EP1002752A1 - Method of manufacturing continuous substrate and apparatus therefor - Google Patents
Method of manufacturing continuous substrate and apparatus therefor Download PDFInfo
- Publication number
- EP1002752A1 EP1002752A1 EP98923120A EP98923120A EP1002752A1 EP 1002752 A1 EP1002752 A1 EP 1002752A1 EP 98923120 A EP98923120 A EP 98923120A EP 98923120 A EP98923120 A EP 98923120A EP 1002752 A1 EP1002752 A1 EP 1002752A1
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- EP
- European Patent Office
- Prior art keywords
- sheet material
- sheet materials
- forming
- hot press
- continuous
- 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.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H19/00—Changing the web roll
- B65H19/10—Changing the web roll in unwinding mechanisms or in connection with unwinding operations
- B65H19/18—Attaching, e.g. pasting, the replacement web to the expiring web
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H19/00—Changing the web roll
- B65H19/10—Changing the web roll in unwinding mechanisms or in connection with unwinding operations
- B65H19/18—Attaching, e.g. pasting, the replacement web to the expiring web
- B65H19/1842—Attaching, e.g. pasting, the replacement web to the expiring web standing splicing, i.e. the expiring web being stationary during splicing contact
- B65H19/1852—Attaching, e.g. pasting, the replacement web to the expiring web standing splicing, i.e. the expiring web being stationary during splicing contact taking place at a distance from the replacement roll
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H19/00—Changing the web roll
- B65H19/10—Changing the web roll in unwinding mechanisms or in connection with unwinding operations
- B65H19/14—Accumulating surplus web for advancing to machine while changing the web roll
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/46—Splicing
- B65H2301/462—Form of splice
- B65H2301/4621—Overlapping article or web portions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/46—Splicing
- B65H2301/463—Splicing splicing means, i.e. means by which a web end is bound to another web end
- B65H2301/46325—Separate element, e.g. clip
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/46—Splicing
- B65H2301/463—Splicing splicing means, i.e. means by which a web end is bound to another web end
- B65H2301/4633—Glue
- B65H2301/46332—Glue hot melt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/46—Splicing
- B65H2301/463—Splicing splicing means, i.e. means by which a web end is bound to another web end
- B65H2301/4634—Heat seal splice
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/10—Handled articles or webs
- B65H2701/17—Nature of material
- B65H2701/175—Plastic
- B65H2701/1752—Polymer film
Definitions
- This invention relates to a method for forming a continuous material by connecting sheet materials and an apparatus for forming a continuous material by connecting sheet materials which is used for carrying out the method. More particularly, it relates to a method for forming a continuous material by connecting sheet materials which are used in various fields including the processing of metal foils, the processing of metal-plastic composite film materials, and the processing of heat-resistant resin films such as polyimides and which require high-temperature processing in the range of 200°C to less than 550°C by means of coating and drying equipment, heat-treating equipment or the like, as well as an apparatus for forming a continuous material by connecting sheet materials which is used for carrying out the method.
- ultrasonic welding has been employed as a method for connecting metal foils with each other.
- connecting methods using or staples have been employed to connect heat-resistant plastics, such as polyimides, with each other.
- Ultrasonic welding can be used to connect different metal foils, but cannot be used to connect heat-resistant plastics such as polyimides.
- the connecting method using a heat-resistant adhesive tape can be employed in a temperature range of less than 200°C, but shows a reduction in adhesion strength when it is employed at temperatures higher than 200°C. Consequently, the joint may be separated when a tension of 0.1 to 50 kgf/cm is applied to the material.
- the connecting method using staples fails to give sufficient bonding strength when it is employed for thin metal foils, plastic films and other materials having a thickness of not greater than 18 mm. Consequently, this method is not satisfactory in that the material may be broken when a tension of 0.1 to 50 kgf/cm is applied thereto.
- an object of the present invention is to provide a method for forming a continuous material by connecting sheet materials wherein a metal foil and a heat-resistant plastic can be satisfactorily connected together, to say nothing of metal foils or heat-resistant plastics, and wherein the connected materials will not be separated even where they are processed at a temperature in the range of 200°C to less than 550°C and under a tension in the range of 0.1 to 50 kgf/cm, as well as an apparatus for forming a continuous material which is used for carrying out the aforesaid method.
- thermocompression bonding the material locking device is operated so that the part to be joined by thermocompression bonding comes to a standstill within the hot press, and the accumulator is also operated so that the feed speed of the sheet material on the downstream side is adjusted to a predetermined value.
- the completely connected sheet materials can be processed continuously.
- the present invention provides a method for forming a continuous material by connecting a preceding sheet material with a succeeding other sheet material in end-to-end relationship while feeding them in their longitudinal direction, the method comprising the steps of:
- Preferred embodiments of the above-described method for forming a continuous material by connecting sheet materials in accordance with the present invention include a method for forming a continuous material by connecting sheet materials as described above wherein the thermocompression bonding is performed at a temperature in the range of 200°C to less than 550°C and a pressure in the range of 0.001 to 50 kgf/cm 2 ; a method for forming a continuous material by connecting sheet materials as described above wherein the trailing edge of the preceding sheet material 4 and the leading edge of the succeeding other sheet material 6 each have a length of 10 to 1,000 mm; a method for forming a continuous material by connecting sheet materials as described above wherein the preceding sheet material 4 and the succeeding other sheet material 6 each comprise a metal foil or heat-resistant resin film having a thickness of 5 to 500 ⁇ m; and a method for forming a continuous material by connecting sheet materials as described above wherein the resin bonding layer has a thickness of 0.1 to 50 ⁇ m.
- Each of the above-described methods for forming a continuous material by connecting sheet materials is preferably employed especially where the connected sheet materials are continuously processed at a temperature in the range of 200 °C to less than 550°C and under a tension in the range of 0.1 to 50 kgf/cm.
- the present invention also provides an apparatus for forming a continuous material by connecting sheet materials which is used for carrying out each of the above-described methods for forming a continuous material by connecting sheet materials, the apparatus comprising a hot press for effecting thermocompression bonding of a temporarily joined part formed by making the trailing edge of a preceding sheet material and the leading edge of a succeeding other sheet material overlap with a bonding layer interposed therebetween, and temporarily joining them together; a material locking device for locking a part of the preceding sheet material in order to bring the temporarily joined part to a standstill within the hot press; and an accumulator for keeping the traveling speed of the preceding material constant on the downstream side of the material locking device.
- sheet materials can be satisfactorily processed without suffering from breakage, separation, meandering, variation in tension, or the like. Moreover, by connecting sheet materials according to the present invention, they can be stably and efficiently connected with each other, and they can be fed to a subsequent step at a constant feed speed.
- An outline of the method for forming a continuous material by connecting sheet materials in accordance with the present invention is as follows. First of all, while a preceding sheet material is being fed by a feeding means, the trailing edge of the preceding sheet material and the leading edge of a succeeding other sheet material are made to overlap with a resin bonding layer interposed therebetween, and temporarily joined together by means of an adhesive tape or the like. The temporarily joined sheet materials are fed downstream by the feeding means. As soon as the temporarily joined part reaches a hot press, a part of the preceding sheet material is locked by means of a sheet material locking device, so that the temporarily joined part comes to a standstill within the hot press. At this time, an accumulator is operated to keep the feed speed of the preceding sheet material constant.
- the hot press is operated to effect thermocompression bonding of the temporarily joined part of the sheet materials having the resin bonding layer therebetween.
- the material locking device unlocks the preceding sheet material, so that the sheet materials connected by the resulting joint travel toward the accumulator.
- FIGs. 1 to 4 are given for the purpose of explaining the construction and operation of one form of apparatus used for carrying out the method for forming a continuous material by connecting sheet materials in accordance with the present invention.
