 1.02 mm and a porosity of 67%.
  • an unvulcanized fluororubber solution was prepared by dissolving unvulcanized fluororubber at a predetermined concentration in a solvent in which butyl acetate and methyl ketone were mixed at a mass ratio of 1: 1.
  • the glass woven fabric was immersed in each unvulcanized fluororubber solution and then squeezed with two rolls. Next, each glass woven fabric impregnated with the unvulcanized fluororubber solution was sufficiently dried to remove the solvent. In this way, two cushion material bodies were prepared.
  • the surface material was prepared (step S2). Specifically, aramid paper "Nomex Paper Type 410 (5 mil)" (manufactured by DuPont Teijin Advanced Paper Co., Ltd.) that was calendered in the manufacturing process was used as the core layer. A polyimide resin varnish mixed with conductive titanium oxide was applied as a surface resin layer to the surface of the core layer as a thin film in which fiber irregularities appeared. As a result, a surface resin layer made of a polyimide resin was formed. The thickness of the surface resin layer was 1 to 10 ⁇ m. Next, an unvulcanized fluororubber solution was applied to the back surface side of the core layer and dried to form a back surface rubber layer as an adhesive layer. In this way, two surface materials were prepared.
  • the above-mentioned two-layer cushion material main body was laminated with the adhesive material sandwiched therebetween, and further, the surface material was laminated on the front surface and the back surface such that the back surface rubber layer was in contact with the cushion material main body.
  • the laminate was hot-pressed to vulcanize the unvulcanized fluororubber impregnated in the cushion material body and the unvulcanized fluororubber applied to the back surface of the surface material to bond and integrate the whole. This was designated as Inventive Example 1.
  • the following method for producing cushioning materials of Inventive Example 2 and Comparative Examples 1 to 5 was basically the same as that of Inventive Example 1, but the composition of the surface material was different as shown in Table 1 below. .
  • Example 2 of the present invention was one in which PPS (polyphenylene sulfide) paper “PPS paper” (manufactured by Hirose Paper Co., Ltd.) that had been subjected to hot press treatment was used as the core layer of the surface material.
  • PPS polyphenylene sulfide
  • Comparative example 1 has no surface resin layer.
  • Comparative Example 2 uses PPS (polyphenylene sulfide) paper “PPS paper” (manufactured by Hirose Paper Co., Ltd.) that is not subjected to heat pressing as the core layer of the surface material.
  • PPS paper polyphenylene sulfide paper
  • FIG. 2 A schematic sectional view of the surface layer material 3A of Comparative Example 2 is shown in FIG.
  • the surface material 3A of Comparative Example 2 has a higher air permeability and a lower bulk density than Example 1 of the present invention because the core layer 31a is not subjected to hot pressing. Therefore, the resin that becomes the surface resin layer 32a permeates the inside of the core layer 31a, the surface resin layer 32a cannot completely cover the surface of the core layer 31a, and fluffing is observed.
  • Comparative Example 3 was obtained by subjecting a needle punched non-woven fabric of aramid fiber (“Conex” manufactured by Teijin Ltd.) as a core layer of the surface material to a hot press treatment.
  • a schematic sectional view of the surface layer material 3B of Comparative Example 3 is shown in FIG.
  • the surface material 3B of Comparative Example 3 had a higher air permeability and a lower bulk density than Example 1 of the present invention, although the core layer 31b was subjected to hot pressing. Therefore, the resin to be the surface resin layer 32b permeates the inside of the core layer 31b, so that the surface resin layer 32b cannot completely cover the surface of the core layer 31b, and fluffing is observed.
  • Comparative Example 4 uses glass cloth as the core layer of the surface material. Comparative Example 4 is disclosed in detail in Japanese Patent Laid-Open No. 2004-344962 (Patent Document 2).
  • Comparative Example 5 has a surface resin layer thickness of 300 ⁇ m.
  • the surface resin layer of Comparative Example 5 filled up the irregularities of the fibers of the core layer.
  • Press compression test A mirror surface plate made of a SUS plate and a cushion material are overlapped with each other, and heated at 230 ° C. for 60 minutes while being pressed with a pressure of 4 MPa in the thickness direction with a press machine, then cooled for 10 minutes, and then pressed. Was released. The contact state with the mirror plate when the press was released was confirmed.
  • Impact test As shown in FIG. 7, a hammer 40 in which a spherical terminal 42 having a diameter of 10 mm and a height of 2 mm made of SUS was attached to a jig 41 of a pressure tester was used. The hammer 40 was applied to the outer edge surface of the cushion material at a speed of 300 mm / min, and a test of applying an impact of a load of 5 kgf was repeated 10 times.
