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JP5754530B2 - ガラス・樹脂複合体の製造方法 - Google Patents
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JP5754530B2 - ガラス・樹脂複合体の製造方法 - Google Patents

ガラス・樹脂複合体の製造方法 Download PDF

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Publication number
JP5754530B2
JP5754530B2 JP2014064403A JP2014064403A JP5754530B2 JP 5754530 B2 JP5754530 B2 JP 5754530B2 JP 2014064403 A JP2014064403 A JP 2014064403A JP 2014064403 A JP2014064403 A JP 2014064403A JP 5754530 B2 JP5754530 B2 JP 5754530B2
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JP
Japan
Prior art keywords
glass
resin
film
resin composite
glass ribbon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP2014064403A
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English (en)
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JP2014166952A (ja
Inventor
樋口　俊彦
俊彦 樋口
基 神庭
基 神庭
杉本　直樹
直樹 杉本
近藤　聡
聡 近藤
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AGC Inc
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Asahi Glass Co Ltd
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Publication date
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Priority to JP2014064403A priority Critical patent/JP5754530B2/ja
Publication of JP2014166952A publication Critical patent/JP2014166952A/ja
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Publication of JP5754530B2 publication Critical patent/JP5754530B2/ja
Expired - Fee Related legal-status Critical Current
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/02—Forming molten glass coated with coloured layers; Forming molten glass of different compositions or layers; Forming molten glass comprising reinforcements or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73117—Tg, i.e. glass transition temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/746—Joining plastics material to non-plastics material to inorganic materials not provided for in groups B29C66/742 - B29C66/744