- FIG. 1 illustrates sheet materials having a resin bonding layer interposed therebetween.
- FIG. 2 illustrates the sheet materials whose joined part has come to a standstill within a hot press.
- FIG. 3 illustrates the sheet materials being subjected to thermocompression bonding by operating the hot press.
- FIG. 4 illustrates the completely connected sheet materials.
- this form of apparatus includes a hot press 1 in order to connect the trailing edge of a preceding sheet material 4 being fed by a feeding means (not shown) and being processed, with the leading edge of a succeeding other sheet material 6 to be processed, by means of a resin bonding layer 5.
- thermocompression bonding may be chosen according to the type of the resin bonding layer, it is usually in the range of 200°C to less than 550°C and preferably in the range of 200 to 450°C.
- pressure employed for hot pressing it is preferably in the range of 0.001 to 50 kgf/cm 2 and more preferably in the range of 0.001 to 1 kgf/cm 2 so that a sufficient adhesion strength may be achieved and no damage may be caused to the sheet materials.
- the hot platens In order to transfer heat and pressure uniformly, it is preferable to cover the hot platens with heat-resistant rubber. Alternatively, it is also preferable to provide the hot platens with a raised pattern and thereby increase the applied pressure locally.
- No particular limitation is placed on the time required for hot pressing. However, from a practical point of view, it ranges from 0.1 second to 30 minutes, preferably from 0.5 second to 10 minutes, and more preferably from 1 second to 5 minutes.
- the length of the part in which the sheet materials are connected by thermocompression bonding No particular limitation is placed on the length of the part in which the sheet materials are connected by thermocompression bonding. However, with consideration for the tension applied to the sheet material being processed in a subsequent step, and the like, it is usually in the range of about 10 to 1,000 mm and preferably in the range of 50 to 500 mm.
- this apparatus includes a material locking device 2 for stopping the movement of the trailing edge of the preceding sheet material 4 being processed, during bonding by the hot press 1; and an accumulator 3 for keeping the traveling speed of the preceding sheet material 4 being processed constant on the downstream side of the material locking device 2 (i.e., on the side of the material locking device 2 which is opposite to the hot press 1).
- the material locking device 2 preferably consists of a pair of rolls which can be engaged with each other to pinch and lock the sheet material.
- the accumulator 3 preferably consists of a plurality of rolls arranged in such a way that the length of the sheet material wound around the rolls is regulated, for example, by shifting the opposed rolls in a direction orthogonal to the feed direction of the sheet material, whereby the traveling speed of the sheet material 4 being processed can be kept constant even when it is locked by the material locking device 2.
- the sheet materials which can be used as the sheet materials 4 and 6 include metal foils such as copper foil, stainless foil, aluminum foil, Ni-Fe alloy foil, and copper-based alloy foil; heat-resistant plastic films such as polyimides, polyamides, aramids and liquid crystal polymers; and composite films composed of metal foils and heat-resistant plastics.
- the thickness of the sheet materials is preferably in the range of about 5 to 500 ⁇ m, more preferably about 5 to 100 ⁇ m, and most preferably about 5 to 50 ⁇ m.
- the resin bonding layer 5 used as the bonding layer may comprise any resin layer characterized by thermoplasticity.
- a non-thermoplastic polyimide film, a metal foil as described above, and other films having a resin boding layer formed on either side thereof may also be used.
- the resin bonding layer constituting the bonding layer has a thickness of about 0.1 to 100 ⁇ m.
- thermoplastic resin preferably having a glass transition temperature of 150 to 350°C is used for the resin boding layer, and examples thereof include thermoplastic polyimides, aromatic polyamide-imides, aromatic polyetherimides and silicone-modified polyimides. Especially preferred are thermoplastic polyimides.
- thermoplastic polyimide forming the thermoplastic polyimide film used as the bonding layer there may be used well-known thermoplastic polyimides synthesized from a diamine and a tetracarboxylic acid dianhydride. More specifically, the diamine may preferably comprise at least one diamine selected from 1,3-bis(3-aminophenoxy) benzene, 4,4'-bis(3-aminophenoxy)biphenyl and 3,3'-diaminobenzophenone.
- the tetracarboxylic acid dianhydride may preferably comprise at least one tetracarboxylic acid dianhydride selected from 3,3',4,4'-(diphenyl ether)tetracarboxylic acid dianhydride, 3,3',4,4'-benzophenonetetracarboxylic acid dianhydride, pyromellitic acid dianhydride and 3,3',4,4'-biphenyltetracarboxylic acid dianhydride.
- the thermoplastic polyimide film used in the present invention preferably comprises a film of a polycondensation polymer prepared from at least one diamine component selected from the above-enumerated diamines and at least one tetracarboxylic acid dianhydride component selected from the above-enumerated tetracarboxylic acid dianhydrides.
- the molar ratio in which the diamine components is reacted with the tetracarboxylic acid dianhydride component is usually such that the amount of tetracarboxylic acid dianhydride component used is in the range of 0.75 to 1.25 moles per mole of the diamine component.
- the amount of tetracarboxylic acid dianhydride component used is in the range of 0.8 to 1.2 moles.
- a portion of the aforesaid diamine may be replaced by other diamines.
- the amine compounds which can be used for substitutional purposes include, for example, m-phenylenediamine, o-phenylenediamine, p-phenylenediamine, m-aminobenzylamine, p-aminobenzylamine, bis(3-aminophenyl) sulfide, (3-aminophenyl) (4-aminophenyl) sulfide, bis(4-aminophenyl) sulfide, bis(3-aminophenyl) sulfoxide, (3-aminophenyl) (4-aminophenyl) sulfoxide, bis(3-aminophenyl) sulfone, (3-aminophenyl) (4-aminophenyl) sulfone, bis(4-aminophenyl) sulfone, 3,4'-d
- amine compounds may be used alone or in admixture of two or more.
- the proportion of the aforesaid specific diamine which may be replaced by other amine compounds is usually in the range of 0 to 50 mole % of the diamine.
- the aforesaid tetracarboxylic acid dianhydride may be used in combination with other tetracarboxylic acid dianhydrides.
- the tetracarboxylic acid dianhydrides which can be used for this purpose include, for example, ethylenetetracarboxylic acid dianhydride, butanetetracarboxylic acid dianhydride, cyclopentanecarboxylic acid dianhydride, pyromellitic acid dianhydride, 2,2',3,3'-benzophenonetetracarboxylic acid dianhydride, 2,2',3,3'-biphenyltetracarboxylic acid dianhydride, 2,2-bis(3,4-dicarboxyphenyl) propane dianhydride, bis(3,4-dicarboxyphenyl) ether dianhydride, bis(2,3-dicarboxyphenyl) ether dianhydride, bis(3,4-dicarboxyphenyl) s
- tetracarboxylic acid dianhydrides may be used alone or in admixture of two or more.
- the proportion of the aforesaid specific tetracarboxylic acid dianhydride which may be replaced is usually in the range of 0 to 50 mole % of the tetracarboxylic acid dianhydride.
- a dicarboxylic acid anhydride may be added in order to cap the chain ends of the thermoplastic polyimide used as a raw material for the formation of a thermoplastic polyimide film.
- the dicarboxylic acid anhydrides which can be used for this purpose include phthalic anhydride, 2,3-benzophenonedicarboxylic acid anhydride, 3,4-benzophenonedicarboxylic acid anhydride, 2,3-dicarboxyphenyl phenyl ether anhydride, 2,3-biphenyldicarboxylic acid anhydride, 3,4-biphenyldicarboxylic acid anhydride, 2,3-dicarboxyphenyl phenyl sulfone anhydride, 3,4-dicarboxyphenyl phenyl sulfone anhydride, 2,3-dicarboxyphenyl phenyl sulfide anhydride, 1,2-naphthalenedicarboxylic acid anhydride, 2,3--benz
- dicarboxylic acid anhydrides may be substituted by groups having no reactivity with amines or dicarboxylic acid anhydrides.