  • FIG. 8 is a graph showing the air permeability and bulk density of the core layers used in Inventive Examples 1 and 2 and Comparative Examples 1 to 3 and 5.
  • 8A shows the calendered aramid paper used in Inventive Example 1, Comparative Example 1 and Comparative Example 5, having an air permeability of 0 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 and a bulk density of 0. It was 9 g / cm 3 .
  • 8B shows the PPS paper that has been subjected to the hot press treatment used in Example 2 of the present invention and has an air permeability of 4.8 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 and a bulk density of 0.88 g / cm 3 . there were.
  • FIG. 8 is the PPS paper used in Comparative Example 2 which has not been subjected to the hot press treatment and has an air permeability of 29.5 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 and a bulk density of 0.43 g / cm 3 . there were.
  • D in FIG. 8 is the hot-pressed aramid nonwoven fabric used in Comparative Example 3, which has an air permeability of 2.8 cm 3 ⁇ cm ⁇ 2 ⁇ s ⁇ 1 and a bulk density of 0.68 g / cm 3. It was
  • Comparative Example 2 In Comparative Example 2 (FIGS. 5 and 9 (d)), fluffing was observed, although unevenness was present on the surface. This is because Comparative Example 2 has a high air permeability and a low bulk density as compared with Inventive Example 2 because the hot press treatment is not performed. Therefore, in Comparative Example 2, the surface of the core layer cannot be sufficiently covered with the surface resin layer, and fluffing of the core layer occurs.
  • Comparative Example 3 In Comparative Example 3 (FIG. 6, FIG. 9 (e), FIG. 11 (b)), fluffing was observed although the surface had irregularities.
  • the core layer has a high air permeability and a low bulk density, although the hot pressing process is performed. Therefore, in Comparative Example 3, the surface of the core layer could not be sufficiently covered with the surface resin layer.
  • the present invention examples 1 and 2 can prevent fuzzing, do not cause close contact with the hot platen or the mirror plate, and are strong against impact.
