WO2022054720A1 - 発熱フィルムの製造方法、発熱フィルム、レンズおよび車載カメラ - Google Patents
発熱フィルムの製造方法、発熱フィルム、レンズおよび車載カメラ Download PDFInfo
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- WO2022054720A1 WO2022054720A1 PCT/JP2021/032499 JP2021032499W WO2022054720A1 WO 2022054720 A1 WO2022054720 A1 WO 2022054720A1 JP 2021032499 W JP2021032499 W JP 2021032499W WO 2022054720 A1 WO2022054720 A1 WO 2022054720A1
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- generating film
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Classifications
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- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/12—Optical coatings produced by application to, or surface treatment of, optical elements by surface treatment, e.g. by irradiation
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
- G02B7/02—Mountings, adjusting means, or light-tight connections, for optical elements for lenses
- G02B7/021—Mountings, adjusting means, or light-tight connections, for optical elements for lenses for more than one lens
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
- G02B1/041—Lenses
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
- G02B27/0006—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00 with means to keep optical surfaces clean, e.g. by preventing or removing dirt, stains, contamination, condensation
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B27/00—Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
- G02B27/02—Viewing or reading apparatus
- G02B27/028—Viewing or reading apparatus characterised by the supporting structure
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
- G02B7/02—Mountings, adjusting means, or light-tight connections, for optical elements for lenses
- G02B7/028—Mountings, adjusting means, or light-tight connections, for optical elements for lenses with means for compensating for changes in temperature or for controlling the temperature; thermal stabilisation
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B15/00—Special procedures for taking photographs; Apparatus therefor
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B17/00—Details of cameras or camera bodies; Accessories therefor
- G03B17/02—Bodies
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B17/00—Details of cameras or camera bodies; Accessories therefor
- G03B17/02—Bodies
- G03B17/12—Bodies with means for supporting objectives, supplementary lenses, filters, masks, or turrets
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B17/00—Details of cameras or camera bodies; Accessories therefor
- G03B17/55—Details of cameras or camera bodies; Accessories therefor with provision for heating or cooling, e.g. in aircraft
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B30/00—Camera modules comprising integrated lens units and imaging units, specially adapted for being embedded in other devices, e.g. mobile phones or vehicles
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
- H04N23/00—Cameras or camera modules comprising electronic image sensors; Control thereof
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/02—Details
- H05B3/03—Electrodes
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
- H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
- H05B3/14—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
- H05B3/146—Conductive polymers, e.g. polyethylene, thermoplastics
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/24—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor being self-supporting
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/017—Manufacturing methods or apparatus for heaters
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2214/00—Aspects relating to resistive heating, induction heating and heating using microwaves, covered by groups H05B3/00, H05B6/00
- H05B2214/02—Heaters specially designed for de-icing or protection against icing
Definitions
- the present invention relates to a method for manufacturing a heat-generating film, a heat-generating film, a lens, and an in-vehicle camera.
- Patent Document 1 discloses a lens unit having a snow melting function by a heater portion that generates heat when energized.
- Patent Document 2 discloses an image pickup device that includes a diameter plate connected to a heat source between a lens and an image pickup unit and suppresses the occurrence of dew condensation on the lens.
- the manufacturing method according to the present disclosure is a manufacturing method of a heat-generating film that heats a lens.
- the present invention includes a supply step of supplying the film raw material in a heated state or a normal temperature state depending on the supply thickness of the film raw material containing a carbon filler, a binder resin, and a solvent.
- the heat-generating film according to the present disclosure is a heat-generating film that heats the lens. It contains a carbon filler and a resin, and the sum of the contents of the carbon filler and the resin is 90% or more based on the whole heat-generating film.
- the present disclosure it is possible to manufacture a heat-generating film having excellent environmental resistance by a simple manufacturing process. More specifically, since the heat-generating film is manufactured through a supply process of supplying the film raw material in a heated state or a normal temperature state depending on the supply thickness of the film raw material, the carbon filler and the resin contained in the heat-generating film are used. The sum of the contents can be 90% or more.
- FIG. 1 (a) is a perspective view showing a state in which a film raw material is supplied to a lens
- FIG. 1 (b) is an enlarged cross-sectional view of a region b surrounded by a broken line in FIG. 1 (a).
- 2 (a) and 2 (b) are process cross-sectional views schematically showing a conventionally known method for manufacturing a heat-generating film.
- FIG. 3 is a process sectional view schematically showing a method for producing a heat-generating film according to the first embodiment of the present disclosure.
- FIG. 4A is a perspective view schematically showing the heat-generating film according to the embodiment of the present disclosure
- FIG. 4B is a cross-sectional view schematically showing the heat-generating film according to the embodiment of the present disclosure.
- FIG. 5 is a cross-sectional view of an in-vehicle camera provided with a lens according to the embodiment of the present disclosure.
- FIG. 6 is a comparison diagram showing a contrast between a cross section of a film raw material containing a high boiling point solvent and a cross section of a film raw material containing a low boiling point solvent.
- FIG. 7 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to the second embodiment of the present disclosure.
- FIG. 8 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to the second embodiment of the present disclosure.
- FIG. 9 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to the second embodiment of the present disclosure.
- FIG. 10 is a process perspective view schematically showing a method for producing a heat-generating film according to the second embodiment of the present disclosure.
- FIG. 11 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to a modification 1 of the second embodiment of the present disclosure.
- FIG. 12 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to Modification 2 of the second embodiment of the present disclosure.
- FIG. 13 is a process perspective view schematically showing a method for manufacturing a heat-generating film according to a modification 3 of the second embodiment of the present disclosure.
- FIG. 14 is a perspective view of a second embodiment of the heat-generating film of the present disclosure.
- FIG. 15 (a) is a plan view of the second embodiment of the heat-generating film of the present disclosure
- FIG. 15 (b) is a cross-sectional view taken along the line bb of FIG. 15 (a) in the direction of arrow.
- FIG. 16 is a perspective view of a third embodiment of the heat-generating film of the present disclosure.
- 17 (a) is a plan view of the third embodiment of the heat-generating film of the present disclosure
- FIG. 17 (b) is a cross-sectional view taken along the line bb of FIG. 17 (a) in the direction of arrow.
- FIG. 18 is a cross-sectional view of a modified example of the third embodiment of the heat-generating film of the present disclosure.
- FIG. 18 is a cross-sectional view of a modified example of the third embodiment of the heat-generating film of the present disclosure.
- FIG. 19 is a plan view of a modified example of the third embodiment of the heat-generating film of the present disclosure.
- FIG. 20 is a plan view of a modified example of the third embodiment of the heat-generating film of the present disclosure.
- 21 (a) is a plan view of a fourth embodiment of the heat-generating film of the present disclosure, and FIG. 21 (b) is a cross-sectional view taken along the line bb of FIG. 21 (a) in the direction of arrow.
- 22 (a) is a plan view of a modified example of the fourth embodiment of the heat-generating film of the present disclosure, and FIG. 22 (b) is a cross-sectional view taken along the line bb of FIG. 22 (a) in the direction of arrow. ..
- FIG. 23 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the third embodiment of the present disclosure.
- FIG. 24 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the third embodiment of the present disclosure.
- FIG. 25 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the third embodiment of the present disclosure.
- FIG. 26 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the third embodiment of the present disclosure.
- FIG. 27 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating film according to the fourth embodiment of the present disclosure.
- FIG. 24 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the third embodiment of the present disclosure.
- FIG. 24 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating films of the second embodiment and the
- FIG. 28 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating film according to the fourth embodiment of the present disclosure.
- FIG. 29 is a process perspective view schematically showing a manufacturing method for manufacturing the heat-generating film according to the fourth embodiment of the present disclosure.