    • B29C66/7465—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
    • B29C66/91643—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile
    • B29C66/91645—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile by steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91933—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined higher than said fusion temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91935—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined lower than said fusion temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • B29C66/91943—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
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    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B29B15/125—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by dipping
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B29B15/127—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by spraying
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Description

本発明は、ガラスの持つ特性を有しつつ、ハンドリング性、搬送性及び加工性に優れたガラス・樹脂複合体の製造方法に関するものである。
近年、ディスプレイ用基板や、センサー・素子カバーなどの用途において使用されるガラス板の薄肉化が進んでいる。しかしながら、ガラス板の板厚が薄くなる程、ガラスが本来有する「割れやすい」という欠点が顕在化し、搬送時や加工時のハンドリング等が困難となる。
この問題を解決するために、ガラスに樹脂フィルムを積層する方法が提案されている（例えば、特許文献１〜４参照）。しかしながら、樹脂フィルムを積層する前のガラスの切断工程や搬送時に生じるガラス表面への物理的損傷により、十分な機械的強度が確保されているとはいえないという問題があった。
特開２００３−３３７５４９号公報 特表２００２−５３４３０５号公報 特開２００１−１１３６３１号公報 特開２００１−０９７７３３号公報
本発明は前記の問題点に鑑みてなされたものであって、ガラスが極めて薄いものであっても十分な搬送性、ハンドリング性及び加工性を備えたガラス・樹脂複合体の製造方法を提供することを目的とする。
本発明の一態様によれば、
溶融ガラスを成形してガラスリボンにした後、該ガラスリボンの少なくとも１面に樹脂層を形成する工程を有し、
該工程では、両側に剥離可能な被膜が付いた光硬化型樹脂フィルムを、その片側の被膜を剥がして前記ガラスリボンに圧着し、反対側の被膜越しに紫外線を照射して前記光硬化型樹脂フィルムを硬化せしめることにより前記樹脂層を形成することを特徴とするガラス・樹脂複合体の製造方法を提供する。
成形直後のガラスリボンに樹脂層を形成する本発明の製造方法によれば、成形されたガラスリボンが切断工程や搬送工程を経る前に、ガラス表面に樹脂層が形成されるため、ガラス表面への物理的損傷の可能性が低く、高い機械的強度を有するガラス・樹脂複合体を得ることができる。樹脂層を形成する工程によっては、溶融ガラス表面が他の部材と非接触の状態のまま、その表面に樹脂層を形成することも可能であり、原理上はガラス表面への物理的損傷を著しく低下させることもできる。