- the amount of dicarboxylic acid anhydride added is usually in the range of 0.001 to 0.5 mole per 100 moles of the combined amount of the aforesaid specific diamine and tetracarboxylic acid anhydride used as chief raw materials. Preferably, it is in the range of 0.005 to 0.25 mole.
- a monoamine may be added in order to cap the chain ends of the thermoplastic polyimide.
- the monoamines which can be used for this purpose include aniline, o-toluidine, m-toluidine, p-toluidine, 2,3-xylidine, 2,4-xylidine, 2,5-xylidine, 2,6-xylidine, 3,4-xylidine, 3,5-xylidine, o-chloroaniline, m-chloroaniline, p-chloroaniline, o-nitroaniline, o-bromoaniline, m-bromoaniline, o-nitroaniline, m-nitroaniline, p-nitroaniline, o-aminophenol, m-aminophenol, p-aminophenol, o-anisidine, m-anisidine, p-anisidine, o-phenetidine, m-phenetidine, p-phenetidine, o
- monoamines may be used alone or in admixture of two or more.
- the amount of monoamine added is usually in the range of 0.001 to 0.5 mole per 100 moles of the combined amount of the aforesaid specific diamine and tetracarboxylic acid anhydride used as chief raw materials. Preferably, it is in the range of 0.005 to 0.25 mole.
- thermoplastic polyimides aromatic polyetherimides, aromatic polyamide-imides, silicone-modified polyimides and the like may also be used for the resin bonding layer in the method of the present invention.
- Aromatic polyetherimides are polymers having ether linkages and imide linkages as essential bonding units, and consist essentially of repeating units of the following general formula (1).
- Z is a trifunctional aromatic group in which two of the three functional groups are attached to the adjacent carbon atoms, and Ar is a divalent aromatic reside.
- Specific examples of the repeating units includes those represented by the following formulae (2) to (8).
- aromatic polyetherimides are commercially available from General Electric Company, U.S.A., under the trade names of Ultem-1000, Ultem-4000, Ultem-6000 and the like.
- Aromatic polyamide-imides are polymers having imide and amide linkages in the repeating units of the main chain, and consist of repeating units represented b the following general formula (9). wherein Ar is a trivalent aromatic group containing at least one benzene ring, and Z is a divalent organic group.
- aromatic polyamide-imides which can be used in the present invention are aromatic polyamide-imides having repeating units represented by the following general formula (10) or (11).
- aromatic polyamide-imides are commercially available from AMOCO, U.S.A., under the trade name of TORLON.
- the silicone-modified polyimides which can be used in the method of the present invention are polycondensation polymers prepared from a diamine containing a siliconediamine as an essential component, and a tetracarboxylic acid dianhydride.
- Typical siliconediamines are a,w-bisaminopolydimethylsiloxanes of the following general formula (12).
- n preferably has a value of 0 to 10. It is especially preferable to use a polymer in which n is 4 to 10, or a mixture of such a polymer and a monomer in which n is 0.
- the siliconediamine content in the total amine is preferably in the range of 5 to 15 mole %. At siliconediamine contents of 5 mole % or greater, the resulting polymer desirably has low water-absorbing properties. At siliconediamine contents of 50 mole % or less, the resulting polymer desirably has a high glass transition temperature and hence good heat resistance.
- the diamines other than siliconediamines, which can be used for the preparation of silicone-modified polyimides include the same diamines as can be used as raw materials for the preparation of thermoplastic polyimides.
- the tetracarboxylic acid dianhydrides which can be used for this purpose include those described previously.
- FIG. 1 a preceding sheet material 4 being processed is fed through a hot press 1 by a feeding means (not shown).
- a feeding means not shown.
- the trailing edge of the preceding sheet material 4 and the leading edge of a succeeding other sheet material 6 to be processed are made to overlap with a resin bonding layer 5 interposed therebetween, and temporarily joined together by means of an adhesive tape 7.
- This adhesive tape 7 may comprise a commercially available double-coated adhesive tape.
- the hot press 1, a material locking device 2 and an accumulator 3 are not operated.
- the trailing edge of the sheet material 4 and the leading edge of the sheet material 6 are fed in the temporarily joined state.
- a part of the sheet material 4 being processed is locked by means of a material locking device 2 installed between the hot press 1 and an accumulator 3, so that the temporarily joined part comes to a standstill within the hot press 1.
- the accumulator 3 is operated to keep the traveling rate of the sheet material 4 being processed constant.
- the hot press 1 is operated to effect thermocompression bonding of the trailing edge of the sheet material 4 and the leading edge of the sheet material 6 with the resin bonding layer 5 interposed therebetween.
- the sheet material 4 is released from the lock by the material locking device 2.
- the joint between the sheet materials 4 and 6 travels toward accumulator 3.
- the method and apparatus of this embodiment can connect the sheet materials 4 and 6 stably and efficiently to form a continuous material.
- the connected sheet materials 4 and 6 are processed in a subsequent step using coating and drying equipment, heat-treating equipment, or other equipment, where it is exposed to a high temperature in the range of 200°C to less than 550°C and a tension in the range of 0.1 to 50 kgf/cm. Even under such severe processing conditions, the connected sheet materials can be satisfactorily processed without suffering from any trouble such as breakage, meandering, or variation in tension.
- Example 1 there was employed a feeder for feeding sheet materials continuously to a drying furnace having a temperature of 300°C.
- the sheet material being fed was copper foil and its thickness was 18 ⁇ m.
- the sheet material to be processed next time was a polyimide film and its thickness was 13 ⁇ m.
- thermoplastic polyimide film there was used a polyimide film [manufactured by Kaneka Corp. under the trade name of Apical; having a thickness of 25 ⁇ m] having thermoplastic polyimide layers (each having a thickness of 8 ⁇ m) on both sides thereof.
- thermoplastic polyimide In order to prepare the aforesaid thermoplastic polyimide, polyamic acid varnish obtained by mixing 3,3',4,4'-benzophenonetetracarboxylic acid dianhydride with 1,3'-bis(3-aminophenoxy)benezene in dimethylacetamide at room temperature was used as a starting material. This polyamic acid was applied to the aforesaid polyimide film, dried and imidized to form a thermoplastic polyimide layer. The temperature used for this purpose was 300°C.
- a material locking device was operated to bring the overlapping part to a standstill within a hot press. Using hot platens disposed on both sides, the overlapping part was pressed at a pressure of 0.1 kgf/cm 2 and a temperature of 300°C for 30 seconds. Observation of the joint revealed that the sheet materials were satisfactorily joined together.
- the hot platens were provided with a raised pattern so that the pressure of the press is focused on the raised regions. The pressure calculated from the area of the raised regions was 1.0 kgf/cm 2 .
- the polyimide film was fed to the drying furnace having a temperature of 300°C and processed therein.
- the tension applied to the sheet material being processed was 5 kgf/cm, indicating that a great tensile force was exerted thereon.
- the sheet material was satisfactorily processed without suffering from any trouble such as breakage, meandering, or variation in tension.
- Example 2 the processing temperature was set at 250°C and the same apparatus as in Example 1 was used.
- the sheet material being processed and the sheet material to be connected comprised a copper film and a polyimide film, respectively, which were similar to those used in Example 1.
- As the thermoplastic polyimide film there was used a film manufactured by Mitsui Chemical Industry Co., Ltd. under the trade name of Regulus. Hot pressing was performed at a pressure of 0.1 kgf/cm 2 and a temperature of 340°C for 1 minute. At the joint, the sheet materials were satisfactorily joined together. Following the copper foil, the polyimide film was fed to the furnace. The sheet material being processed was exposed to a temperature of 250°C and a tension of 10 kgf/m. However, the sheet material was satisfactorily processed without suffering from any trouble such as breakage, meandering, or variation in tension.