  • 1 cushion material for heat press 2 cushion material main body, 3, 3A, 3B surface material, 31, 31a, 31b core layer, 32, 32a, 32b surface resin layer, 33 backside rubber layer, 40 hammer, 41 pressure tester Jig, 42 spherical terminals, 51 hot plate, 52 laminated plate, 53 mirror plate.

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Abstract

熱プレス用クッション材（１）は、板状形態のクッション材本体と、クッション材本体の表面および裏面に設けられる表面材（３）とを備え、表面材（３）は、不織構造の耐熱繊維材料から形成されるコア層（３１）と、コア層の表面全体を覆う表面樹脂層（３２）とを含み、コア層（３１）は、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下であり、嵩密度が０．８ｇ／ｃｍ３以上である。

Description

熱プレス用クッション材および熱プレス用クッション材の製造方法
　この発明は、熱プレス用クッション材に関する。さらに詳しくは、この発明は、銅張積層板、フレキシブルプリント基板、多層板等のプリント基板や、ＩＣカード、液晶表示板、セラミックス積層板などの精密機器部品（以下、本発明において「積層板」と称する）を製造する工程で、対象製品をプレス成形や熱圧着する際に使用される熱プレス用クッション材および熱プレス用クッション材の製造方法に関する。
　プリント基板等の積層板の製造において、プレス成形や熱圧着の工程では、図１６に示すようにプレス対象製品である積層板５２を、加熱・加圧手段としての熱盤５１の間に挟み込み、一定の圧力と熱をかける方法が用いられる。精度の良い成形品を得るためには、熱プレスにおいて、積層板５２に加えられる熱と圧力を全面に亘って均一化する必要がある。このような目的で、熱盤５１と積層板５２との間に平板状のクッション材１を介在させた状態で熱プレスが行なわれる。なお、積層板５２とクッション材１との間には、鏡面板５３が介在している。
　ここで、クッション材１に要求される一般特性としては、熱盤５１や積層板５２の持つ凹凸を吸収するクッション性、プレス面内全体に亘って熱盤５１から積層板５２に温度と圧力とを均一に伝達するための面内均一性、熱盤５１から積層板５２に効率良く熱を伝達するための熱伝達性、プレス温度に耐えうる耐熱性等が挙げられる。
　一般的に、熱プレス用クッション材は、繊維を含む板状形態のクッション材本体と、クッション材本体の上下の最表面に位置する表層とを備える。このような技術が特許文献１（特開２０１４－８７９９９号公報）に開示されている。特許文献１には、表層は、熱プレス用クッション材に主として離型性を付与するために設けられ、表層の材料として、合成樹脂フィルムや、離型性樹脂塗膜などが使用されていることが開示されている。
　特許文献２（特開２００４－３４４９６２号公報）および特許文献３（特開２０１１－１１６０３４号公報）には、熱プレス用クッション材の表層材が開示されている。特許文献２には、シート状のクッション材本体と、クッション材本体上に形成された離型性塗膜とを備えた表層材が開示されている。表層材の基材は、具体的にはガラスクロスが用いられている。特許文献３には、表層材の一方面を覆う樹脂層と、表層材の他方面を覆うゴム層と、樹脂層およびゴム層の間に配置される嵩高糸を用いた織布層とを備え、織布層の樹脂層側は、織布の一部に樹脂層を構成する樹脂が含侵した織布－樹脂複合層とされ、織布層のゴム層側は、織布の一部にゴム層を構成するゴムが含侵した織布－ゴム複合層とされ、織布層の内部に空隙が設けられた表層材が開示されている。
　その他に、アラミド繊維からなる織布や紙が表層材として用いられることもある。
特開２０１４－８７９９９号公報 特開２００４－３４４９６２号公報 特開２０１１－１１６０３４号公報
　従来の表層では、取り扱い中に冶具との接触や衝撃を受け、また繰り返し使用することで、表層の表面から毛羽が発生したり、表層の一部が破損したりする場合がある。また、表層材として合成樹脂フィルムを用いた場合、表面の平滑性が高いため、熱盤や鏡面板とクッション材が密着してしまい、作業効率が低下する。
　本発明は、上記の課題を解決するためになされたものであり、その目的は、表層材からの毛羽の発生や破損を防止することができ、熱盤や鏡面板との密着を防止することができる熱プレス用クッション材および熱プレス用クッション材の製造方法を提供することである。