参考例１によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例２によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例３によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例４によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例５によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例６によるガラス・樹脂複合体の製造方法を示す概略模式図である。 参考例９によるガラス・樹脂複合体の製造方法を示す概略模式図である。 実施例によるガラス・樹脂複合体の製造方法を示す概略模式図である。
以下、ガラス・樹脂複合体の製造方法について説明する。
ガラス・樹脂複合体の製造方法の第１の態様は、連続的に成形されるガラスリボンの表面上に、樹脂フィルムを形成する方法である。前記ガラスリボンはソーダライムガラス、無アルカリガラスなど、種々のものが使用可能であるが、強度や化学的耐久性の点で、無アルカリガラスが好ましい。溶融ガラスをガラスリボンとして成形するには、フロート法、フュージョン法、ダウンドロー法、スロットダウン法又はリドロー法を選択しうる。
ガラスリボンは、１０μｍから３００μｍの厚さを有することが好ましく、特に５０μｍから１５０μｍの厚さを有することが好ましい。ガラスリボンの厚さが１０μｍよりも薄い場合には樹脂層の形成が困難であり、またガラスリボンの厚さが３００μｍよりも厚い場合には、ガラス単体での強度が確保されるため、樹脂層を形成する必要性が少なく、またガラス自体の可撓性が失われるため、ロール状のガラス・樹脂複合体を得ることが困難となる。
前記樹脂層に用いられる樹脂は、ガラスに対して強靭性を付与しうるものであればどのような種類のものでも使用できるが、ガラス・樹脂複合体の用途によって要求される耐熱性や耐薬品性等に応じて選択することが好ましい。
前記樹脂としては、例えば、ポリエステル樹脂、ポリカーボネート樹脂、ポリエーテルスルホン樹脂、ポリオレフィン樹脂、ポリビニルアルコール樹脂、シリコーン樹脂、ポリアミド樹脂、アクリル樹脂、ポリスチレン樹脂、トリアセチルセルロース樹脂、ポリイミド樹脂、ポリ塩化ビニル樹脂、フッ素樹脂等が挙げられる。また、これらの共重合体やフィラー等の添加剤を含有したものでもよい。
ガラス・樹脂複合体の構成としては、ガラス／樹脂層の二層構成とすることも、樹脂層／ガラス／樹脂層の三層構成として両側表面を樹脂層とすることもできる。ガラス・樹脂複合体をディスプレイ基板として使用する場合には、デバイス側表面には高い平坦性が求められるため、ガラス／樹脂層の二層構成とすることが好ましい。
樹脂層を形成する方法としては、次の方法が好適である。
（１）あらかじめ成形したフィルム状の樹脂を、熱溶融性樹脂を含有する熱溶融層を介してガラスリボンと積層する方法。
（２）熱溶融性樹脂を含有するフィルム状の樹脂を、直接ガラスリボンと積層する方法。
（３）熱溶融樹脂を直接又は接着層若しくは粘着層を介してガラスリボンに塗布し、樹脂層を形成する方法。
（４）硬化性樹脂を直接又は接着層若しくは粘着層を介してガラスリボンに塗布した後、硬化せしめる方法。
なお、前記熱溶融性樹脂が融点を有する場合は該融点をＴｍとし、前記熱溶融性樹脂が融点を有さない場合は熱溶融性樹脂のガラス転移点をＴｇとするとき、前記（１）の方法の場合は、成形後のガラスリボンの温度がＴｍ−５０℃〜Ｔｍ＋２０℃、（熱溶融性樹脂が融点を有する場合）、または、Ｔｇ〜Ｔｇ＋１００℃（熱溶融性樹脂が融点を有さない場合）の範囲にある時点で、熱溶融層を介して樹脂フィルムをガラスリボンに密着させることが好ましい。また、前記（２）の方法の場合、は成形後のガラスリボンの温度がＴｍ−５０℃〜Ｔｍ＋２０℃（熱溶融性樹脂が融点を有する場合）または、Ｔｇ〜Ｔｇ＋１００℃（熱溶融性樹脂が融点を有さない場合）の範囲にある時点で、熱溶融層を介して樹脂フィルムをガラスリボンに密着させることが好ましい。なぜならば、ガラスリボンの温度がＴｍ−５０℃またはＴｇ未満であると樹脂フィルムと密着せず、ガラスリボンの温度がＴｍ＋２０℃またはＴｇ＋１００℃を超えると熱溶融槽が界面から流出しガラスリボンと樹脂フィルムとを密着させることができないからである。上記において、成形後のガラスリボンの温度は、特にＴｍ−３０℃〜Ｔｍ＋５℃、（熱溶融性樹脂が融点を有する場合）、または、Ｔｇ〜Ｔｇ＋８０℃（熱溶融性樹脂が融点を有さない場合）の範囲にあることが好ましい。
さらに、樹脂層を形成する方法としては、上記の樹脂層形成方法の他に次の方法も好ましく使用できる。