- 30 (a) is an SEM image of a heat-generating film of a comparative example
- FIG. 30 (b) is an elemental analysis mapping image
- FIG. 30 (c) is an elemental analysis table based on FIG. 30 (b).
- 31 (a) is an SEM image of the heat-generating film of the example
- FIG. 31 (b) is an elemental analysis mapping image
- FIG. 31 (c) is an elemental analysis table based on FIG. 31 (b).
- FIG. 32 (a) is a graph showing the relationship between the resistance value and the elapsed time in an environment of a temperature of 85 ° C. and a humidity of 85% with respect to the heat-generating film of the comparative example
- FIG. 32 (b) is a graph showing the relationship between the heat-generating film and FIG. 32 (a).
- FIG. 33 (a) is a graph showing the relationship between the resistance value and the elapsed time in an environment of a temperature of 85 ° C. and a humidity of 85% with respect to the heat-generating film of the example
- FIG. 33 (b) is a graph showing the relationship of the elapsed time.
- a heater material in which a transparent conductive film such as ITO is formed as a thin film on a resin base material such as PET film, polyimide, or liquid crystal polymer, or carbon particles and a dielectric material on the resin base material.
- a resin base material such as PET film, polyimide, or liquid crystal polymer, or carbon particles and a dielectric material on the resin base material.
- a lens in which a film raw material containing carbon particles and a solvent is conventionally coated on a lens base material 100'and the film raw material is baked to provide a heat generating film 10' is known ( FIG. 1 (a)).
- a method of arranging the dispenser 51 above the lens base material 100'and applying the film raw material using the dispenser 51 can be mentioned (FIG. 1 (FIG. 1). b)).
- FIG. 2A shows a heat-generating film obtained by applying the film raw material 11'to the designed thickness using the dispenser 51, and then performing oven temporary baking (100 ° C.) for 10 minutes and main curing baking (200 ° C.) for 60 minutes.
- the cross section of is shown schematically. It is known that the volume of the heat-generating film raw material having a heater function shrinks to about 1/10 by baking, and in order to obtain a heat-generating film having a thickness of about 400 ⁇ m, a dispenser 51 has a thickness of about 4 mm. It was necessary to apply the film raw material 11'until. When the film raw material 11'is applied so as to be a thick film in this way, as shown in FIG. 2A, it is not possible to obtain a heat-generating film 10'with a desired shape, and the shape becomes unstable. Had.
- the manufacturing process schematically shown in FIG. 2B can be considered. That is, after applying one layer of the film raw material 11'with the dispenser 51, the oven temporary baking (100 ° C.) is performed for 10 minutes. Then, after applying one layer of the film raw material again, the oven temporary baking is performed again in the same manner. A manufacturing method is conceivable in which this is repeated until a heat-generating film precursor having a desired thickness is obtained, and then the main curing bake (200 ° C.) is performed for 60 minutes.
- the problem that the shape of the manufactured heat-generating film 10'is unstable can be solved, but the manufacturing process becomes complicated by repeating the coating of the film raw material and the oven temporary baking. Further, as will be described later, in the above manufacturing method, when the heat-generating film is subjected to a quality test in an environment of high temperature (85 ° C.) and high humidity (85%), the resistance value of the heat-generating film changes significantly after a long period of time, and the reliability is increased. It was a detriment to sex.
- FIG. 3 is a process sectional view schematically showing a method for producing a heat-generating film according to the first embodiment of the present disclosure.
- the film raw material 11 contains a carbon filler, a binder resin and a solvent.
- Carbon fillers are conductive and may be granular, flake or fibrous, carbon black, acetylene black, ketjen black, furnace black, natural graphite, artificial (artificial) graphite, kissed graphite, amorphous. At least one may be selected from the group consisting of carbon, hard carbon, soft carbon, activated carbon, carbon nanofibers, carbon nanotubes, and fullerene.
- conductivity in the present specification means that the surface electric resistance value is 107 ⁇ or less.
- the binder resin may contain a functional group that contributes to the curing reaction. Specifically, from the viewpoint of heat resistance or durability of the heat-generating film, it is preferable to contain a fluororesin, and more preferably, a fluororubber compound may be used.
- the binder resin contained in the film raw material may include the one in the state before the curing reaction.
- the solvent is preferably a low boiling point solvent having a boiling point of 150 ° C. or lower.
- the "boiling point" referred to in the present specification indicates the boiling point at 1 atm.
- the solvent is preferably a non-polar solvent.
- non-polar solvent means a solvent having a relative permittivity of 15 or less.
- toluene relative permittivity: 2.3
- xylene relative permittivity: 2.4
- butyl acetate relative permittivity: 5.0
- methylisobutylketone ratio
- At least one may be selected from the group consisting of a permittivity: 14.0), and if these solvents are contained, other solvents may be contained.
- the film raw material containing the carbon filler, the binder resin and the solvent preferably has a viscosity of 10,000 cps or more and 50,000 cps or less.
- viscosity refers to the viscosity at room temperature (20 ° C to 25 ° C).
- the film raw material has a certain degree of viscosity, so that unnecessary wetting and spreading is suppressed and the film shape has independent electrical characteristics and is stable without contacting peripheral members. Easy to handle.
- a BH type viscometer is used for measuring the viscosity, and as an example of the measurement conditions, a measured value of 25 ° C./1 minute and 50 rpm may be used.
- the method for producing a heat-generating film of the present disclosure includes a supply step of supplying a film raw material containing a carbon filler, a binder resin and a solvent.
- the film raw material 11 may be supplied to the lens base material 100. Specifically, it is preferable to supply the film raw material 11 so that the outer contour is circular and has a hole in the center (that is, a donut shape) in a plan view.
- the supply device 50 for supplying the film raw material may use a dispenser in order to supply the film raw material onto the lens base material with high accuracy, but the present invention is not limited to this example, and the spray coating device, the slit coater device, the die coater device, and the screen. At least one may be selected from the group consisting of a printing device, an inkjet device or a pad printing device. Further, a plurality of devices may be combined and supplied.
- the film raw material 11 When the film raw material 11 is supplied to the lens base material 100, the film raw material is supplied in a heated state or a normal temperature state of the lens base material 100 according to the supply thickness of the film raw material. Therefore, a heating element 60 for bringing the lens base material 100 into a heated state or a normal temperature state may be used.
- a thermal heater block may be used as the heating element 60, and the thermal heater block may have a structure that fits with the bottom surface of the lens base material 100.
- any heating method may be adopted as long as the film raw material can be heated.
- the heating element is provided with a method of heating by providing a coil heater in the heat heater block, a method of flowing a heat medium through the heat heater block to heat the heat, and a method of providing a microwave and high frequency heating device in the heater block. At least one may be selected from the group consisting of heating methods.
- the heating temperature in the heated state while suppressing the foaming generated on the surface of the coating film due to the volatilization of the solvent component is preferably about 30 to 80 ° C.
- the room temperature state indicates a room temperature (20 ° C to 25 ° C).
- the device for heating the heating element in contact with the lens base material has been described, but the present invention is not limited to this example, and for example, the heating element for heating without contacting the lens base material (
- the heating element for heating without contacting the lens base material may be a blower device such as a dryer).
- the supply thickness when the supply thickness is less than 120 ⁇ m, it is preferable to perform the supply step in a normal temperature state, and when the supply thickness is 120 ⁇ m or more, the supply step is performed in a heated state. It is preferable to do it.
- the supply thickness means the thickness of the coating film material after drying. This supply thickness will be described in detail with reference to FIG.