　本発明に係る熱プレス用クッション材は、板状形態のクッション材本体と、クッション材本体の表面および裏面に設けられる表面材とを備え、表面材は、不織構造の耐熱繊維材料から形成されるコア層と、コア層の表面全体を覆う表面樹脂層とを含み、コア層は、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下であり、嵩密度が０．８ｇ／ｃｍ３以上である。
　好ましくは、コア層は、有機繊維からなる。
　また、表面樹脂層の厚みが厚すぎると、プレス対象製品に対して密着し、作業効率が低下する。さらに、表面樹脂層の厚みが厚すぎると、表面樹脂層が割れて脱落するおそれがある。
　すなわち、表面樹脂層は、耐熱繊維材料の繊維の凹凸が表れる程度の薄膜とされることが好ましい。
　好ましくは、表面樹脂層は、コア層の裏面全体を覆う裏面ゴム層をさらに含み、クッション材本体と表面材は、裏面ゴム層を介して接着されている。
　好ましくは、表面樹脂層は、フッ素樹脂、ポリイミド樹脂、ポリアミド樹脂、ＰＴＦＥおよびＰＥＥＫからなる群から選択された少なくとも１つの樹脂を含む。
　好ましくは、表面樹脂層には、導電性充填剤を含む。
　本発明に係る熱プレス用クッション材の製造方法は、板状形態のクッション材本体と、クッション材本体の表面および裏面に設けられた表面材とを備えた熱プレス用クッション材の製造方法である。表面材の製造工程は、不織構造の耐熱繊維材料から形成されるコア層を、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下、嵩密度が０．８ｇ／ｃｍ３以上となるように加熱加圧処理する工程と、コア層の耐熱繊維材料の繊維の凹凸が表れる程度の薄膜となるように、表面樹脂層でコア層の表面全体を覆う工程とを備える。熱プレス用クッション材の製造工程は、上記工程で製造された表面材をクッション材本体に貼り付ける工程を備える。
　好ましくは、表面材を加熱加圧処理する工程は、カレンダー処理または熱プレス処理である。
　本発明の熱プレス用クッション材および熱プレス用クッション材の製造方法によれば、表層材からの毛羽の発生や破損を防止することができ、熱盤や鏡面板との密着を防止することができる。
本発明の一実施形態に係る熱プレス用クッション材を示す図解的断面図である。 表層材の図解的断面図である。 本発明の一実施形態に係る熱プレス用クッション材の製造方法を示すフローチャートである。 表面材の製造方法を示すフローチャートである。 比較例２の表層材の図解的断面図である。 比較例３の表層材の図解的断面図である。 試験治具を模式的に示す図である。 通気度と嵩密度との関係を示すグラフである。 クッション材の表面を示す写真であり、（ａ）は本発明例１の写真、（ｂ）は本発明例２の写真、（ｃ）は比較例１の写真、（ｄ）は比較例２の写真、（ｅ）は比較例３の写真、（ｆ）は比較例４の写真、（ｇ）は比較例５の写真である。 本発明例１を示す写真であり、（ａ）は図９（ａ）を拡大した写真、（ｂ）はクッション材の縦断面の写真である。 クッション材の表面部分を含む縦断面の部分写真であり、（ａ）は比較例１の写真、（ｂ）は比較例３の写真である。 衝撃試験を行った後のクッション材の表面を示す写真であり、（ａ）は本発明例１の写真、（ｂ）は本発明例２の写真、（ｃ）は比較例１の写真、（ｄ）は比較例２の写真、（ｅ）は比較例３の写真、（ｆ）は比較例４の写真、（ｇ）は比較例５の写真である。 衝撃試験を行った後の本発明例１の表面部分を含む縦断面の部分写真である。 衝撃試験を行った後の比較例２の表面部分を含む縦断面の部分写真である。 衝撃試験を行った後の比較例３の表面部分を含む縦断面の部分写真である。 熱プレス工程を説明するための図である。
　本発明の実施の形態について、図面を参照しながら詳細に説明する。なお、図中同一または相当部分には同一符号を付し、その説明は繰り返さない。
　以下に、本発明の実施形態を説明する。
　図１は、本発明の一実施形態に係る熱プレス用クッション材１を示している。図１に示すように、熱プレス用クッション材１は、板状形態のクッション材本体２と、クッション材本体２の表面および裏面に設けられる表面材３とを備える。
　クッション材本体２は、たとえば、織布と、この織布に含浸したゴムとからなる繊維－ゴム複合材料の層である。織布を構成する経糸および緯糸のうちの少なくともいずれか一方に、ガラス繊維からなる嵩高糸（バルキーヤーン）を用いる。この繊維－ゴム複合材料の層は、内部に空隙を有する。繊維－ゴム複合材料層の厚みは０．５ｍｍ～５ｍｍ程度であり、シート状である。
　好ましくは、織布の構成繊維に対するゴムの体積比率が５～５０％となるように、織布全体の隙間にゴムを含浸させる。より好ましいゴムの体積比率は５～３５％である。また、繊維－ゴム複合材料層中においては、織布の隙間がゴムで完全には塞がれておらず、ある程度の空隙性を持っている。繊維－ゴム複合材料層の空隙率は、好ましくは２０～６５％、より好ましくは２５～６５％である。