- sheet materials are connected in end-to-end relationship by thermocompression boding using a resin bonding layer as the bonding layer.
- a subsequent processing step is carried out under severe conditions including a temperature in the range of 200°C to less than 550°C and a tension in the range of 0.1 to 50 kgf/cm, the sheet materials can be satisfactorily processed without suffering from breakage, separation, meandering, variation in tension, or the like.
- by connecting sheet materials according to the present invention they can be connected stably and efficiently, and they can be fed to a subsequent step at a constant feed speed.
- FIG. 1 A first figure.
- FIG. 1 is a view of one form of apparatus used for carrying out the method for forming a continuous material by connecting sheet materials in accordance with the present invention, illustrating the sheet materials having a resin bonding layer (a thermoplastic polyimide film) interposed therebetween;
- a resin bonding layer a thermoplastic polyimide film
- FIG. 2 is a view of one form of apparatus used for carrying out the method for forming a continuous material by connecting sheet materials in accordance with the present invention, illustrating the sheet materials whose joined part has come to a standstill within a hot press;
- FIG. 3 is a view of one form of apparatus used for carrying out the method for forming a continuous material by connecting sheet materials in accordance with the present invention, illustrating the sheet materials being subjected to thermocompression bonding by operating the hot press;
- FIG. 4 is a view of one form of apparatus used for carrying out the method for forming a continuous material by connecting sheet materials in accordance with the present invention, illustrating the completely connected sheet materials.
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Abstract
The present invention relates to a method for forming
a continuous material by connecting sheet materials which
are used in various fields including the processing of
metal foils, the processing of metal-plastic composite film
material, and the processing of thermoplastic resin films
such as polyimides, and an apparatus used for carrying out
this method.
A method has now been found in which, using a
connecting apparatus comprising a hot press, a material
locking device and an accumulator, a continuous material
can be formed by interposing a resin bonding layer between
the trailing edge of a sheet material and the leading edge
of another sheet material, and subjecting this part to
thermocompression bonding. Moreover, during
thermocompression bonding, the material locking device is
operated so that the part to be joined by thermocompression
bonding comes to a standstill within the hot press, and the
accumulator is also operated so that the feed speed of the
sheet material on the downstream side is adjusted to a
predetermined value. Thus, the completely connected sheet
materials can be processed continuously. The present
invention provides a method for forming a continuous
material by connecting sheet materials in the above-described
manner, and an apparatus used for carrying out
this method.
Description
This invention relates to a method for forming a
continuous material by connecting sheet materials and an
apparatus for forming a continuous material by connecting
sheet materials which is used for carrying out the method.
More particularly, it relates to a method for forming a
continuous material by connecting sheet materials which are
used in various fields including the processing of metal
foils, the processing of metal-plastic composite film
materials, and the processing of heat-resistant resin films
such as polyimides and which require high-temperature
processing in the range of 200°C to less than 550°C by means
of coating and drying equipment, heat-treating equipment or
the like, as well as an apparatus for forming a continuous
material by connecting sheet materials which is used for
carrying out the method.
Conventionally, ultrasonic welding has been employed
as a method for connecting metal foils with each other.
Moreover, connecting methods using or staples have been
employed to connect heat-resistant plastics, such as
polyimides, with each other.
Ultrasonic welding can be used to connect different
metal foils, but cannot be used to connect heat-resistant
plastics such as polyimides. On the other hand, the
connecting method using a heat-resistant adhesive tape can
be employed in a temperature range of less than 200°C, but
shows a reduction in adhesion strength when it is employed
at temperatures higher than 200°C. Consequently, the joint
may be separated when a tension of 0.1 to 50 kgf/cm is
applied to the material. Moreover, the connecting method
using staples fails to give sufficient bonding strength
when it is employed for thin metal foils, plastic films and
other materials having a thickness of not greater than 18
mm. Consequently, this method is not satisfactory in that
the material may be broken when a tension of 0.1 to 50
kgf/cm is applied thereto.
In view of the above-described disadvantages of the
prior art, an object of the present invention is to provide
a method for forming a continuous material by connecting
sheet materials wherein a metal foil and a heat-resistant
plastic can be satisfactorily connected together, to say
nothing of metal foils or heat-resistant plastics, and
wherein the connected materials will not be separated even
where they are processed at a temperature in the range of
200°C to less than 550°C and under a tension in the range of
0.1 to 50 kgf/cm, as well as an apparatus for forming a
continuous material which is used for carrying out the
aforesaid method.
In order to solve the above-described problem, the
present inventors made intensive investigations and have
now found a method in which, using a connecting apparatus
comprising a hot press, a material locking device and an
accumulator, a continuous material can be formed by
interposing a resin bonding layer between the trailing edge
of a sheet material and the leading edge of another sheet
material, and subjecting this part to thermocompression
bonding. During thermocompression bonding, the material
locking device is operated so that the part to be joined by
thermocompression bonding comes to a standstill within the
hot press, and the accumulator is also operated so that the
feed speed of the sheet material on the downstream side is
adjusted to a predetermined value. Thus, the completely
connected sheet materials can be processed continuously.
The present invention has been completed on the basis of
these findings.
That is, the present invention provides a method for
forming a continuous material by connecting a preceding
sheet material with a succeeding other sheet material in
end-to-end relationship while feeding them in their
longitudinal direction, the method comprising the steps of:
Preferred embodiments of the above-described method
for forming a continuous material by connecting sheet
materials in accordance with the present invention include
a method for forming a continuous material by connecting
sheet materials as described above wherein the
thermocompression bonding is performed at a temperature in
the range of 200°C to less than 550°C and a pressure in the
range of 0.001 to 50 kgf/cm2; a method for forming a
continuous material by connecting sheet materials as
described above wherein the trailing edge of the preceding
sheet material 4 and the leading edge of the succeeding
other sheet material 6 each have a length of 10 to 1,000
mm; a method for forming a continuous material by
connecting sheet materials as described above wherein the
preceding sheet material 4 and the succeeding other sheet
material 6 each comprise a metal foil or heat-resistant
resin film having a thickness of 5 to 500 µm; and a method
for forming a continuous material by connecting sheet
materials as described above wherein the resin bonding
layer has a thickness of 0.1 to 50 µm. Each of the above-described
methods for forming a continuous material by
connecting sheet materials is preferably employed
especially where the connected sheet materials are
continuously processed at a temperature in the range of 200
°C to less than 550°C and under a tension in the range of
0.1 to 50 kgf/cm.
In another aspect, the present invention also provides
an apparatus for forming a continuous material by
connecting sheet materials which is used for carrying out
each of the above-described methods for forming a
continuous material by connecting sheet materials, the
apparatus comprising a hot press for effecting
thermocompression bonding of a temporarily joined part
formed by making the trailing edge of a preceding sheet
material and the leading edge of a succeeding other sheet
material overlap with a bonding layer interposed
therebetween, and temporarily joining them together; a
material locking device for locking a part of the preceding
sheet material in order to bring the temporarily joined
part to a standstill within the hot press; and an
accumulator for keeping the traveling speed of the
preceding material constant on the downstream side of the
material locking device.
According to the present invention, even where a
subsequent processing step is carried out under severe
conditions including a temperature in the range of 200°C to
less than 550°C and a tension in the range of 0.1 to 50
kgf/cm, sheet materials can be satisfactorily processed
without suffering from breakage, separation, meandering,
variation in tension, or the like. Moreover, by connecting
sheet materials according to the present invention, they
can be stably and efficiently connected with each other,
and they can be fed to a subsequent step at a constant feed
speed.
The present invention is more specifically described
hereinbelow.