- the shape of the heat-generating film 10 to be manufactured differs depending on the flat area of the flat portion 111 (see FIG. 4B) on the back surface of the lens. That is, when the flat area of the flat portion of the lens is large in a plan view, the diameter of the hole in the center of the heat-generating film 10 manufactured as shown in FIG. 4A on the left is reduced to reduce the diameter of the heat-generating film 10. May be thinned. On the other hand, when the flat area of the flat portion of the lens is small in plan view, the diameter of the hole in the center of the heat-generating film 10 manufactured as shown in the right figure of FIG. 4A is increased to increase the diameter of the heat-generating film 10. May be thickened. As an example, FIG.
- FIG. 4A on the left illustrates a heat-generating film 10 having an outer contour diameter of 15.5 mm, a central hole diameter of 9 mm, and a film thickness of less than 120 ⁇ m
- FIG. 4A on the right shows an example.
- An example is a heat-generating film 10 having an outer contour diameter of 15.5 mm, a central hole diameter of 13.1 mm, and a film thickness of 120 ⁇ m or more.
- the film thickness may be set so that their volumes are substantially equal. In this case, the heat-generating film is used. It becomes easy to manage the resistance value per volume of the heater.
- a baking step of baking the film raw material may be carried out.
- the baking step may be performed by baking at a temperature of 180 ° C. to 220 ° C. for 60 minutes or more. This baking step causes a reaction in which the film raw material is cured to produce the heat-generating film 10. Before the baking step, a temporary baking step of temporarily curing the film raw material may be performed.
- a heat-generating film that heats the lens is manufactured.
- An electrode 20 (see FIG. 4B) for applying electric power to the heat-generating film 10 may be formed, and the electrode 20 is formed on the back surface of the heat-generating film 10 in order to facilitate wiring. It is preferable to form it on the surface opposite to the surface in contact with the lens).
- the heat-generating film 10 is arranged so as to be in direct contact with the lens 110, and the lens 110 can be heated by heating the heat-generating film 10. Further, the heat-generating film that generates heat of this lens may be used in a camera for exterior use, and may be provided in, for example, an in-vehicle camera (see FIG. 5).
- the heat-generating film manufactured through the manufacturing process of the present disclosure has a stable shape as compared with the heat-generating film manufactured by the manufacturing process schematically shown in FIG. 2 (a). Further, the heat-generating film can be manufactured by a simple process as compared with the manufacturing process schematically shown in FIG. 2 (b).
- the mode of supplying the film raw material to the lens base material 100 has been described, but the present invention is not limited to this example, and for example, the film raw material may be directly supplied to the lens 110.
- the heating element in that case may have a structure that fits with the lens 110.
- the heat-generating film manufactured through the manufacturing process of the present disclosure can directly form the heat-generating film with respect to the lens base material 100, the minimum number of parts can be obtained without using a base material or the like. Therefore, the cost can be reduced. Further, since the electrode 20 is installed on the back surface of the heat generating film 10 (the surface opposite to the surface in contact with the lens), the electrode and the lead member can be easily connected. If the flat area of the flat part of the lens is small and a load per area is applied, the thickness of the heat-generating film should be 120 ⁇ m or more, and if the flat area of the flat part of the lens is large and no load is applied per area, heat is generated. Since the thickness of the film is less than 120 ⁇ m, it is possible to produce a heat-generating film having good pressure resistance. It was
- FIG. 6 is a comparison diagram showing a contrast between a cross section of a film raw material containing a high boiling point solvent and a cross section of a film raw material containing a low boiling point solvent.
- FIG. 6 shows the film raw material 11'when a high boiling point solvent is used, the heat-generating film precursor 10a'after baking, and the heat-generating film 10 when measuring resistance in a high temperature (85 ° C.) and high humidity (85%) environment.
- the cross section of' is shown for each process.
- the solvent was difficult to volatilize, and when the cross section of the heat-generating film precursor 10a'after baking was seen, a loophole was formed in the volatile portion of the solvent.
- moisture or impurities caused by the surrounding high humidity environment were found in the loophole portion.
- the inventor of the present application has found that the resistance value of the heat-generating film 10'becomes unstable due to the intrusion.
- the lower part of FIG. 6 shows the film raw material 11 when a low boiling point solvent is used, the heat-generating film precursor 10a after baking, and the heat-generating film when measuring resistance in a high temperature (85 ° C.) and high humidity (85%) environment.
- the cross section of 10 is shown for each process.
- the solvent is easily volatilized, so that the loophole of the solvent is reduced when looking at the cross section of the heat generating film precursor 10a. Therefore, even if the heat-generating film 10 using this low boiling point solvent is tested in a high temperature (85 ° C.) and high humidity (85%) environment, the resistance value of the heat-generating film can be stabilized.
- FIGS. 7 to 10 are process cross-sectional views schematically showing a method for producing a heat-generating film according to the second embodiment of the present disclosure.
- the heat-generating film manufacturing method of the present embodiment may include a support member preparation step, a supply step of supplying a film raw material, a baking step, a peeling step, and a cutting step.
- the support member 70 may be used to support the film raw material (see FIG. 7).
- the support member 70 may include a frame 71 made of metal and a resin member 72 that is fitted to the frame 71 and has good peelability from a film raw material.
- the three resin members 72 may be fitted to the frame 71.
- the resin having good releasability from the film raw material at least one may be selected from the group consisting of a fluororesin, a Teflon resin (Teflon is a registered trademark), a silicone resin, and a polyethylene terephthalate resin film having a silicone resin arranged on the surface.
- the electrode frame 21 may be placed on the support member 70 (see FIG. 7).
- an electrode frame 21 having electrodes for producing three heat-generating films may be placed on the support member 70.
- the material of the electrode frame 21 may be a conductive material such as a copper plate or a copper foil, and may be a stainless foil, a copper material plated with gold, a stainless steel plated with gold, or the like.
- the thickness of the electrode frame 21 may be 5 to 50 ⁇ m or less. More preferably, it may be 30 ⁇ m or less.
- the corners of the contact surface between the frame 71 and the resin member 72 in the electrode frame 21 may be R-shaped, more preferably circular. This avoids stress concentration, prevents unexpected cracks on the film surface, and facilitates peeling.
- the film raw material may be supplied onto the support member 70 (see FIG. 8).
- a heating element 60 for bringing the support member 70 into a heated state or a normal temperature state may be used.
- the heating element 60 can be in contact with the support member 70 to heat the film raw material 11.
- at least one heating element 60 may be selected from the group consisting of a method using a coil heater, a method using a heat medium, and a method using microwaves and high frequency heating.
- the heating temperature in the heated state while suppressing the foaming generated on the surface of the coating film due to the volatilization of the solvent component is preferably about 30 to 80 ° C.
- the film raw material 11 may be supplied so as to cover at least the frame 71 and the resin member 72 by a coater device such as a die coater or a slit coater. Further, the film raw material 11 may be supplied so as to cover the frame 71, the resin member 72, and the electrode frame 21.
- the frame 71 enables simultaneous processing of a large number of products while preventing deformation such as warpage after the curing treatment of the coating film material, and can improve production efficiency.
- the supply thickness of the film raw material is less than 120 ⁇ m, it is preferable to carry out the supply step in a normal temperature state, and when the supply thickness is 120 ⁇ m or more, it is preferable to carry out the supply step in a heated state. Even when the supply thickness of the film raw material is less than 120 ⁇ m, the supply step may be performed in a heated state.
- the baking step may be carried out.
- the baking step may be performed by baking at a temperature of 180 ° C. to 220 ° C. for 60 minutes or more.
- the baking step causes a reaction in which the film raw material is cured, and the heat-generating film precursor 10a may be produced.
- a temporary baking step such as temporarily curing the film raw material may be performed.
- the three resin members 72 may be peeled off from the back surface of the support member 70 (see FIG. 9). By peeling off the three resin members 72, the heat-generating film precursor 10a obtained by the baking step may be exposed on the back surface of the support member 70.
- the structure of the support member 70 having the resin member 72 such that the three resin members 72 become one may be used.