　クッション材本体２を織布－ゴム複合材料の層とする場合、織布に含浸するゴムとしては、好ましくは、フッ素ゴム、ＥＰＭ、ＥＰＤＭ、水素化二トリルゴム、シリコーンゴム、アクリルゴムおよびブチルゴムからなる群から選択された１種または２種以上の材料である。なお、クッション材本体２は、必ずしも織布－ゴム複合材料の層である必要はなく、従来、クッション材本体として用いられている構造とすることができる。すなわち、クッション材本体２は、織布、不織布、ゴムおよび合成樹脂の何れかの単体または２種以上の複合体の、単層構造あるいは同種または異種の層の積層構造とすることができる。
　図２は、表面材３を示している。表面材３は、熱プレス用クッション材１に主として離型性を付与するために設けられるものである。図２に示すように、表面材３は、コア層３１と、コア層３１の表面全体を覆う表面樹脂層３２と、コア層３１の裏面全体を覆う裏面ゴム層３３とを含む。
　コア層３１は、不織構造の耐熱繊維材料から形成される。なお、本発明で不織構造とは、不織布および紙（ペーパー）を含む意味で用いている。具体的には、コア層３１は、有機繊維からなる。有機繊維は、たとえばポリプロピレン、ポリエステル、ポリアミド、ポリビニルアルコール（ビニロン）、芳香族ポリアミド（アラミド）などの材質の繊維を用いることができる。
　コア層３１は、不織構造の耐熱繊維材料を加熱加圧処理することにより形成される。加熱加圧処理は、加熱しながら加圧することであり、具体的には、カレンダー処理または熱プレス処理である。カレンダー処理は、たとえば２００℃以上に加熱した熱ロールと樹脂ロールとの間のニップ部分に不織構造の繊維材料を通過させて、加熱温度、ニップ圧により、処理後の不織構造物の厚み、平滑性などを制御することができる処理である。熱プレス処理は、たとえば２００℃以上に加熱しながら加圧する処理である。
　加熱加圧処理を行うことにより、コア層３１は、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下、嵩密度が０．８ｇ／ｃｍ３以上にとすることができる。コア層３１の通気度が５ｃｍ３・ｃｍ－２・ｓ－１を超え、嵩密度が０．８ｇ／ｃｍ３未満であると、表面に塗布した樹脂がコア層３１の内部に浸透してしまい、コア層３１の表面全体を表面樹脂層３２でカバーできないため、コア層３１の毛羽立ちを防止することができない。また、コア層３１の毛羽は、加熱加圧処理することで、面方向にフラットになる。
　表面樹脂層３２は、コア層３１の繊維の凹凸が表れる程度の薄膜とする。具体的には、表面樹脂層３２の厚みは、０．５μｍ～２００μｍであり、好ましくは１μｍ～５０μｍである。表面樹脂層３２にコア層３１の繊維の凹凸が表れているため、熱プレス用クッション材１が熱盤５１や鏡面板５３に密着しない。表面樹脂層３２が薄すぎると、十分に繊維をカバーできないため、毛羽が発生するおそれがあり、また、表面樹脂層３２に導電性充填剤を混入した場合でも静電気が発生するおそれがある。表面樹脂層３２が厚すぎると、表面樹脂層３２上にコア層３１の繊維の凹凸が表れないため、熱盤５１や鏡面板５３と密着し、作業効率が低下する。表面樹脂層３２は、コア層３１の表面部分に染み込んで、繊維間の空隙に入り込んでいる。
　表面樹脂層３２は、たとえばフッ素樹脂、ポリイミド樹脂、ポリアミド樹脂、ＰＴＦＥおよびＰＥＥＫからなる群から選択された少なくとも１つの樹脂を含む。また、表面樹脂層３２は、導電性充填剤を含むのが好ましい。導電性充填剤は、たとえば導電性酸化亜鉛、導電性酸化チタン、カーボンブラック、カーボン樹脂、カーボンナノチューブなどである。表面樹脂層３２に導電性充填剤を混合することで、静電気の発生を抑制することができる。
　裏面ゴム層３３は、クッション材本体２と表面材３とを接着する役割を果たす。裏面ゴム層３３は、たとえばフッ素ゴムの接着剤である。ゴムはフッ素ゴム、ＥＰＭ、ＥＰＤＭ、水素化ニトリルゴム、シリコーンゴム、アクリルゴムおよびブチルゴムからなる群から選ばれる１種類のゴムまたは２種類以上のゴムの混合物である。裏面ゴム層３３は、コア層３１の裏面部分に染み込んで、繊維間の空隙に入り込んでいる。
　続いて、図３，図４を参照して、本実施の形態の熱プレス用クッション材の製造方法について説明する。
　まず、板状形態のクッション材本体２を準備する（ステップＳ１）。クッション材本体２として繊維－ゴム複合材料層を用いる場合、この工程（ステップＳ１）では、ゴム溶液を織布に含浸させ、乾燥させることで溶液を除去する。織布に含侵したゴムの加硫処理は、この段階で行うことができるが、この段階では行わずに後述するステップＳ３の工程で行うこともできる。
　次に、クッション材本体２の表面および裏面に設けられる表面材３を準備する（ステップＳ２）。この工程（ステップＳ２）では、図２に示す表面材３を製造すべく、コア層３１になる不織構造の耐熱繊維材料と、表面樹脂層３２になる樹脂と、裏面ゴム層３３になる接着剤とを準備する。