An outline of the method for forming a continuous
material by connecting sheet materials in accordance with
the present invention is as follows. First of all, while a
preceding sheet material is being fed by a feeding means,
the trailing edge of the preceding sheet material and the
leading edge of a succeeding other sheet material are made
to overlap with a resin bonding layer interposed
therebetween, and temporarily joined together by means of
an adhesive tape or the like. The temporarily joined sheet
materials are fed downstream by the feeding means. As soon
as the temporarily joined part reaches a hot press, a part
of the preceding sheet material is locked by means of a
sheet material locking device, so that the temporarily
joined part comes to a standstill within the hot press. At
this time, an accumulator is operated to keep the feed
speed of the preceding sheet material constant.
Subsequently, the hot press is operated to effect
thermocompression bonding of the temporarily joined part of
the sheet materials having the resin bonding layer
therebetween. After the connection of the sheet materials
is completed, the material locking device unlocks the
preceding sheet material, so that the sheet materials
connected by the resulting joint travel toward the
accumulator.
Now, one embodiment of the present invention is
described below with reference to the accompanying drawings.
FIGs. 1 to 4 are given for the purpose of explaining
the construction and operation of one form of apparatus
used for carrying out the method for forming a continuous
material by connecting sheet materials in accordance with
the present invention. Specifically, FIG. 1 illustrates
sheet materials having a resin bonding layer interposed
therebetween. FIG. 2 illustrates the sheet materials whose
joined part has come to a standstill within a hot press.
FIG. 3 illustrates the sheet materials being subjected to
thermocompression bonding by operating the hot press. FIG.
4 illustrates the completely connected sheet materials.
As illustrated in FIGs. 1 to 4, this form of apparatus
includes a hot press 1 in order to connect the trailing
edge of a preceding sheet material 4 being fed by a feeding
means (not shown) and being processed, with the leading
edge of a succeeding other sheet material 6 to be processed,
by means of a resin bonding layer 5.
No particular limitation is placed on the type of the
hot press 1. However, it is preferable to use a hot press
having hot platens in which a heater and the like are
incorporated. Although the heating temperature employed
for thermocompression bonding may be chosen according to
the type of the resin bonding layer, it is usually in the
range of 200°C to less than 550°C and preferably in the
range of 200 to 450°C. Although no particular limitation
is placed on the pressure employed for hot pressing, it is
preferably in the range of 0.001 to 50 kgf/cm2 and more
preferably in the range of 0.001 to 1 kgf/cm2 so that a
sufficient adhesion strength may be achieved and no damage
may be caused to the sheet materials.
In order to transfer heat and pressure uniformly, it
is preferable to cover the hot platens with heat-resistant
rubber. Alternatively, it is also preferable to provide
the hot platens with a raised pattern and thereby increase
the applied pressure locally. No particular limitation is
placed on the time required for hot pressing. However,
from a practical point of view, it ranges from 0.1 second
to 30 minutes, preferably from 0.5 second to 10 minutes,
and more preferably from 1 second to 5 minutes. No
particular limitation is placed on the length of the part
in which the sheet materials are connected by
thermocompression bonding. However, with consideration for
the tension applied to the sheet material being processed
in a subsequent step, and the like, it is usually in the
range of about 10 to 1,000 mm and preferably in the range
of 50 to 500 mm.
Moreover, this apparatus includes a material locking
device 2 for stopping the movement of the trailing edge of
the preceding sheet material 4 being processed, during
bonding by the hot press 1; and an accumulator 3 for
keeping the traveling speed of the preceding sheet material
4 being processed constant on the downstream side of the
material locking device 2 (i.e., on the side of the
material locking device 2 which is opposite to the hot
press 1).
The material locking device 2 preferably consists of a
pair of rolls which can be engaged with each other to pinch
and lock the sheet material. The accumulator 3 preferably
consists of a plurality of rolls arranged in such a way
that the length of the sheet material wound around the
rolls is regulated, for example, by shifting the opposed
rolls in a direction orthogonal to the feed direction of
the sheet material, whereby the traveling speed of the
sheet material 4 being processed can be kept constant even
when it is locked by the material locking device 2.
The sheet materials which can be used as the sheet
materials 4 and 6 include metal foils such as copper foil,
stainless foil, aluminum foil, Ni-Fe alloy foil, and
copper-based alloy foil; heat-resistant plastic films such
as polyimides, polyamides, aramids and liquid crystal
polymers; and composite films composed of metal foils and
heat-resistant plastics. The thickness of the sheet
materials is preferably in the range of about 5 to 500 µm,
more preferably about 5 to 100 µm, and most preferably
about 5 to 50 µm.
The resin bonding layer 5 used as the bonding layer
may comprise any resin layer characterized by
thermoplasticity. A non-thermoplastic polyimide film, a
metal foil as described above, and other films having a
resin boding layer formed on either side thereof may also
be used. In any case, the resin bonding layer constituting
the bonding layer has a thickness of about 0.1 to 100 µm.
A thermoplastic resin preferably having a glass
transition temperature of 150 to 350°C is used for the
resin boding layer, and examples thereof include
thermoplastic polyimides, aromatic polyamide-imides,
aromatic polyetherimides and silicone-modified polyimides.
Especially preferred are thermoplastic polyimides.
As the thermoplastic polyimide forming the
thermoplastic polyimide film used as the bonding layer,
there may be used well-known thermoplastic polyimides
synthesized from a diamine and a tetracarboxylic acid
dianhydride. More specifically, the diamine may preferably
comprise at least one diamine selected from 1,3-bis(3-aminophenoxy)
benzene, 4,4'-bis(3-aminophenoxy)biphenyl and
3,3'-diaminobenzophenone.
The tetracarboxylic acid dianhydride may preferably
comprise at least one tetracarboxylic acid dianhydride
selected from 3,3',4,4'-(diphenyl ether)tetracarboxylic
acid dianhydride, 3,3',4,4'-benzophenonetetracarboxylic
acid dianhydride, pyromellitic acid dianhydride and
3,3',4,4'-biphenyltetracarboxylic acid dianhydride.
The thermoplastic polyimide film used in the present
invention preferably comprises a film of a polycondensation
polymer prepared from at least one diamine component
selected from the above-enumerated diamines and at least
one tetracarboxylic acid dianhydride component selected
from the above-enumerated tetracarboxylic acid dianhydrides.
The molar ratio in which the diamine components is reacted
with the tetracarboxylic acid dianhydride component is
usually such that the amount of tetracarboxylic acid
dianhydride component used is in the range of 0.75 to 1.25
moles per mole of the diamine component. Preferably, the
amount of tetracarboxylic acid dianhydride component used
is in the range of 0.8 to 1.2 moles.