- a cutting step of cutting the heat-generating film precursor 10a corresponding to the lens shape may be performed (see FIG. 10). Further, the resin member 72 may be peeled off after the cutting step is performed without peeling the resin member 72. Further, another material having the same shape as the resin member 72 may be inserted and cut. Further, when further cutting, the heat-generating film precursor 10a of FIG. 9 may be cut from the back side of the surface. In the cutting step, the heat-generating film precursor 10a is cut so that the outer contour is circular and has a hole in the center in a plan view, and the thicker the heat-generating film precursor, the larger the diameter of the heat-generating film. The precursor may be cleaved.
- the film thickness of the heat-generating film precursor when the film thickness of the heat-generating film precursor is less than 120 ⁇ m, the film is cut so that the diameter of the central hole becomes smaller, and the film thickness is reduced.
- the film thickness When is 120 ⁇ m or more, it may be cut so that the diameter of the central hole is large. That is, by cutting so that the volumes of both are substantially equal, it becomes easy to manage the resistance value per volume of the heater of the heat generating film.
- the heat-generating film can be manufactured through the above steps.
- This heat-generating film includes a heat-generating portion 12 that generates heat over the entire closed region. Then, by bringing the manufactured heat-generating film into contact with the lens, a lens provided with the heat-generating film can be manufactured. Further, the heat-generating film that generates heat of this lens may be used in a camera for exterior use, and may be provided in, for example, an in-vehicle camera.
- FIGS. 11 to 13 are process cross-sectional views schematically showing a method for manufacturing a heat-generating film according to Modifications 1 to 3 of the second embodiment of the present disclosure, respectively.
- the frame 71 made of metal and the support member 70 provided with the resin member 72 having good peelability from the film raw material have been described.
- the entire support member 70 may be used as a resin having good releasability from the film raw material (see FIG. 11).
- the peeling step can be completed in the form of a continuous coating film by peeling the support member 70 from the film raw material, so that the three resin members described in the second embodiment described above can be peeled off. It is efficient when manufacturing a product on a trial basis, for example, the product can be taken out with a smaller product pitch, and the manufacturing process is easy.
- the heat generating portion 12 is a conductive resistor in the entire closed region, the formation of the electrode 20 may be omitted.
- the film raw material is supplied by a coater device such as a die coater or a slit coater has been described, but instead of this configuration, the film raw material is supplied by using the dispenser 51. It may be (see FIG. 12). According to such a configuration, the film raw material can be accurately supplied by the dispenser 51. If the film raw material using the dispenser 51 is supplied, the cutting step for obtaining the heat-generating film 10 may be omitted.
- a screen printing device 52 may be used to supply the film raw material by moving the screen (see FIG. 13). According to such a configuration, a desired heat-generating film can be mass-produced by the screen printing method.
- the heat-generating film of the present disclosure -Structure of heat-generating film (first embodiment of heat-generating film)- Next, the heat-generating film manufactured by the above-described heat-generating film manufacturing method of the present disclosure will be described.
- the heat-generating film that heats the lens of the present disclosure comprises a carbon filler, a resin, and other inclusions, and the sum of the contents of the carbon filler and the resin is 90% or more.
- the "contents other than the carbon filler and the resin" referred to in the present specification indicate a content that is preferably present as a constituent component of the heat-generating film and an undesired content as a component of the heat-generating film.
- the “contents preferably present as constituents of the heat-generating film” refer to inclusions other than the carbon filler and the resin, which are caused by improving the characteristics of the heat-generating film.
- the “contents preferably present as constituents of the heat-generating film” refer to, for example, magnesium oxide particles, aluminum oxide, and silicon oxide particles.
- the “undesired inclusion” means a substance that is not substantially essential as a component of the heat-generating film in a broad sense, and exists as a component of a carbon filler, a resin and a heat-generating film in a narrow sense. Refers to substances other than the preferred inclusions.
- the "undesired content” refers to a composition other than carbon fibers, a binder resin, magnesium oxide particles, aluminum oxide and silicon oxide particles.
- the undesired inclusions may include, for example, barium sulfide particles, as well as moisture, pores and air.
- the heat-generating film may include a heat-generating portion that generates heat over the entire closed region.
- the entire closed region may be used as the heat generating portion.
- the "closed region” as used herein means, for example, a region surrounded by a straight line or a curved line and closed.
- the “whole area” is not limited to 100% of the closed region, and may be preferably 90% or more, more preferably 95% or more, and even more preferably 99% or more of the region.
- the film thickness of the heat-generating film is preferably 5 ⁇ m or more and 400 ⁇ m or less. By setting the film thickness in this range, the resistance value of the heat-generating film can be a desired design.
- the heat-generating film of the present disclosure is considered to be mainly used for applying electric power to the heat-generating film to melt the freezing matter adhering to the lens.
- the electric power applied to the heat-generating film needs to be such that the lens function is not impaired even if the lens is heated by the applied electric power. Further, it is required to melt a predetermined amount of freezing matter in a short time by using a heat-generating film.
- the resistance value of the heat-generating film was designed in consideration of these factors, and the resistance value of the heat-generating film of the present disclosure was set to about 20 to 60 ⁇ .
- the carbon filler may contain carbon fibers, and can reduce the fluctuation of the resistance value during operation as compared with the conventionally known carbon particles alone.
- the resin preferably contains a fluororesin.
- a fluororesin By containing a fluororesin, a heat-generating film having good heat resistance or durability can be obtained.
- the heat-generating film has a circular outer contour and a hole in the center in a plan view. With such a shape, a heat-generating film that matches the lens shape can be obtained.
- the heat generating portion 12 is in the form of a film, and as described above, the film thickness is preferably 5 ⁇ m or more and 400 ⁇ m or less.
- a base material 13 for holding the heat generating portion 12 may be provided.
- holding the heat-generating portion means a state in which the heat-generating portion is held in contact with the heat-generating portion, and the base material 13 is arranged below the heat-generating portion 12 to retain the heat-generating portion 12. This includes not only the state of being hung down, but also the state in which the heat generating portion 12 is maintained by arranging the base material 13 above or to the side of the heat generating portion 12.
- the base material 13 includes a state in which the heat generating portion 12 and the base material 13 are laminated so as to be in contact with each other.
- the rigidity of the heat generating film 10 can be increased.
- the heat-generating film is provided with the base material 13, it is possible to suppress the heat shrinkage of the film due to the high temperature of the heat-generating portion 12.
- the thickness of the base material 13 is preferably 5 ⁇ m or more and 100 ⁇ m or less.
- the base material 13 may have a circular outer contour and a hole in the center in a plan view corresponding to the heat generating portion 12.
- the shape of the base material 13 is not limited to this embodiment, and the contour or the shape of the hole may be elliptical or rectangular, and the contour and the shape of the hole may be different (for example, the contour may be rectangular).
- the shape of the hole may be an ellipse).
- the base material 13 preferably has heat resistance and insulating properties. Therefore, as the material used for the base material 13, for example, a heat-resistant insulating sheet such as polyimide, LCP, or polycarbonate may be used.
- heat resistance of the base material means having resistance to at least the heat generated by the heat generating portion
- insulation of the base material means having at least the heat generating portion having conductivity. It refers to the degree of insulation that can be electrically insulated.
- the base material 13 side may be brought into contact with the lens to generate heat (see FIGS. 15 (a) and 15 (b)).
- the lens can be easily heated by providing the wiring 22 on the heat generating portion 12 side. It also has the effect of retaining the heat of the heated lens by the base material 13 (heat insulating effect).
- the heat generating portion 12 side may be brought into contact with the lens. In this case, it can be realized by providing wiring for supplying electric power to the heat generating portion 12 inside the lens. Since the heat generating portion 12 comes into direct contact with the lens, the lens can be heated efficiently.