　図４に示すように、準備したコア層３１を加熱加圧処理する（ステップＳ２１）。具体的には、コア層３１の耐熱繊維材料の繊維を、カレンダー処理または熱プレス処理する。これにより、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下、嵩密度が０．８ｇ／ｃｍ３以上となる。
　次に、コア層３１の表面全体を表面樹脂層３２で覆う工程を行う（ステップＳ２２）。具体的には、コア層３１の繊維の凹凸が表れる程度の薄膜となるように、コア層３１の表面全体に樹脂を塗布して表面樹脂層３２を形成する。また、コア層３１の裏面全体に裏面ゴム層３３になる接着剤を塗布する。
　最後に、図３に示すように、クッション材本体２の表面および裏面に表面材３を貼り付ける工程を行う（ステップＳ３）。具体的には、表面材３の裏面ゴム層３３側がクッション材本体２と接するようにクッション材本体２と表面材３とを積層し、加熱加圧処理することにより、裏面ゴム層３３の加硫とともにクッション材本体２と表面材３を一体化させる。なお、クッション材本体２に含侵したゴムの加硫は、ステップＳ１の工程で行っていない場合は、クッション材本体２と表面材３とを接着一体化する際の加熱加圧処理で、裏面ゴム層３３の加硫と同時に行うことができる。
　本実施の形態の熱プレス用クッション材およびその製造方法によれば、コア層３１を加熱加圧処理する工程（ステップＳ２１）によって、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下、嵩密度が０．８ｇ／ｃｍ３以上となり、表面樹脂層３２がコア層３１の表面全体を覆う工程（ステップＳ２２）によって、表面材３の毛羽立ちを防止することができる。さらに、表面樹脂層３２がコア層３１の耐熱繊維材料の繊維の凹凸が表れる程度の薄膜となるため、熱プレス用クッション材１が熱盤５１や鏡面板５３に密着せず、作業効率が向上する。
　以下、実施例を挙げて本発明をより詳細に説明するが、本発明はこれらに限定されるものではない。
　表１は、本発明例１，２および比較例１～５について行った実験の評価結果を示す。
　まず、クッション材本体を準備した（ステップＳ１）。クッション材本体は、バルキーヤーンを用いたガラス織布「Ｔ８６０」（ユニチカ株式会社製）を用いた。この織布は、緯糸がＥガラス繊維（繊維径６μｍ）３２００本よりなる番手３０５ｔｅｘの合撚糸を嵩高加工したバルキーヤーンであり、経糸がＥガラス繊維（繊維径６μｍ）１６００本よりなる番手１３５ｔｅｘの嵩高加工していない合撚糸であり、緯糸と経糸とを２重織りに製織したものである。この織布は、重量が８５０ｇ／ｍ２、厚みが１．０２ｍｍ、空隙率が６７％である。一方、酢酸ブチルとメチルケトンとを質量比１：１の割合で混合した溶剤に、未加硫フッ素ゴムを所定の濃度で溶解してなる未加硫フッ素ゴム溶液を用意した。ガラス織布を各未加硫フッ素ゴム溶液に浸漬した後、それぞれ２本のロールで絞った。次いで、未加硫フッ素ゴム溶液が浸透した各ガラス織布を十分に乾燥させて溶剤を除去した。このようにしてクッション材本体を２枚作成した。
　次に、表面材を準備した（ステップＳ２）。具体的には、コア層として製造過程でカレンダー処理が施されたアラミド紙「ノーメックスペーパー　タイプ４１０（５ｍｉｌ）」（デュポン帝人アドバンスドペーパー社製）を用いた。表面樹脂層として導電性酸化チタンを混入したポリイミド樹脂ワニスを、繊維の凹凸が表れる程度の薄膜としてコア層の表面に塗布した。これにより、ポリイミド樹脂からなる表面樹脂層を形成した。表面樹脂層の厚さは１～１０μｍであった。次いで、コア層の裏面側に未加硫フッ素ゴム溶液を塗布し、乾燥させて接着層としての裏面ゴム層を形成した。このようにして、表面材を２つ作成した。上述した２層のクッション材本体を、接着材を間に挟んで積層し、さらにその表面および裏面に、表面材を、裏面ゴム層がクッション材本体に当接するように積層した。この積層物に対して熱プレスを行い、クッション材本体に含侵した未加硫フッ素ゴム及び表面材の裏面に塗布した未加硫フッ素ゴムを加硫し、全体を接着一体化した。これを本発明例１とした。
　以下に示す本発明例２および比較例１～５のクッション材の製造方法は、基本的に本発明例１と同様であったが、表面材の構成が下記表１に示すように異なっていた。
　表面材のコア層として熱プレス処理を行ったＰＰＳ（ポリフェニレンサルファイド）紙「ＰＰＳペーパー」（廣瀬製紙株式会社製）を用いたものを本発明例２とした。
　表面樹脂層を設けないものを比較例１とした。
　表面材のコア層として熱プレス処理を行っていないＰＰＳ（ポリフェニレンサルファイド）紙「ＰＰＳペーパー」（廣瀬製紙株式会社製）を用いたものを比較例２とした。比較例２の表層材３Ａの図解的断面図を図５に示す。比較例２の表面材３Ａは、コア層３１ａに熱プレス処理を行っていないため、本発明例１と比較して通気度が高く、嵩密度低い。そのため、コア層３１ａの内部まで表面樹脂層３２ａとなる樹脂が染み込み、表面樹脂層３２ａは、コア層３１ａの表面を完全にカバーできず、毛羽立ちがみられる。