A portion of the aforesaid diamine may be replaced by
other diamines. The amine compounds which can be used for
substitutional purposes include, for example, m-phenylenediamine,
o-phenylenediamine, p-phenylenediamine,
m-aminobenzylamine, p-aminobenzylamine, bis(3-aminophenyl)
sulfide, (3-aminophenyl) (4-aminophenyl) sulfide, bis(4-aminophenyl)
sulfide, bis(3-aminophenyl) sulfoxide, (3-aminophenyl)
(4-aminophenyl) sulfoxide, bis(3-aminophenyl)
sulfone, (3-aminophenyl) (4-aminophenyl) sulfone, bis(4-aminophenyl)
sulfone, 3,4'-diaminobenzophenone, 4,4'-diaminobenzophenone,
3,3'-diaminodiphenylmethane, 3,4'-diaminodiphenylmethane,
4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenyl
ether, 3,3'-diaminodiphenyl ether, 3,4'-diaminodiphenyl
ether, bis[4-(3-aminophenoxy)phenyl]methane,
bis[4-(4-aminophenoxy)phenyl]methane, 1,1-bis[4-(3-aminophenoxy)phenyl]ethane,
1,1-bis[4-(4-aminophenoxy)phenyl]ethane,
1,2-bis[4-(3-aminophenoxy)phenyl]ethane,
1,2-bis[4-(4-aminophenoxy)phenyl]ethane,
2,2-bis[4-(3-aminophenoxy)phenyl]propane,
2,2-bis[4-(4-aminophenoxy)phenyl]propane,
2,2-bis[4-(3-aminophenoxy)phenyl]butane,
2,2-bis[3-(3-aminophenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane,
2,2-bis[4-(4-aminophenoxy)phenyl]-1,1,1,3,3,3-hexafluoropropane,
1,3-bis(3-aminophenoxy)benzene, 1,4-bis(3-aminophenoxy)benzene,
1,4'-bis(4-aminophenoxy)benzene,
4,4'-bis(4-aminophenoxy)biphenyi, bis[4-(3-aminophenoxy)phenyl]
ketone, bis[4-(4-aminophenoxy)phenyl]
ketone, bis[4-(3-aminophenoxy)phenyl] sulfide, bis[4-(4-aminophenoxy)phenyl]
sulfide, bis[4-(3-aminophenoxy)phenyl]
sulfoxide, bis[4-(aminophenoxy)phenyl] sulfoxide, bis[4-(3-aminophenoxy)phenyl]
sulfone, bis[4-(4-aminophenoxy)phenyl]
sulfone, bis[4-(3-aminophenoxy)phenyl] ether, bis[4-(4-aminophenoxy)phenyl]
ether, 1,4-bis[4-(3-aminophenoxy)benzoyl]benzene,
1,3-bis[4-(3-aminophenoxy)benzoyl]benzene,
4,4'-bis[3-(4-aminophenoxy)benzoyl]diphenyl
ether, 4,4'-bis[3-(3-aminophenoxy)benzoyl]diphenyl
ether, 4,4'-bis[4-(4-amino-α,
α-dimethylbenzyl)phenoxy]benzophenone, 4,4'-bis[4-(4-amino-α,α-dimethylbenzyl)phenoxy]diphenyl
sulfone, bis[4-{4-(4-aminophenoxy)phenoxy}phenyl]
sulfone, 1,4-bis[4-(4-aminophenoxy)-α,α-dimethylbenzyl]benzene
and 1,3-bis[4-(4-aminophenoxy)-α,α-dimethylbenzyl]benzene.
These amine compounds may be used alone or in
admixture of two or more. The proportion of the aforesaid
specific diamine which may be replaced by other amine
compounds is usually in the range of 0 to 50 mole % of the
diamine.
The aforesaid tetracarboxylic acid dianhydride may be
used in combination with other tetracarboxylic acid
dianhydrides. The tetracarboxylic acid dianhydrides which
can be used for this purpose include, for example,
ethylenetetracarboxylic acid dianhydride,
butanetetracarboxylic acid dianhydride,
cyclopentanecarboxylic acid dianhydride, pyromellitic acid
dianhydride, 2,2',3,3'-benzophenonetetracarboxylic acid
dianhydride, 2,2',3,3'-biphenyltetracarboxylic acid
dianhydride, 2,2-bis(3,4-dicarboxyphenyl) propane
dianhydride, bis(3,4-dicarboxyphenyl) ether dianhydride,
bis(2,3-dicarboxyphenyl) ether dianhydride, bis(3,4-dicarboxyphenyl)
sulfone dianhydride, 1,1-bis(2,3-dicarboxyphenyl)methane
dianhydride, bis(3,4-dicarboxyphenyl)methane
dianhydride, 4,4'-(p-phenylenedioxy)diphthalic
acid dianhydride, 4,4'-(m-phenylenedioxy)diphthalic
acid dianhydride, 2,3,6,7-naphthalenetetracarboxylic
acid dianhydride, 1,4,5,8-naphthalenetetracarboxylic
acid dianhydride, 1,2,3,4-benzenetetracarboxylic
acid dianhydride, 3,4,9,10-perylenetetracarboxylic
acid dianhydride, 2,3,6,7-anthracenetetracarboxylic
acid dianhydride and 1,2,7,8-phenanthrenetetracarboxylic
acid dianhydride.
These tetracarboxylic acid dianhydrides may be used
alone or in admixture of two or more. The proportion of
the aforesaid specific tetracarboxylic acid dianhydride
which may be replaced is usually in the range of 0 to 50
mole % of the tetracarboxylic acid dianhydride.
In the present invention, a dicarboxylic acid
anhydride may be added in order to cap the chain ends of
the thermoplastic polyimide used as a raw material for the
formation of a thermoplastic polyimide film. The
dicarboxylic acid anhydrides which can be used for this
purpose include phthalic anhydride, 2,3-benzophenonedicarboxylic
acid anhydride, 3,4-benzophenonedicarboxylic
acid anhydride, 2,3-dicarboxyphenyl
phenyl ether anhydride, 2,3-biphenyldicarboxylic
acid anhydride, 3,4-biphenyldicarboxylic
acid anhydride, 2,3-dicarboxyphenyl
phenyl sulfone anhydride, 3,4-dicarboxyphenyl phenyl
sulfone anhydride, 2,3-dicarboxyphenyl phenyl sulfide
anhydride, 1,2-naphthalenedicarboxylic acid anhydride, 2,3-naphthalenedicarboxylic
acid anhydride, 1,8-naphthalenedicarboxylic
acid anhydride, 1,2-anthracenedicarboxylic
acid anhydride, 2,3-anthracenedicarboxylic
acid anhydride and 1,9-anthracenedicarboxylic
acid anhydride.
These dicarboxylic acid anhydrides may be substituted
by groups having no reactivity with amines or dicarboxylic
acid anhydrides. The amount of dicarboxylic acid anhydride
added is usually in the range of 0.001 to 0.5 mole per 100
moles of the combined amount of the aforesaid specific
diamine and tetracarboxylic acid anhydride used as chief
raw materials. Preferably, it is in the range of 0.005 to
0.25 mole.
Similarly, a monoamine may be added in order to cap
the chain ends of the thermoplastic polyimide. The
monoamines which can be used for this purpose include
aniline, o-toluidine, m-toluidine, p-toluidine, 2,3-xylidine,
2,4-xylidine, 2,5-xylidine, 2,6-xylidine, 3,4-xylidine,
3,5-xylidine, o-chloroaniline, m-chloroaniline,
p-chloroaniline, o-nitroaniline, o-bromoaniline, m-bromoaniline,
o-nitroaniline, m-nitroaniline, p-nitroaniline,
o-aminophenol, m-aminophenol, p-aminophenol,
o-anisidine, m-anisidine, p-anisidine, o-phenetidine, m-phenetidine,
p-phenetidine, o-aminobenzaldehyde, m-aminobenzaldehyde,
p-aminobenzaldehyde, o-aminobenzonitrile,
m-aminobenzonitrile, p-aminobenzonitrile, 2-aminobiphenyl,
3-aminobiphenyl, 4-aminobiphenyl, 2-aminophenol phenyl
ether, 3-aminophenol phenyl ether, 4-aminophenol phenyl
ether, 2-aminobenzophenone, 3-aminobenzophenone, 4-aminobenzophenone,
2-aminophenol phenyl sulfide, 3-aminophenol
phenyl sulfide, 4-aminophenol phenyl sulfide,
2-aminophenol phenyl sulfone, 3-aminophenol phenyl sulfone,
4-aminophenol phenyl sulfone, α-naphthylamine, β-naphthylamine,
1-amino-2-naphthol, 2-amino-1-naphthol, 4-amino-1-naphthol,
5-amino-1-naphthol,
2-amino-1-naphthol, 5-amino-2-naphthol, 7-amino-2-naphthol,
8-amino-2-naphthol, 1-aminoanthracene, 2-aminoanthracene
and 9-aminoanthracene.