- the base material 13 may be provided with at least two through holes 13a for supplying electric power to the heat generating portion 12.
- the heat generating portion 12 is exposed when viewed in a plan view from the base material 13 side (see FIG. 16). It is possible to supply electric power to the heat generating portion 12 through the exposed portion of the heat generating portion 12.
- the electrode 20 When supplying electric power to the heat generating portion 12 through the through hole 13a, the electrode 20 may be embedded in the through hole 13a (see FIGS. 17 (a) and 17 (b)). Moreover, you may make an electrical connection using a conducting wire or the like without embedding the electrode 20. Further, from the viewpoint of manufacturing described later, a part of the heat generating portion 12 may be arranged in the through hole 13a (see FIG. 18).
- the through holes 13a may be arranged at symmetrical positions with the base material 13 as the center.
- the "target position” as used herein means a position where the through holes 13a overlap each other when rotated by 180 ° about the center of the base material 13 as a rotation axis. In this way, when the two through holes 13a are arranged at symmetrical positions with respect to the base material 13, the distances between the through holes 13a are substantially equal, so that the heat generating portion 12 can generate heat uniformly.
- the through holes 13a may be arranged at an asymmetrical position around the base material 13 (see FIG. 19).
- the "non-target position" as used herein means a position where the through holes 13a do not overlap each other even when rotated by 180 ° with the center of the base material 13 as the rotation axis.
- the distance between the through holes 13a will be different. For example, according to FIG. 19, in the distance between through holes along the heat generating portion 12, the distance between through holes along the upper heat generating portion 12 is L1 and the distance between through holes along the lower heat generating portion 12 is L2.
- the through-hole distance L1 is longer than the through-hole distance L2. That is, the current does not easily flow on the through-hole distance L1 side of the heat generating portion 12, and the current easily flows on the through-hole distance L2 side. Then, the heat generation portion 12 is less likely to generate heat on the L1 side of the through-hole distance, and is more likely to generate heat on the L2 side of the through-hole distance, so that the heat generation can be biased. According to such a configuration, for example, when the existence tendency of the freezing substance is known, for example, a large amount of the freezing substance is present on the L2 side of the through-hole distance, the heat generation is biased and the heat is effectively generated. be able to.
- the diameter of the through hole may be changed as the form of the through hole.
- the through hole diameter d1 on the right side may be used, and the through hole diameter d2 (> d1) on the left side may be used. Even in such a form, the heat-generating film can be effectively heated.
- the heat-generating film 10 may further include a covering portion 14 that covers the heat-generating portion 12.
- a covering portion 14 that covers the heat-generating portion 12.
- the covering portion 14 preferably has heat resistance and insulating properties. Therefore, as the material used for the covering portion 14, for example, a heat-resistant insulating resin such as polyimide, LCP, or polycarbonate may be used. Further, a photosensitive resin may be used for patterning to cover the heat generating portion 12.
- heat resistance of the covering portion means having resistance to at least the heat generated by the heat generating portion
- insulating property of the covering portion means having at least the heat generating portion having conductivity. It refers to the degree of insulation that can be electrically insulated.
- the heat generating portion 12 of the heat generating film 10 of the present embodiment is covered with the covering portion 14, it is possible to make it less susceptible to the influence of the external environment (for example, temperature or humidity).
- the term "covering the heat generating portion” as used herein is not limited to the fact that the entire outer surface of the heat generating portion 12 is covered, but also includes the case where a part of the heat generating portion 12 is covered. do. That is, as shown in FIGS. 22 (a) and 22 (b), a part of the heat generating portion 12 may be covered with the covering portion 14.
- the support member 70' may be a plate-shaped member having good peelability with respect to the base material 13.
- the base material 13 may be placed on the support member 70'(see FIG. 23).
- the base material 13 may have heat resistance and insulating properties, and for example, a heat resistant insulating sheet such as polyimide, LCP, or polycarbonate may be used.
- the base material 13 may be formed with a through hole 13a for supplying electric power to the alignment marker 13b and the heat generating film.
- the position of the through hole 13a may be the target position or the non-target position described above.
- the size of the through hole 13a may be the same or different.
- the film raw material may be supplied onto the base material 13 (see FIG. 24). At that time, a heating element 60 for bringing the support member 70'to a heated state or a normal temperature state may be used. According to the supply process, as described with reference to FIG. 18, a part of the heat generating portion 12 is arranged in the through hole 13a. The amount of the film raw material supplied may be controlled so that the heat generating portion 12 is not arranged in the through hole 13a.
- the baking step may be carried out.
- the baking step may be performed by baking at a temperature of 180 ° C. to 220 ° C. for 60 minutes or more.
- the baking step causes a reaction in which the film raw material is cured, and the heat-generating film precursor 10a may be produced.
- a temporary baking step such as temporarily curing the film raw material may be performed.
- the support member 70' is peeled from the base material 13 (see FIG. 25), and after finishing the peeling step, a cutting step of cutting the heat-generating film precursor 10a according to the lens shape is carried out. (See FIG. 26). Further, the electrode 20 may be embedded in the through hole 13a.
- the heat-generating film of the third embodiment shown in FIG. 16 can be manufactured.
- the heat-generating film of the second embodiment can be manufactured by using the base material 13 in which the through hole 13a is not formed.
- the patterned film raw material is supplied onto the base material 13 after the above-mentioned support member preparation step.
- the method for patterning the film raw material include a method using printing by a screen printing device or pad printing, and a method using drawing by a dispenser device, an inkjet device, a spray coating device, or the like.
- a heating element 60 for bringing the support member 70'to a heated state or a normal temperature state may be used.
- the baking step may be carried out.
- the baking step may be performed by baking at a temperature of 180 ° C. to 220 ° C. for 60 minutes or more.
- the baking step causes a reaction in which the film raw material is cured, and the heat-generating film precursor 10a may be produced.
- a temporary baking step such as temporarily curing the film raw material may be performed.
- a covering material 14'for forming the covering portion 14 may be supplied.
- the covering portion 14 preferably has heat resistance and insulating properties. Therefore, as the covering material 14'used for the covering portion 14, for example, a heat-resistant insulating resin such as polyimide, LCP, or polycarbonate may be used.
- the temporary curing at 100 ° C. or higher and 150 ° C. or lower may be performed for 1 hour or less, and the main curing at 200 ° C. or higher and 250 ° C. or lower may be performed for 2 hours or less.
- the support member 70' is peeled from the base material 13 (see FIG. 29), and after finishing the peeling step, a cutting step of cutting the heat-generating film precursor 10a according to the lens shape is performed. It may be carried out. Further, the electrode 20 may be embedded in the through hole 13a.
- the heat-generating film of the fourth embodiment shown in FIG. 21 or FIG. 22 can be manufactured.
- Example Heat-generating film manufactured by the manufacturing process schematically shown in FIG. 3
- Comparative example Heat-generating film manufactured by the manufacturing process schematically shown in FIG. 2 (b).
- Carbon filler Carbon black
- Binder resin Fluoro rubber compound and crystalline silica
- Solvent n-butyl acetate and methyl isobutyl ketone (hardener) Methanol, diethylenetriamine and silane compounds (diluting solvent) Methyl isobutyl ketone
- the contents of the verification test were observation of SEM images, elemental analysis, and aging measurement of the resistance value of the heat-generating film in a high-temperature and high-humidity environment for the heat-generating films of Examples and Comparative Examples.
- FIG. 30 (a) is an SEM image of the heat-generating film of the comparative example
- FIG. 31 (a) is an SEM image of the heat-generating film of the example.
- the SEM image is an image obtained by observing the surface of the heat-generating film at an acceleration voltage of 5 kV and 10000 times with a scanning electron microscope (JSM-7900F) manufactured by JEOL Ltd.