（５）実質的に硬化性樹脂からなるフィルムを、接着剤層若しくは粘着剤層を介してガラスリボンに積層する方法。
（６）部分的に硬化した硬化性樹脂のシート状物をガラスリボンに圧着し、次いで前記硬化性樹脂を硬化せしめる方法。
熱溶融樹脂や硬化性樹脂をガラスリボン表面に塗布する方法としては、スプレーコート法、ダイコート法、フローコート法、ディップコート法等を採用できる。硬化性樹脂の硬化方法としては、加熱硬化、紫外線硬化、湿熱硬化等を採用できる。
樹脂層は、ガラスリボンを成形後、徐冷工程を経て常温付近に冷却された後に形成してもよいし、徐冷工程前又は徐冷工程中でガラスリボンが加熱状態にある段階で形成してもよい。徐冷工程前又は徐冷工程中に樹脂層を形成する場合には、ガラスリボンの有する熱エネルギーをフィルム状樹脂表面の溶融や粘接着力の向上に利用することができる。
また、第１の態様によるガラス・樹脂複合体の製造方法によれば、ガラスリボン表面に樹脂層を形成した後、巻き取り装置を用いてロール状に巻かれたガラス・樹脂複合体を得ることができる。このようなロール状に巻かれたガラス・樹脂複合体は、いわゆるロール・トゥ・ロール方式によるディスプレイデバイスの製造工程に適用できる。ガラス・樹脂複合体をロール状に巻き取るにあたっては、必要に応じて紙（合紙）や樹脂フィルム等を、複合体と複合体との間に介在させることもできる。
例えば、第１の態様によるガラス・樹脂複合体の製造方法により得たロール状物を解放しながら連続的にガラス・樹脂複合体を供給しつつ、フォトリソグラフィ工程によりガラス上に薄膜トランジスタ（ＴＦＴ）を形成した後、所望の長さにガラス・樹脂複合体を切断し、次いで樹脂を剥離・除去することによりＴＦＴ付きガラス基板を得ることができる。
さらに、第２の態様によるガラス・樹脂複合体の製造方法は、連続的に供給された樹脂フィルムの一部又は全面に接着剤又は粘着剤を塗布し、次いで前記樹脂フィルムにおける接着剤又は粘着剤の塗布面の上に、所定寸法に切断されたガラス基板を貼付する方法である。
また、第３の態様によるガラス・樹脂複合体の製造方法は、所定寸法に切断され、一方の表面に接着剤又は粘着剤が塗布されたガラス基板を、連続的に供給された樹脂フィルムに貼付する方法である。この場合、前記ガラス基板の接着剤又は粘着剤の塗布面が樹脂フィルムに対向する面となる。
第１の態様は連続的な樹脂フィルムと連続的なガラスリボンの複合体の製造方法であるのに対し、第２及び第３の態様は連続的な樹脂フィルムと不連続なガラス基板の複合体の製造方法であるという点で異なる。
第２及び第３の態様における樹脂フィルムは、第１の態様と同様に、ポリエステル樹脂、ポリカーボネート樹脂、ポリエーテルスルホン樹脂、ポリオレフィン樹脂、ポリビニルアルコール樹脂、シリコーン樹脂、ポリアミド樹脂、アクリル樹脂、ポリスチレン樹脂、トリアセチルセルロース樹脂、ポリイミド樹脂、ポリ塩化ビニル樹脂、若しくはフッ素樹脂、又はこれらの共重合体やフィラー等の添加剤を含有したものを用いることができる。
第２の態様の製造方法において、接着剤又は粘着剤を樹脂フィルムに塗布するにあたっては、ダイコーターやロールコーターを用いることができる。また、第３の態様の製造方法において、接着剤又は粘着剤をガラス基板に塗布するにあたっては、ダイコーター、ロールコーター、スクリーン印刷機等を用いることができる。
次いで、前記の方法によって樹脂フィルム又はガラス基板に塗布された接着剤又は粘着剤を、熱や紫外線等を用いた方法により適宜硬化せしめ、樹脂フィルム及びガラス基板を強固に固着する。
このような製造方法によって得られたガラス・樹脂複合体は、第１の態様に係る製造方法の場合と同様に、樹脂フィルム上にガラス基板を貼付した後、巻き取り装置を用いてロール状に巻くことができる。
第２及び第３の態様の製造方法により得られたガラス・樹脂複合体のロール状物は、第１の態様の場合と同様にロール・トゥ・ロール方式によるディスプレイデバイスの製造工程に適用しうる。
ここで、ガラス上に薄膜トランジスタ（ＴＦＴ）を形成した後、所望の長さにガラス・樹脂複合体を切断するにあたっては、隣接するガラス基板とガラス基板の間（ガラス基板が貼付されておらず樹脂フィルムのみの箇所）を切断することが好ましい。なぜならば、ガラスと樹脂フィルムの両者を同時に切断する場合と比較して、樹脂フィルムのみを切断する方が容易なためである。以下、図を用いて本発明の実施例、参考例、及び比較例を説明する。ただし、本発明は後述の実施例の態様に限定されるものではない。