　表面材のコア層としてアラミド繊維（帝人株式会社製「コーネックス」）のニードルパンチ不織布に熱プレス処理を行ったものを比較例３とした。比較例３の表層材３Ｂの図解的断面図を図６に示す。比較例３の表面材３Ｂは、コア層３１ｂに熱プレス処理を行っているものの、本発明例１と比較して通気度が高く、嵩密度低かった。そのため、コア層３１ｂの内部にも表面樹脂層３２ｂとなる樹脂が染み込み、表面樹脂層３２ｂは、コア層３１ｂの表面を完全にカバーできず、毛羽立ちがみられる。
　表面材のコア層としてガラスクロスを用いたものを比較例４とした。なお、比較例４は、特開２００４－３４４９６２号公報（特許文献２）に詳細に開示されている。
　表面樹脂層の厚さを３００μｍとしたものを比較例５とした。比較例５の表面樹脂層は、コア層の繊維の凹凸を埋め尽くしていた。
　（評価方法）
　本発明例１，２、比較例１～５について、表面状態の確認、プレス圧縮試験および衝撃試験を行った。
　表面状態の確認：目視にて表面状態を確認した。
　プレス圧縮試験：ＳＵＳプレートからなる鏡面板とクッション材とを重ね、プレス機にて厚み方向に４ＭＰａの圧力で加圧した状態で、２３０℃で６０分間加熱し、次いで１０分間冷却し、その後プレスを解除した。プレスを解放したときの鏡面板との密着状態を確認した。
　衝撃試験：図７に示すように、加圧試験機の治具４１にＳＵＳで作成した直径１０ｍｍ、高さ２ｍｍの球状端子４２を取り付けたハンマ４０を使用した。クッション材の外縁端面に速度３００ｍｍ／ｍｉｎの速さでハンマ４０を当て、荷重５ｋｇｆの衝撃を加えるテストを１０回繰り返した。
　本発明例１，２、比較例１～５のクッション材について、上述の条件で、表面状態の確認し、プレス圧縮試験および耐衝撃試験行った。その結果を表１に示す。
　表１の表面状態において、「〇」は凹凸が確認できたこと、または、毛羽立ちが確認できなかったことを示しており、「×」は凹凸が確認できなかったこと、または、毛羽立ちが確認できたことを示している。また、表１のプレス圧縮試験において、「〇」は静電気が発生しなかったこと、または、鏡面板と密着しなかったことを示しており、「×」は静電気が発生したこと、または、鏡面板と密着したことを示している。さらに、表１の衝撃試験において、「〇」は毛羽立ちや破損が発生しなかったことを示しており、「×」は毛羽立ちや破損が発生したことを示している。
Figure JPOXMLDOC01-appb-T000001
　図８は、本発明例１，２および比較例１～３，５で用いたコア層の通気度および嵩密度を示すグラフである。図８のＡは、本発明例１、比較例１および比較例５で用いたカレンダー処理を行ったアラミド紙であり、通気度が０ｃｍ３・ｃｍ－２・ｓ－１、嵩密度が０．９ｇ／ｃｍ３であった。図８のＢは、本発明例２で用いた熱プレス処理を行ったＰＰＳ紙であり、通気度が４．８ｃｍ３・ｃｍ－２・ｓ－１、嵩密度が０．８８ｇ／ｃｍ３であった。図８のＣは、比較例２で用いた熱プレス処理を行っていないＰＰＳ紙であり、通気度が２９．５ｃｍ３・ｃｍ－２・ｓ－１、嵩密度が０．４３ｇ／ｃｍ３であった。図８のＤは、比較例３で用いた熱プレス処理を行ったアラミド不織布であり、通気度が２．８ｃｍ３・ｃｍ－２・ｓ－１、嵩密度が０．６８ｇ／ｃｍ３であった。
　（評価結果）
　図９～図１１は、本発明例１，２および比較例１～５の表面状態を示す写真である。まず、表面状態について確認すると、本発明例１（図９（ａ）、図１０（ａ）、図１０（ｂ））は、表面に凹凸が存在し、毛羽立ちの発生は見られなかった。本発明例２（図９（ｂ））も同様であった。
　一方で、比較例１（図９（ｃ）、図１１（ａ））は、表面に凹凸が存在するものの、毛羽立ちの発生が見られた。これは、表面樹脂層を設けていないためである。
　比較例２（図５、図９（ｄ））は、表面に凹凸が存在するものの、毛羽立ちの発生が見られた。これは、比較例２は、熱プレス処理を行っていないため、本発明例２と比較して通気度が高く、嵩密度が低い。そのため、比較例２では、コア層の表面を表面樹脂層で十分に被覆できず、コア層の毛羽立ちが発生してしまうからである。
　比較例３（図６、図９（ｅ）、図１１（ｂ））は、表面に凹凸が存在するものの、毛羽立ちの発生が見られた。これは、比較例３は、熱プレス処理を行っているものの、コア層の通気度が高く、嵩密度が低い。そのため、比較例３では、コア層の表面を表面樹脂層で十分に被覆できなかったためである。
　比較例４（図９（ｆ））は、表面に凹凸が存在し、毛羽立ちの発生も見られなかった。比較例５（図９（ｇ））は、表面に凹凸が存在せず、毛羽立ちの発生が見られなかった。これは、表面樹脂層の塗布をコア層の繊維の凹凸を埋め尽くすように多量にしたからである。