- FIG. 31 (b) is an elemental analysis mapping image of an example.
- the elemental analysis mapping image is an image obtained by Oxford Instruments' Ultratime Extreme at an acceleration voltage of 10 kV and 2000 times.
- the elemental analysis table of FIG. 30 (c) corresponds to FIG. 30 (b), and the area ratio of the portion A'(that is, the area ratio of the binder resin) is 63.2%, that of the portion B'.
- the area ratio (that is, the area ratio of the carbon filler) was 18.0%, and the sum of the partial A'and the partial B'was 81.2%.
- the portion A corresponds to the binder resin
- the portion B corresponds to the carbon filler
- the portion C corresponds to the magnesium oxide particles and the portion.
- D corresponds to aluminum oxide or silicon oxide particles
- partial E corresponds to an unassigned component.
- the elemental analysis table of FIG. 31 (c) corresponds to FIG. 31 (b), and the area ratio of the portion A (that is, the area ratio of the binder resin) is 74.9%, and the area ratio of the portion B is (That is, the area ratio of the carbon filler) was 21.1%, and the sum of the portions A and B was 96.0%.
- the sum of the carbon filler and the resin content is 90% or more based on the heat-generating film as a whole. Further, when the content of the carbon filler is 15% or more and 25% or less, it is preferable from the viewpoint of conductivity.
- the standard of the content rate shows the ratio when the whole heat-generating film is used as a reference.
- FIGS. 32 (a) and 33 (a) show.
- the vertical axis represents the resistance value ( ⁇ ) and the horizontal axis represents the elapsed time.
- graphs showing the rate of change of the resistance value corresponding to the graphs of FIGS. 32 (a) and 33 (a) are shown in FIGS. 32 (b) and 33 (b).
- the vertical axis indicates the rate of change (%) of the resistance value
- the horizontal axis indicates the elapsed time.
- the graphs shown by the circle points ( ⁇ ) are the graphs for the heat-generating film having a film thickness of 50 ⁇ m, and are indicated by the triangular points ( ⁇ ).
- the graph is a graph for a heat-generating film having a film thickness of 140 ⁇ m, and the graph shown by the square dots ( ⁇ ) corresponds to a graph for a heat-generating film having a film thickness of 350 ⁇ m.
- the resistance value was about 150 ⁇ in the initial state, and the change in the resistance value was small even after 1000 hours.
- the resistance value of about 84 ⁇ in the initial state increases to about 117 ⁇ after 1000 hours, and according to FIG. 32 (b). It was confirmed that the resistance value increased by 40% after 1000 hours.
- the resistance value of about 59 ⁇ in the initial state increased to about 96 ⁇ after 1000 hours, and according to FIG. 32 (b), it increased to about 96 ⁇ . It was confirmed that the resistance value increased by 64% after 1000 hours.
- the resistance value was larger than the design value (20 to 60 ⁇ ).
- the graphs of FIGS. 33 (a) and 33 (b) for the heat-generating film of the example the graphs shown by the triangular points ( ⁇ ) are the graphs for the heat-generating film having a film thickness of 260 ⁇ m, and are indicated by circle points ( ⁇ ).
- the graph is equivalent to a graph for a heat-generating film having a film thickness of 360 ⁇ m.
- the resistance value is about 53 ⁇ in the initial state, and the change in the resistance value is small at about 59 ⁇ even after 1000 hours have passed. It was confirmed. Further, according to the graph shown by the round dots (film thickness: 360 ⁇ m), it was confirmed that the resistance value was about 41.3 ⁇ in the initial state, and the change in the resistance value was small at about 45 ⁇ even after 1000 hours had passed. did. Then, according to the graphs shown by the triangular points and the round points in FIG. 33 (b), it was confirmed that the rate of change of the resistance value was about 10%. That is, the resistance value of the heat-generating film could be in the range of the design value (20 to 60 ⁇ ), and the change in the resistance value could be reduced even in a high-temperature and high-humidity environment.
- the heat-generating film produced by the manufacturing method of the present disclosure has excellent environmental resistance.