These monoamines may be used alone or in admixture of
two or more. The amount of monoamine added is usually in
the range of 0.001 to 0.5 mole per 100 moles of the
combined amount of the aforesaid specific diamine and
tetracarboxylic acid anhydride used as chief raw materials.
Preferably, it is in the range of 0.005 to 0.25 mole.
Beside the above-described thermoplastic polyimides,
aromatic polyetherimides, aromatic polyamide-imides,
silicone-modified polyimides and the like may also be used
for the resin bonding layer in the method of the present
invention.
Aromatic polyetherimides are polymers having ether
linkages and imide linkages as essential bonding units, and
consist essentially of repeating units of the following
general formula (1).
In the above formula, Z is a trifunctional aromatic
group in which two of the three functional groups are
attached to the adjacent carbon atoms, and Ar is a divalent
aromatic reside. Specific examples of the repeating units
includes those represented by the following formulae (2) to
(8).
These aromatic polyetherimides are commercially
available from General Electric Company, U.S.A., under the
trade names of Ultem-1000, Ultem-4000, Ultem-6000 and the
like.
Aromatic polyamide-imides are polymers having imide
and amide linkages in the repeating units of the main chain,
and consist of repeating units represented b the following
general formula (9).
wherein Ar is a trivalent aromatic group containing at
least one benzene ring, and Z is a divalent organic group.
The especially preferred aromatic polyamide-imides
which can be used in the present invention are aromatic
polyamide-imides having repeating units represented by the
following general formula (10) or (11).
These aromatic polyamide-imides are commercially
available from AMOCO, U.S.A., under the trade name of
TORLON.
The silicone-modified polyimides which can be used in
the method of the present invention are polycondensation
polymers prepared from a diamine containing a
siliconediamine as an essential component, and a
tetracarboxylic acid dianhydride. Typical siliconediamines
are a,w-bisaminopolydimethylsiloxanes of the following
general formula (12).
In formula (12), n preferably has a value of 0 to 10. It
is especially preferable to use a polymer in which n is 4
to 10, or a mixture of such a polymer and a monomer in
which n is 0.
The siliconediamine content in the total amine is
preferably in the range of 5 to 15 mole %. At
siliconediamine contents of 5 mole % or greater, the
resulting polymer desirably has low water-absorbing
properties. At siliconediamine contents of 50 mole % or
less, the resulting polymer desirably has a high glass
transition temperature and hence good heat resistance. The
diamines other than siliconediamines, which can be used for
the preparation of silicone-modified polyimides, include
the same diamines as can be used as raw materials for the
preparation of thermoplastic polyimides. The
tetracarboxylic acid dianhydrides which can be used for
this purpose include those described previously.
Now, the operation of this form of apparatus for
connecting sheet materials is explained with reference to
FIGs. 1 to 4. First of all, as illustrated in FIG. 1, a
preceding sheet material 4 being processed is fed through a
hot press 1 by a feeding means (not shown). Before passing
through the hot press 1, the trailing edge of the preceding
sheet material 4 and the leading edge of a succeeding other
sheet material 6 to be processed are made to overlap with a
resin bonding layer 5 interposed therebetween, and
temporarily joined together by means of an adhesive tape 7.
This adhesive tape 7 may comprise a commercially available
double-coated adhesive tape. In this step, the hot press 1,
a material locking device 2 and an accumulator 3 are not
operated.
Next, as illustrated in FIG. 2, the trailing edge of
the sheet material 4 and the leading edge of the sheet
material 6 are fed in the temporarily joined state. As
soon as the temporarily joined part reaches the hot press 1,
a part of the sheet material 4 being processed is locked by
means of a material locking device 2 installed between the
hot press 1 and an accumulator 3, so that the temporarily
joined part comes to a standstill within the hot press 1.
At this time, the accumulator 3 is operated to keep the
traveling rate of the sheet material 4 being processed
constant.
Moreover, as illustrated in FIG. 3, the hot press 1 is
operated to effect thermocompression bonding of the
trailing edge of the sheet material 4 and the leading edge
of the sheet material 6 with the resin bonding layer 5
interposed therebetween.
After the connection of the sheet materials 4 and 6 by
thermocompression bonding is completed, the sheet material
4 is released from the lock by the material locking device
2. Thus, as illustrated in FIG. 4, the joint between the
sheet materials 4 and 6 travels toward accumulator 3.
As described above, the method and apparatus of this
embodiment can connect the sheet materials 4 and 6 stably
and efficiently to form a continuous material. The
connected sheet materials 4 and 6 are processed in a
subsequent step using coating and drying equipment, heat-treating
equipment, or other equipment, where it is exposed
to a high temperature in the range of 200°C to less than
550°C and a tension in the range of 0.1 to 50 kgf/cm. Even
under such severe processing conditions, the connected
sheet materials can be satisfactorily processed without
suffering from any trouble such as breakage, meandering, or
variation in tension.
Several embodiments of the present invention are more
specifically explained with reference to the following
examples.
In Example 1, there was employed a feeder for feeding
sheet materials continuously to a drying furnace having a
temperature of 300°C. The sheet material being fed was
copper foil and its thickness was 18 µm. The sheet
material to be processed next time was a polyimide film and
its thickness was 13 µm.
After the feeding of the copper foil was finished and
before the feeding of the polyimide film was started, the
trailing edge of the copper foil and the leading edge of
the polyimide film was made to overlap (with a length of
overlap of 300 mm) and joined with a double-coated adhesive
tape. At the same time, a resin bonding layer comprising a
thermoplastic polyimide film was interposed therebetween.
As the thermoplastic polyimide film, there was used a
polyimide film [manufactured by Kaneka Corp. under the
trade name of Apical; having a thickness of 25 µm] having
thermoplastic polyimide layers (each having a thickness of
8 µm) on both sides thereof.
In order to prepare the aforesaid thermoplastic
polyimide, polyamic acid varnish obtained by mixing
3,3',4,4'-benzophenonetetracarboxylic acid dianhydride with
1,3'-bis(3-aminophenoxy)benezene in dimethylacetamide at
room temperature was used as a starting material. This
polyamic acid was applied to the aforesaid polyimide film,
dried and imidized to form a thermoplastic polyimide layer.
The temperature used for this purpose was 300°C.
A material locking device was operated to bring the
overlapping part to a standstill within a hot press. Using
hot platens disposed on both sides, the overlapping part
was pressed at a pressure of 0.1 kgf/cm2 and a temperature
of 300°C for 30 seconds.
Observation of the joint revealed that the sheet materials were satisfactorily joined together. The hot platens were provided with a raised pattern so that the pressure of the press is focused on the raised regions. The pressure calculated from the area of the raised regions was 1.0 kgf/cm2.
Observation of the joint revealed that the sheet materials were satisfactorily joined together. The hot platens were provided with a raised pattern so that the pressure of the press is focused on the raised regions. The pressure calculated from the area of the raised regions was 1.0 kgf/cm2.
Following the copper foil, the polyimide film was fed
to the drying furnace having a temperature of 300°C and
processed therein. The tension applied to the sheet
material being processed was 5 kgf/cm, indicating that a
great tensile force was exerted thereon. However, the
sheet material was satisfactorily processed without
suffering from any trouble such as breakage, meandering, or
variation in tension.
In Example 2, the processing temperature was set at
250°C and the same apparatus as in Example 1 was used. The
sheet material being processed and the sheet material to be
connected comprised a copper film and a polyimide film,
respectively, which were similar to those used in Example 1.
As the thermoplastic polyimide film, there was used a film
manufactured by Mitsui Chemical Industry Co., Ltd. under
the trade name of Regulus. Hot pressing was performed at a
pressure of 0.1 kgf/cm2 and a temperature of 340°C for 1
minute. At the joint, the sheet materials were
satisfactorily joined together. Following the copper foil,
the polyimide film was fed to the furnace. The sheet
material being processed was exposed to a temperature of
250°C and a tension of 10 kgf/m. However, the sheet
material was satisfactorily processed without suffering
from any trouble such as breakage, meandering, or variation
in tension.