　次に、プレス圧縮試験について確認すると、表１に示すように、本発明例１，２および比較例２，３，４は、静電気が発生せず、鏡面板に対して密着しなかった。一方で、比較例１は、静電気が発生し、プレス機に対して密着した。比較例１は、表面樹脂層が設けられていなかったからである。比較例５は、静電気は発生しなかったが鏡面板に密着した。これは、表面樹脂層が厚く、コア層の繊維の凹凸を埋め尽くしていたためである。
　図１２～図１５は、本発明例１，２および比較例１～５に衝撃試験を行った後のクッション材の表面を示す写真である。
　衝撃試験では、本発明の本発明例１（図１２（ａ））および本発明例２（図１２（ｂ））は、全く問題はなかった。すなわち、表面からの毛羽立ちや破損は見られなかった。一方で、比較例１～４（図１２（ｃ）～（ｆ））は、繊維のほつれや繊維毛羽の脱落等が見られた。特に、コア層を表面樹脂層で覆っていない比較例１、および、コア層の表面全体を表面樹脂層で覆うことができていない比較例２（図１４）および比較例３（図１５）は、衝撃を加えると、表面から破損が見られた。コア層がガラスクロスである比較例４（図１２（ｆ））は、衝撃により表面材の破損が見られた。
　衝撃試験の結果より、本発明例１，２および比較例５のクッション材は、比較例１～４のクッション材よりも衝撃に対して耐久性を有することが明らかとなった。
　以上の結果より、本発明例１，２は、毛羽立ちが防止でき、熱盤や鏡面板との密着も起こらず、衝撃にも強いということがわかる。
　今回開示された実施の形態は全ての点で例示であって、制限的なものではないと考えられるべきである。本発明の範囲は上記した説明ではなくて特許請求の範囲によって示され、特許請求の範囲と均等の意味および範囲内での全ての変更が含まれることが意図される。
　１　熱プレス用クッション材、２　クッション材本体、３，３Ａ，３Ｂ　表面材、３１，３１ａ，３１ｂ　コア層、３２，３２ａ，３２ｂ　表面樹脂層、３３　裏面ゴム層、４０　ハンマ、４１　加圧試験機の治具、４２　球状端子、５１　熱盤、５２　積層板、５３　鏡面板。

Claims (8)

  1. 　板状形態のクッション材本体と、
    　前記クッション材本体の表面および裏面に設けられる表面材とを備え、
    　前記表面材は、不織構造の耐熱繊維材料から形成されるコア層と、前記コア層の表面全体を覆う表面樹脂層とを含み、
    　前記コア層は、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下であり、嵩密度が０．８ｇ／ｃｍ３以上である、熱プレス用クッション材。
  2. 　前記コア層は、有機繊維からなる、請求項１に記載の熱プレス用クッション材。
  3. 　前記表面樹脂層は、前記耐熱繊維材料の繊維の凹凸が表れる程度の薄膜とされている、請求項１または２に記載の熱プレス用クッション材。
  4. 　前記表面樹脂層は、前記コア層の裏面全体を覆う裏面ゴム層をさらに含み、
    　前記クッション材本体と前記表面材は、前記裏面ゴム層を介して接着されている、請求項１～３のいずれかに記載の熱プレス用クッション材。
  5. 　前記表面樹脂層は、フッ素樹脂、ポリイミド樹脂、ポリアミド樹脂、ＰＴＦＥおよびＰＥＥＫからなる群から選択された少なくとも１つの樹脂を含む、請求項１～４のいずれかに記載の熱プレス用クッション材。
  6. 　前記表面樹脂層には、導電性充填剤を含む、請求項１～５のいずれかに記載の熱プレス用クッション材。
  7. 　板状形態のクッション材本体と、
    　前記クッション材本体の表面および裏面に設けられた表面材とを備えた熱プレス用クッション材の製造方法において、
    　前記表面材の製造工程は、不織構造の耐熱繊維材料から形成されるコア層を、通気度が５ｃｍ３・ｃｍ－２・ｓ－１以下、嵩密度が０．８ｇ／ｃｍ３以上となるように加熱加圧処理する工程と、
    　前記コア層の前記耐熱繊維材料の繊維の凹凸が表れる程度の薄膜となるように、表面樹脂層で前記コア層の表面全体を覆う工程とを備え、
    　熱プレス用クッション材の製造工程は、前記表面材を前記クッション材本体に貼り付ける工程を備える、熱プレス用クッション材の製造方法。
  8. 　前記表面材を加熱加圧処理する工程は、カレンダー処理または熱プレス処理である、請求項７に記載の熱プレス用クッション材の製造方法。
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US20210402725A1 (en) 2021-12-30
US11628637B2 (en) 2023-04-18
TW202021770A (zh) 2020-06-16
KR20210070268A (ko) 2021-06-14
CN112752641A (zh) 2021-05-04
EP3865274A1 (en) 2021-08-18
EP3865274A4 (en) 2022-06-29
JP2020059180A (ja) 2020-04-16

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