（参考例１） 本参考例について図１を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、徐冷部２にて１２０℃付近まで徐冷する。その後、ウレタン系ホットメルト接着剤層（厚さ３０μｍ、融点１２０℃； 図示せず）を介して、厚さ５０μｍの樹脂フィルム（ポリエチレンテレフタレートフィルム）３をガラスリボン１の両面に１２０℃に調節されたニップローラー４を用いて積層することにより、ガラス・樹脂複合体５を得る。
（比較例１） 既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、一旦室温に徐冷する。その後、前記ガラスリボンの片面に、厚さ５０μｍの熱可塑性ポリイミド樹脂フィルム（三井化学社製 オーラムフィルム、ガラス転移点：２５０℃）を２３０℃（樹脂ローラーの設定最高温度）にて熱融着を試みる。
（比較例２） 既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、１５０℃付近まで徐冷し、ウレタン系ホットメルト接着剤層（厚さ３０μｍ、融点１２０℃）を介して、厚さ５０μｍのポリエチレンテレフタレートフィルムをガラスリボンの両面に１５０℃に調整されたニップローラーを用いて積層する。
（参考例２） 本参考例について図２を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、常温付近（約２０℃、以下同じ。）まで徐冷する。そして、アクリル系接着剤層（図示せず）を介して、厚さ５０μｍの樹脂フィルム（ポリエチレンテレフタレートフィルム）３をガラスリボン１の片面にニップローラー４を用いて積層することにより、ガラス・樹脂複合体５を得る。
（参考例３） 本参考例について図３を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、徐冷部２の途中の、ガラスリボン１の表面温度が３００℃にある段階で、厚さ５０μｍの熱可塑性ポリイミド樹脂フィルム３（三井化学社製 オーラムフィルム、ガラス転移点＝２５０℃）をガラスリボン１の片面にニップローラー４を用いて熱融着することにより、ガラス・樹脂複合体を得る。
（参考例４） 本参考例について図４を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、常温付近まで徐冷する。そして、ダイコーター６を用いて、溶融した熱可塑性アクリル樹脂（図示せず）を厚さ５０μｍとなるようにガラスリボン１の片面に塗布する。その後、前記熱可塑性アクリル樹脂を冷却固化せしめ、ガラス・樹脂複合体５を得る。
（参考例５） 本参考例について図５を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、常温付近まで徐冷する。そして、ダイコーター６を用いて、熱硬化性シリコーン樹脂（図示せず）を厚さ２０μｍとなるようにガラスリボン１の片面に塗布する。その後、オーブン７によって前記熱硬化性シリコーン樹脂を１００℃にて１０分間加熱硬化せしめ、ガラス・樹脂複合体５を得る。
（参考例６） 本参考例について図６を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、徐冷部２を通過させて常温付近まで徐冷する。そして、ディップコーター８を用いて、硬化性樹脂（アクリル系紫外線硬化性樹脂）９を厚さ５０μｍとなるようにガラスリボン１の両面に付与する。その後、紫外線照射装置１０を用いて紫外線を照射することにより前記アクリル系ＵＶ硬化性樹脂を硬化せしめ、ガラス・樹脂複合体５を得る。
（参考例７） 既知のフロート法により線膨張係数３８×１０−７／℃のガラスフィルム（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、常温付近まで徐冷し、その後前記ガラスフィルムを所定の寸法（７３０×９２０ｍｍ）に切断し、平板状のガラス基板を得る。このガラス基板を、連続的に供給される厚さ５０μｍのポリエチレンテレフタレートフィルムに貼付することにより、ガラス・樹脂複合体を得る。ガラスと樹脂フィルムを貼付するにあたっては、ポリエチレンテレフタレートフィルムの表面にアクリル系接着剤層を塗布する。
（参考例８） 既知のフロート法により線膨張係数３８×１０−７／℃のガラスフィルム（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、常温付近まで徐冷し、その後前記ガラスフィルムを所定の寸法（７３０×９２０ｍｍ）に切断し、平板状のガラス基板を得る。このガラス基板を、連続的に供給される厚さ５０μｍのポリエチレンテレフタレートフィルムに貼付することにより、ガラス・樹脂複合体を得る。ガラスと樹脂フィルムを貼付するにあたっては、ガラス基板の表面にアクリル系接着剤層を塗布する。