According to the present invention, sheet materials
are connected in end-to-end relationship by
thermocompression boding using a resin bonding layer as the
bonding layer. Thus, even where a subsequent processing
step is carried out under severe conditions including a
temperature in the range of 200°C to less than 550°C and a
tension in the range of 0.1 to 50 kgf/cm, the sheet
materials can be satisfactorily processed without suffering
from breakage, separation, meandering, variation in tension,
or the like. Moreover, by connecting sheet materials
according to the present invention, they can be connected
stably and efficiently, and they can be fed to a subsequent
step at a constant feed speed.
FIG. 1 is a view of one form of apparatus used for
carrying out the method for forming a continuous material
by connecting sheet materials in accordance with the
present invention, illustrating the sheet materials having
a resin bonding layer (a thermoplastic polyimide film)
interposed therebetween;
FIG. 2 is a view of one form of apparatus used for
carrying out the method for forming a continuous material
by connecting sheet materials in accordance with the
present invention, illustrating the sheet materials whose
joined part has come to a standstill within a hot press;
FIG. 3 is a view of one form of apparatus used for
carrying out the method for forming a continuous material
by connecting sheet materials in accordance with the
present invention, illustrating the sheet materials being
subjected to thermocompression bonding by operating the hot
press; and
FIG. 4 is a view of one form of apparatus used for
carrying out the method for forming a continuous material
by connecting sheet materials in accordance with the
present invention, illustrating the completely connected
sheet materials.
- 1
- Hot press
- 2
- Material locking device
- 3
- Accumulator
- 4
- Sheet material being processed
- 5
- Resin bonding layer
- 6
- Sheet material to be processed
- 7
- Adhesive tape
Claims (9)
- A method for forming a continuous material by connecting a preceding sheet material with a succeeding other sheet material in end-to-end relationship while feeding them in their longitudinal direction, said method comprising the steps of:(1) interposing a resin bonding layer 5 between the trailing edge of the preceding sheet material 4 and the leading edge of the succeeding other sheet material 6, and temporarily joining them together;(2) after the preceding sheet material 4 and the succeeding other sheet material 6 are fed until the temporarily joined part reaches a hot press 1, operating a material locking device 2 to lock a part of the preceding sheet material 4 and thereby bring the temporarily joined part to a standstill within the hot press 1, and also operating an accumulator 3 to keep the feed speed of the preceding sheet material 4 constant on the downstream side thereof;(3) operating the hot press 1 to effect thermocompression bonding of the temporarily joined part and thereby connect the preceding sheet material 4 with the succeeding other sheet material 6; and(4) releasing the preceding sheet material 4 from the lock by the material locking device 2 and feeding the connected sheet materials downstream through the accumulator 3.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein said thermocompression bonding is performed at a temperature in the range of 200°C to less than 550°C and a pressure in the range of 0.001 to 50 kgf/cm2.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein the trailing edge of the preceding sheet material 4 and the leading edge of the succeeding other sheet material 6 each have a length of 10 to 1,000 mm.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein the preceding sheet material 4 and the succeeding other sheet material 6 each comprise a metal foil or heat-resistant resin film having a thickness of 5 to 500 µm.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein the resin bonding layer comprises a film of a thermoplastic resin selected from the group consisting of thermoplastic polyimides, aromatic polyetherimides, aromatic polyamideimides and silicone-modified polyimides.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 5 wherein the resin bonding layer comprises a thermoplastic polyimide film.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein the resin bonding layer has a thickness of 0.1 to 50 µm.
- A method for forming a continuous material by connecting sheet materials as claimed in claim 1 wherein the connected sheet materials are continuously processed at a temperature in the range of 200°C to less than 550°C and under a tension in the range of 0.1 to 50 kgf/cm.
- An apparatus for forming a continuous material by connecting sheet materials which is used for carrying out a method for forming a continuous material by connecting sheet materials as claimed in any one of claims 1 to 8, said apparatus comprising:a hot press for effecting thermocompression bonding of a temporarily joined part formed by making the trailing edge of a preceding sheet material and the leading edge of a succeeding other sheet material overlap with a bonding layer interposed therebetween, and temporarily joining them together;a material locking device for locking a part of the preceding sheet material in order to bring the temporarily joined part to a standstill within said hot press; andan accumulator for keeping the traveling speed of the preceding material constant on the downstream side of said material locking device.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/JP1998/002472 WO1999062803A1 (en) | 1996-11-28 | 1998-06-04 | Method of manufacturing continuous substrate and apparatus therefor |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1002752A1 true EP1002752A1 (en) | 2000-05-24 |
EP1002752A4 EP1002752A4 (en) | 2001-04-25 |
Family
ID=14208337
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98923120A Withdrawn EP1002752A4 (en) | 1998-06-04 | 1998-06-04 | Method of manufacturing continuous substrate and apparatus therefor |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1002752A4 (en) |
KR (1) | KR100386103B1 (en) |
WO (1) | WO1999062803A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2005105633A1 (en) | 2004-04-28 | 2005-11-10 | Sony Chemical & Information Device Corporation | Anisotropic conductive film holding tape and mounting method |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2601967A1 (en) * | 1976-01-20 | 1977-07-21 | Ver Seidenwebereien Ag | Bonding textile length ends - by interposing a web between the ends, applying a solvent or swelling agent and heating while pressing |
WO1984004486A1 (en) * | 1983-05-19 | 1984-11-22 | Esseltepack Ab | Method and means for joining and sealing of material parts and use of such means in containers |
US4816111A (en) * | 1984-10-11 | 1989-03-28 | Nuova Isotex S.P.A. | System for processing fabrics or webs continuously |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS62135584A (en) * | 1985-12-09 | 1987-06-18 | Toyota Motor Corp | Method of bonding adherend |
JP2844117B2 (en) * | 1990-08-24 | 1999-01-06 | 四国化工機株式会社 | Continuous rewinding device for multiple rolled tapes |
-
1998
- 1998-06-04 WO PCT/JP1998/002472 patent/WO1999062803A1/en active IP Right Grant
- 1998-06-04 KR KR10-2000-7001244A patent/KR100386103B1/en not_active IP Right Cessation
- 1998-06-04 EP EP98923120A patent/EP1002752A4/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2601967A1 (en) * | 1976-01-20 | 1977-07-21 | Ver Seidenwebereien Ag | Bonding textile length ends - by interposing a web between the ends, applying a solvent or swelling agent and heating while pressing |
WO1984004486A1 (en) * | 1983-05-19 | 1984-11-22 | Esseltepack Ab | Method and means for joining and sealing of material parts and use of such means in containers |
US4816111A (en) * | 1984-10-11 | 1989-03-28 | Nuova Isotex S.P.A. | System for processing fabrics or webs continuously |
Non-Patent Citations (1)
Title |
---|
See also references of WO9962803A1 * |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2005105633A1 (en) | 2004-04-28 | 2005-11-10 | Sony Chemical & Information Device Corporation | Anisotropic conductive film holding tape and mounting method |
EP1741650A1 (en) * | 2004-04-28 | 2007-01-10 | Sony Chemical & Information Device Corporation | Anisotropic conductive film holding tape and mounting method |
EP1741650A4 (en) * | 2004-04-28 | 2009-05-06 | Sony Chem & Inf Device Corp | Anisotropic conductive film holding tape and mounting method |
Also Published As
Publication number | Publication date |
---|---|
KR20010022650A (en) | 2001-03-26 |
EP1002752A4 (en) | 2001-04-25 |
KR100386103B1 (en) | 2003-06-02 |
WO1999062803A1 (en) | 1999-12-09 |
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