METHOD OF MANUFACTURING TRANSLUCENT RIGID SUBSTRATE LAMINATE

• US 20130081752A1
• Filed: 06/01/2011
• Published: 04/04/2013
• Est. Priority Date: 06/15/2010
• Status: Active Grant

• Current Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Original Assignee: Denki Kagaku Kogyo Kabushiki Kaisha (TDK Corporation)
• Inventors: Kurimura, Hiroyuki, Ichikawa, Isamu, Nakajima, Gosuke, Miyazaki, Hayato, Hayashi, Yasunori, Tanaka, Kenji, Kanai, Tomoyuki
• Granted Patent: US 9,061,485 B2
• Time in Patent Office: Days
• US Class Current: 156/64
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10706 being photo-polymerized
• CPC Class Codes: B32B 17/10816 by pressing
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only

Abstract

Provided is a method for manufacturing a translucent rigid substrate laminate which can improve a thickness precision while decreasing the risk of fractures. In the method for manufacturing a translucent rigid substrate laminate according to the present invention, translucent rigid substrates are placed opposite to each other such that bonding surfaces thereof are parallel to each other, both rigid substrates are brought toward each other while being kept parallel, the both rigid substrates are preliminarily bonded using a photo-curable fixing agent, the bonded translucent rigid substrates are roll-pressed, and the fixing agent is then cured.

Claims

1. A method for manufacturing a translucent rigid substrate laminate, comprising:

1) a process of preparing a first translucent rigid substrate,

2) a process of preparing a second translucent rigid substrate,

3) a process of applying a photo-curable fixing agent to a first surface of the first translucent rigid substrate and/or a first surface of the second translucent rigid substrate,

4) a process of placing the first surface of the first translucent rigid substrate and the first surface of the second translucent rigid substrate to face each other such that both surfaces are parallel to each other,

5) a process of applying pressure to the first surface of the first translucent rigid substrate and the first surface of the second translucent rigid substrate to bond the both translucent rigid substrates while being kept parallel, to preliminarily adhere the both translucent rigid substrates to each other,

6) a process of roll-pressing the preliminarily adhered translucent rigid substrates,

7) after process

     6) a process of irradiating light for curing the entire fixing agent interposed and spreading between the both translucent rigid substrates to form the translucent rigid substrate laminate, and

8) a process of repeating a series of processes

     1) to

     7) at least one time by regarding the translucent rigid substrate laminate as the first translucent rigid substrate to form the translucent rigid substrate laminate where at least three translucent rigid substrates are bonded.

2. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein,

5′

) a process of forming a provisionally fastened translucent rigid substrate laminate by irradiating light for curing only the outer boundary portion of the fixing agent interposed and spreading between the both translucent rigid substrates while maintaining the pressure is performed between processes (5) and (6), or

6′

) a process of forming a provisionally fastened translucent rigid substrate laminate by irradiating light for curing only the outer boundary portion of the fixing agent interposed and spreading between the both translucent rigid substrates or irradiating light having energy that is lower than energy of process (7) on the entire fixing agent is performed between processes (6) and (7).

3. The method for manufacturing a translucent rigid substrate laminate according to claim 2, wherein a mark for alignment is attached to the surface of each translucent rigid substrate, process (5′

) is performed, and process

     4) or

     5) includes performing position adjustment in a surface direction while imaging the mark by an imaging device.

4. The method for manufacturing a translucent rigid substrate laminate according to claim 2, wherein a mark for alignment is attached to the surface of each translucent rigid substrate, process (6′

) is performed, and the method includes performing position adjustment of the preliminarily adhered translucent rigid substrates in a surface direction while imaging the mark by an imaging device between processes (6) and (6′

).

5. The method for manufacturing a translucent rigid substrate laminate according to claim 3, wherein an imaging device for imaging a mark for alignment of the first translucent rigid substrate from a second surface side of the first translucent rigid substrate, and an imaging device for imaging a mark for alignment of the second translucent rigid substrate from a first or second surface side of the second translucent rigid substrate are provided.

6. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein process (7) is performed by irradiating light on the surface of the second translucent rigid substrate.

7. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein a predetermined printing pattern and/or plating pattern for exhibiting any one of the functions of a plate-shaped product is attached to the surface of each translucent rigid substrate.

8. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein the fixing agent includes a granular material.

9. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein the amount of irradiation of light in process (7) is in a range of 1,000 to 5,000 mJ/cm² when measured by a cumulative illuminometer using a light receptor of 365 nm.

10. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein the translucent rigid substrate is a plate glass.

11. The method for manufacturing a translucent rigid substrate laminate according to claim 1, wherein light is irradiated while changing an angle of incidence in process (7).

12. The method for manufacturing a translucent rigid substrate laminate according to claim 11, wherein process (7) is performed while the translucent rigid substrate laminate is conveyed by a conveyor.

13. A method for manufacturing a plate-shaped product, comprising:

9) a process of dividing the translucent rigid substrate laminate obtained by using the method for manufacturing a translucent rigid substrate laminate according to claim 1 in a thickness direction to form divided translucent rigid substrate laminates in a desired number,

10) a process of performing desired shape processing with respect to each of the divided translucent rigid substrate laminates, and

11) a process of heating the translucent rigid substrate laminate after the shape processing to delaminate the bonded translucent rigid substrates from each other and forming a plurality of plate-shaped products.

14. The method for manufacturing a plate-shaped product according to claim 13, wherein a predetermined printing pattern and/or plating pattern for exhibiting any one of the functions of the plate-shaped product is attached to the surface of each translucent rigid substrate, and the method includes irradiating light for curing an uncured fixing agent toward the side surface of the divided translucent rigid substrate laminate between processes (9) and (11).

15. The method for manufacturing a plate-shaped product according to claim 13, wherein process (11) includes immersing the translucent rigid substrate laminate after the shape processing in warm water to soften the fixing agent in a film form.