（参考例９） 本参考例について図７を用いて説明する。ポリアミック酸のＮ−メチルピロリドン溶液（５０質量％）を、連続搬送されるステンレス鋼シート（表面は鏡面加工、厚さ３００μｍ）上に厚さ８０μｍでダイコートし、次いで２３０℃に設定された連続オーブン内を１０分間通過させ、前記ポリアミック酸のＮ−メチルピロリドン溶液の濃度を８５質量％まで向上させ、当該ポリアミック酸のグリーンシート（部分的に硬化した、硬化性樹脂のシート状物）をステンレス鋼シート上から剥がし、厚さ３０μｍのポリエチレンテレフタレートフィルムで挟み込む。こうして厚さ５０μｍのポリエチレンテレフタレート（ＰＥＴ）被膜付きポリアミック酸グリーンシートを得る。
次に、既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、徐冷部２を通過させて１５０℃付近まで徐冷する。
そして、前記ＰＥＴ被膜付きポリアミック酸グリーンシート１１の片面（ガラスリボン１に接する面）のＰＥＴ被膜を剥がしながら、１５０℃に調整されたニップローラー４を用いて前記ガラスリボン１の両面にＰＥＴ被膜付きポリアミック酸グリーンシート１１を圧着する。次いで、前記ＰＥＴ被膜付きポリアミック酸グリーンシート１１の外側のＰＥＴ被膜１２を剥がしながら３００℃に設定された連続オーブン７内を６０分かけて通過させ、イミド化反応を完結せしめ、ガラス・樹脂複合体５を得る。
（実施例） 本実施例について図８を用いて説明する。既知のフュージョン法により線膨張係数３８×１０−７／℃のガラスリボン１（旭硝子製ＡＮ１００）を１００μｍの厚さに成形し、徐冷部２を通過させて５０℃付近まで徐冷する。その後、ＰＥＴ被膜付き光硬化型樹脂フィルム１３（デュポンＭＲＣドライフィルム社製光硬化型ドライフィルム ＦＸ１００；厚さ５０μｍ）を、片面（内側）のＰＥＴ被膜を剥がしながら前記ガラスリボン１の両面にニップローラー４を用いて圧着する。そして、紫外線照射装置１０を用いて最外層のＰＥＴ被膜越しに紫外線を照射し、前記光硬化型樹脂フィルムの硬化反応を完結せしめ、ガラス・樹脂複合体５を得る。
上記の実施例によって得られるガラス・樹脂複合体は可撓性に優れており、ロール状に巻き取ることができる。そのため、ガラスが極めて薄いものであっても、搬送性、ハンドリング性及び加工性に優れるものである。一方、比較例１の方法では、熱可塑性ポリイミド樹脂フィルムが十分に軟化せずガラス・樹脂複合体を得ることができない。また、比較例２の方法では、ウレタン系ホットメルト接着剤が接着界面から流出し、ガラス・樹脂複合体を得ることができない。
本発明の製造方法によって得られたガラス・樹脂複合体は、ディスプレイ用基板やセンサー・素子カバーに使用することができる。
なお、２００７年１０月３０日に出願された日本特許出願２００７−２８２２９３号の明細書、特許請求の範囲、図面及び要約書の全内容をここに引用し、本発明の明細書の開示として、取り入れるものである。
１ ガラスリボン
２ 徐冷部
３ 樹脂フィルム
４ ニップローラー
５ ガラス・樹脂複合体
６ ダイコーター
７ オーブン
８ ディップコーター
９ 硬化性樹脂
１０ 紫外線照射装置
１１ ＰＥＴ被膜付きポリアミック酸グリーンシート
１２ ＰＥＴ被膜
１３ ＰＥＴ被膜付き光硬化型樹脂フィルム

Claims (4)

  1. 溶融ガラスを成形してガラスリボンにした後、該ガラスリボンの少なくとも１面に樹脂層を形成する工程を有し、
    該工程では、両側に剥離可能な被膜が付いた光硬化型樹脂フィルムを、その片側の被膜を剥がして前記ガラスリボンに圧着し、反対側の被膜越しに紫外線を照射して前記光硬化型樹脂フィルムを硬化せしめることにより前記樹脂層を形成することを特徴とするガラス・樹脂複合体の製造方法。
  2. 前記成形の方法が、フロート法、フュージョン法、ダウンドロー法、スロットダウン法又はリドロー法であることを特徴とする請求項１に記載のガラス・樹脂複合体の製造方法。
  3. 前記ガラスリボンの厚さが１０〜３００μｍであることを特徴とする請求項１又は２に記載のガラス・樹脂複合体の製造方法。
  4. 請求項１〜３のいずれか１項に記載の方法によりガラス・樹脂複合体を得た後、該ガラス・樹脂複合体をロール状に巻き取ることを特徴とするガラス・樹脂複合体の製造方法。
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