- the heat-generating film of the present disclosure can be used for a camera for a surveillance system such as disaster prevention and crime prevention, or a camera for exterior use such as an in-vehicle camera.
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Abstract
Description
炭素フィラー、バインダー樹脂、溶剤を含有するフィルム原料の供給厚さに応じて加温状態または常温状態で前記フィルム原料を供給する供給工程を含む。
炭素フィラーおよび樹脂を含み、炭素フィラーと樹脂との含有率の和が発熱フィルム全体基準で90%以上である。
近年、防災・防犯等の監視システム用のカメラ、または車載カメラといった外装用途のカメラが知られている。これら外装用途のカメラを使用する環境は様々であり、例えば氷や霜などの氷結物が付着するような環境での使用が考えられる。この氷結物がレンズに付着した状態では、被写体からの光が撮像素子上に正常に結像されず好ましくない。そこで、従前からレンズにヒータ機能を備える技術が知られている。このようなヒータ機能を備えたレンズであれば、ヒータの発熱によってレンズに付着した氷結物を溶かすことが可能となる。
-第1実施形態-
本開示の発熱フィルムの製造方法の一実施形態を、図3を参照しながら説明する。図3は、本開示の第1実施形態に係る発熱フィルムの製造方法を模式的に示した工程断面図である。
供給工程では、レンズ基材100にフィルム原料11を供給してよい。具体的には、平面視において外側の輪郭が円形で中央に孔を有するように(つまり、ドーナツ形状となるように)フィルム原料11を供給することが好ましい。フィルム原料を供給する供給装置50は、レンズ基材上に精度よくフィルム原料を供給するため、ディスペンサーを用いてよいが、この例に限られず、スプレーコート装置、スリットコーター装置、ダイコーター装置、スクリーン印刷装置、インクジェット装置またはパッド印刷装置から成る群から少なくとも一つが選択されてもよい。また、複数の装置を組み合わせて供給してもよい。
ベーク工程は、180℃~220℃の温度で60分以上のベークにより行われてよい。このベーク工程によってフィルム原料が硬化する反応が起こって発熱フィルム10が製造される。なお、ベーク工程の前に、フィルム原料を仮硬化させるような仮ベーク工程を行ってもよい。
次に、本開示の発熱フィルムの製造方法の他の実施形態を、図7~10を参照しながら、説明する。図7~10は、本開示の第2実施形態に係る発熱フィルムの製造方法を模式的に示した工程断面図である。
支持部材70は、フィルム原料を支持するために用いられてよい(図7参照)。支持部材70は、金属で形成されたフレーム71と、フレーム71に嵌合し、フィルム原料との剥離性のよい樹脂部材72と、を備えてよい。図示例(図7)では、3つの樹脂部材72がフレーム71に嵌合されてよい。フィルム原料との剥離性のよい樹脂として、フッ素樹脂、テフロン樹脂(テフロンは登録商標)、シリコーン樹脂、シリコーン樹脂を表面に配したポリエチレンテレフタレート樹脂フィルムから成る群から少なくとも一つが選択されてよい。
上述の支持部材準備工程後に、支持部材70上にフィルム原料を供給してよい(図8参照)。その際、支持部材70を加温状態または常温状態にするための加温要素60を用いてよい。この加温要素60は、支持部材70と接触してフィルム原料11を加温することができるものである。加温要素60は、上述したとおり、コイルヒータを用いる方式、熱媒体を用いる方式、マイクロ波および高周波加熱を用いる方式から成る群から少なくとも一つが選択されてよい。溶剤成分揮発による塗膜表面に発生する発泡を抑制しながら、加温状態とする際の加温温度は、30~80℃程度が好ましい。本実施形態の供給工程は、ダイコーターまたはスリットコーター等のコータ装置によって、少なくともフレーム71と樹脂部材72を覆うようにフィルム原料11を供給してよい。また、フレーム71と樹脂部材72と電極フレーム21を覆うようにフィルム原料11を供給してもよい。このように供給することによりフレーム71は塗膜材料の硬化処理後の反りなどの変形を防止しながら多数の製品の同時処理を可能とし生産効率向上を図ることができる。その際、フィルム原料の供給厚さが120μm未満である場合は、常温状態で供給工程を行うことが好ましく、供給厚さが120μm以上の場合は、加温状態で供給工程を行うことが好ましい。なお、フィルム原料の供給厚さが120μm未満である場合でも加温状態で供給工程を行ってもよい。
フィルム原料を支持部材70に供給した後に、ベーク工程を実施してよい。ベーク工程は、180℃~220℃の温度で60分以上のベークにより行われてよい。ベーク工程によってフィルム原料が硬化する反応が起こり、発熱フィルム前駆体10aを製造してよい。なお、本ベーク工程の前に、フィルム原料を仮硬化させるような仮ベーク工程を行ってもよい。
ベーク工程を終えた後に、支持部材70の裏面から3つの樹脂部材72を剥離してよい(図9参照)。3つの樹脂部材72が剥離されることで、支持部材70の裏面に、ベーク工程によって得られた発熱フィルム前駆体10aが露出されてよい。なお、3つの樹脂部材72が1つになるような樹脂部材72を有する支持部材70の構造としてもよい。
剥離工程を終えた後に、発熱フィルム前駆体10aをレンズ形状に対応させて切断する切断工程を実施してよい(図10参照)。また、樹脂部材72を剥離せずに切断工程を実施して切断後に樹脂部材72を剥離してもよい。また樹脂部材72と同様の形状をした別材料を挿入して切断してもよい。また更に切断する際は図9の発熱フィルム前駆体10a面の裏側から切断してもよい。切断工程では、平面視において、外側の輪郭が円形で中央に孔を有するように発熱フィルム前駆体10aを切断し、発熱フィルム前駆体の厚みが厚いほど、孔の直径が大きくなるように発熱フィルム前駆体を切断してよい。具体的には、第1実施形態(図4(a))で説明したとおり、発熱フィルム前駆体の膜厚が120μm未満のときは、中央の孔の直径を小さくなるように切断し、膜厚が120μm以上のときは、中央の孔の直径を大きくなるように切断してよい。つまり、両者の体積が略等しくなるように切断することにより、発熱フィルムのヒータの体積当たりの抵抗値の管理が容易となる。
上述の第2実施形態における支持部材準備工程において、金属で形成されたフレーム71と、フィルム原料との剥離性のよい樹脂部材72を備えた支持部材70を用いる実施形態を説明したが、この構成に代えて、支持部材70全体をフィルム原料との剥離性のよい樹脂としてもよい(図11参照)。このような構成によれば、支持部材70をフィルム原料から剥離することで連続した塗膜の形態で剥離工程を終えることができるため、上述の第2実施形態で説明した3つの樹脂部材を剥離する場合と比較して、製品ピッチを小さくして製品を取出すことができるなど、試験的に製品を製造する際などに効率的であり、製造工程が容易である。なお、本変形例において、発熱部12は、閉領域全域が導電性の抵抗体であるため、電極20の形成を省略してもよい。
上述の第2実施形態における供給工程において、ダイコーターまたはスリットコーター等のコータ装置によって、フィルム原料を供給する実施形態を説明したが、この構成に代えて、ディスペンサー51を用いてフィルム原料を供給してもよい(図12参照)。このような構成によれば、ディスペンサー51により精度よくフィルム原料を供給することができる。なお、ディスペンサー51を用いたフィルム原料を供給すれば発熱フィルム10を得るための切断工程を省略してもよい。
上述の第2実施形態における供給工程において、ディスペンサー、ダイコーターまたはスリットコーター等のコータ装置によって、フィルム原料を供給する実施形態を説明したが、この構成に代えて、スクリーンマスク52aの上からスキージ52bを動かしてフィルム原料を供給するスクリーン印刷装置52を用いてもよい(図13参照)。このような構成によれば、スクリーン印刷法により所望の発熱フィルムを大量生産することができる。
-発熱フィルムの構成(発熱フィルムの第1実施形態)-
次に、上述した本開示の発熱フィルムの製造方法によって製造された発熱フィルムについて説明する。本開示のレンズを発熱させる発熱フィルムは、炭素フィラー、樹脂およびそれ以外の含有物を有して成り、炭素フィラーと樹脂の含有率の和が90%以上である。本明細書でいう「炭素フィラーおよび樹脂以外の含有物」には、発熱フィルムの構成成分として存在することが好ましい含有物と、発熱フィルムの構成成分として非所望の含有物を示している。「発熱フィルムの構成成分として存在することが好ましい含有物」とは、炭素フィラーおよび樹脂以外のもので発熱フィルムの特性を向上させることに起因する含有物をいう。具体的には、「発熱フィルムの構成成分として存在することが好ましい含有物」とは、例えば、酸化マグネシウム粒子、酸化アルミニウムおよび酸化シリコン粒子をいう。一方で、「非所望の含有物」とは、広義には、発熱フィルムの構成成分として実質的に必須ではないものをいい、狭義には、炭素フィラー、樹脂および発熱フィルムの構成成分として存在することが好ましい含有物以外のものをいう。具体的には、「非所望の含有物」とは、炭素繊維、バインダー樹脂、酸化マグネシウム粒子、酸化アルミニウムおよび酸化シリコン粒子以外の組成物を示している。さらに、非所望の含有物には、例えば、硫化バリウム粒子のほか、水分、孔および空気を含んでよい。
次に、発熱フィルムの第2実施形態として、発熱部12を保持する基材13を備えた発熱フィルム10について、図14および図15を参照しながら説明する。
発熱フィルムの第3実施形態として、基材13に少なくとも2つの貫通孔を設けた発熱フィルムについて、図面を参照しながら説明する。
発熱フィルムのさらに他の実施形態として、発熱部を被覆する被覆部14をさらに備えた発熱フィルムについて、図面を参照しながら説明する。
次に、第2実施形態および第3実施形態の発熱フィルムの製造方法について説明する。まず、基材13をさらに備えた発熱フィルム10の製造方法について、図面を参照しながら説明する。なお、発熱フィルムの製造方法は、[本開示の発熱フィルムの製造方法]-第2実施形態-において、<支持部材準備工程>、<供給工程>、<ベーク工程>、<剥離工程>および<切断工程>を詳述したが、上述の説明と重複する説明は、適宜省略する。
支持部材70’は、上述の支持部材70(図7参照)と異なり、基材13に対して剥離性のよい板状の部材としてよい。この支持部材70’に対して、まず基材13を載置してよい(図23参照)。基材13は、耐熱性および絶縁性を有していてよく、例えば、ポリイミド、LCPまたはポリカーボネート等の耐熱性絶縁シートを用いてよい。基材13は、位置合わせ用マーカー13bおよび発熱フィルムに電力を供給するための貫通孔13aが形成されてよい。貫通孔13aの位置は、上述した対象位置または非対象位置としてよい。貫通孔13aの大きさは、同じ大きさでも異なる大きさでもよい。
上述の支持部材準備工程後に、基材13上にフィルム原料を供給してよい(図24参照)。その際、支持部材70’を加温状態または常温状態にするための加温要素60を用いてよい。当該供給工程によれば、図18で説明したとおり、発熱部12の一部が貫通孔13aに配置されることとなる。なお、フィルム原料の供給量を制御して発熱部12を貫通孔13aに配置しない様にしてもよい。
フィルム原料を基材13に供給した後に、ベーク工程を実施してよい。ベーク工程は、180℃~220℃の温度で60分以上のベークにより行われてよい。ベーク工程によってフィルム原料が硬化する反応が起こり、発熱フィルム前駆体10aを製造してよい。なお、本ベーク工程の前に、フィルム原料を仮硬化させるような仮ベーク工程を行ってもよい。
ベーク工程を終えた後に、基材13から支持部材70’を剥離し(図25参照)、剥離工程を終えた後に、発熱フィルム前駆体10aをレンズ形状に対応させて切断する切断工程を実施してよい(図26参照)。また、貫通孔13aに電極20を埋め込んでもよい。
次に、第4実施形態の発熱フィルムの製造方法について説明する。上述の説明と重複する説明は、適宜省略する。
図21に示すような、発熱部12を完全に被覆する被覆部14を備えた発熱フィルムを製造する場合は、上述の支持部材準備工程後に、パターニングされたフィルム原料を基材13上に供給することが好ましい。フィルム原料をパターニングする手法としては、例えば、スクリーン印刷装置またはパッド印刷による印刷を用いた手法ならびにディスペンサー装置、インクジェット装置またはスプレーコート装置等による描画を用いた手法が挙げられる。なお、図22に示すような、発熱部12の一部を被覆する被覆部14を備えた発熱フィルムを製造する場合は、フィルム原料をパターニングしなくてもよい。供給工程時は、支持部材70’を加温状態または常温状態にするための加温要素60を用いてよい。
フィルム原料を基材13に供給した後に、ベーク工程を実施してよい。ベーク工程は、180℃~220℃の温度で60分以上のベークにより行われてよい。ベーク工程によってフィルム原料が硬化する反応が起こり、発熱フィルム前駆体10aを製造してよい。なお、本ベーク工程の前に、フィルム原料を仮硬化させるような仮ベーク工程を行ってもよい。
ベーク工程後に、被覆部14を形成するための被覆材14’を供給してよい。被覆部14は、耐熱性および絶縁性を有していることが好ましい。そのため、被覆部14に用いられる被覆材14’は、例えば、ポリイミド、LCPまたはポリカーボネート等の耐熱性絶縁樹脂を用いてよい。被覆材14’を供給した後に、100℃以上150℃以下の仮硬化を1時間以下、および200℃以上250℃以下の本硬化を2時間以下行ってよい。
被覆部形成工程を終えた後に、基材13から支持部材70’を剥離し(図29参照)、剥離工程を終えた後に、発熱フィルム前駆体10aをレンズ形状に対応させて切断する切断工程を実施してよい。また、貫通孔13aに電極20を埋め込んでもよい。
比較例:図2(b)で模式的に示した製造工程によって製造された発熱フィルム
炭素フィラー : カーボンブラック
バインダー樹脂: フッ素ゴム化合物および結晶性シリカ
溶剤 : 酢酸n-ブチルおよびメチルイソブチルケトン
(硬化剤)
メタノール、ジエチレントリアミンおよびシラン化合物
(希釈溶剤)
メチルイソブチルケトン
図30(a)は、比較例の発熱フィルムのSEM画像、図31(a)は、実施例の発熱フィルムのSEM画像である。なお、SEM画像は、日本電子社製の走査電子顕微鏡(JSM-7900F)により加速電圧5kV、10000倍で発熱フィルム表面を観察した画像である。
図30(b)は、比較例の元素分析マッピング画像、図31(b)は、実施例の元素分析マッピング画像である。なお、元素分析マッピング画像は、Oxford instruments社のUltim Extremeにより、加速電圧10kV、2000倍で得られた画像である。
実施例および比較例の発熱フィルムに対して、高温(85℃)、高湿度(85%)の環境下で抵抗値のエージング測定を示したグラフを図32(a)および図33(a)に示す。図32(a)および図33(a)において、縦軸は抵抗値(Ω)、横軸は経過時間を示している。また、図32(a)および図33(a)のグラフに対応させて抵抗値の変化率を示したグラフを図32(b)および図33(b)に示す。図32(b)および図33(b)において、縦軸は抵抗値の変化率(%)、横軸は経過時間を示している。
11’,11 フィルム原料
10a’,10a 発熱フィルム前駆体
12 発熱部
13 基材
13a 貫通孔
13b 位置合わせ用マーカー
14 被覆部
14’被覆材
20 電極
21 電極フレーム
22 配線
50 供給装置
51 ディスペンサー
52 スクリーン印刷装置
52a スクリーンマスク
52b スキージ
60 加温要素
70,70’ 支持部材
71 フレーム
72 樹脂部材
100,100’ レンズ基材
110 レンズ
111 平坦部分
Claims (31)
- レンズを発熱させる発熱フィルムの製造方法であって、
炭素フィラー、バインダー樹脂および溶剤を含有するフィルム原料の供給厚さに応じて加温状態または常温状態で前記フィルム原料を供給する供給工程を含む、発熱フィルムの製造方法。 - 前記供給厚さが120μm未満である場合は、前記常温状態で前記供給工程を行い、前記供給厚さが120μm以上の場合は、前記加温状態で前記供給工程を行う、請求項1に記載の発熱フィルムの製造方法。
- 前記加温状態の加温温度は、30℃以上80℃以下である、請求項1または2に記載の発熱フィルムの製造方法。
- 前記溶剤は、沸点が150℃以下の低沸点溶剤である、請求項1~3のいずれか1項に記載の発熱フィルムの製造方法。
- 前記溶剤は、非極性溶剤である、請求項1~4のいずれか1項に記載の発熱フィルムの製造方法。
- 前記フィルム原料は、粘度が10,000cps以上50,000cps以下である、請求項1~5のいずれか1項に記載の発熱フィルムの製造方法。
- 前記供給工程は、前記フィルム原料が支持される支持部材にフィルム原料を供給する、請求項1~6のいずれか1項に記載の発熱フィルムの製造方法。
- 前記支持部材は前記レンズである、請求項7に記載の発熱フィルムの製造方法。
- 前記支持部材は、加温要素によって前記加温状態とされる、請求項7または8に記載の発熱フィルムの製造方法。
- 前記供給工程の後に、前記フィルム原料をベークするベーク工程を含む、請求項1~9のいずれか1項に記載の発熱フィルムの製造方法。
- 前記ベーク工程によって得られる発熱フィルム前駆体を前記レンズの形状に対応させて切断する切断工程を含む、請求項10に記載の発熱フィルムの製造方法。
- レンズを発熱させる発熱フィルムであって、
炭素フィラーおよび樹脂を含み、前記炭素フィラーと前記樹脂との含有率の和が前記発熱フィルム全体基準で90%以上である、発熱フィルム。 - 閉領域全域が発熱部である、請求項12に記載の発熱フィルム。
- 前記発熱部を保持する基材をさらに備えた、請求項13に記載の発熱フィルム。
- 前記基材は、耐熱性および絶縁性を有している、請求項14に記載の発熱フィルム。
- 前記基材には、少なくとも2つの貫通孔が設けられている、請求項14または15に記載の発熱フィルム。
- 前記少なくとも2つの貫通孔は、前記基材を中心として対称位置に配置されている、請求項16に記載の発熱フィルム。
- 前記少なくとも2つの貫通孔は、前記基材を中心として非対称位置に配置されている、請求項16に記載の発熱フィルム。
- 前記少なくとも2つの貫通孔は、互いに大きさが異なる、請求項16~18のいずれか1項に記載の発熱フィルム。
- 前記少なくとも2つの貫通孔に、前記発熱部の一部が配置されている、請求項16~19のいずれか1項に記載の発熱フィルム。
- 前記少なくとも2つの貫通孔に、電極が形成されている、請求項16~20のいずれか1項に記載の発熱フィルム。
- 前記発熱部を被覆する被覆部をさらに備えた、請求項13~21のいずれか1項に記載の発熱フィルム。
- 前記炭素フィラーの含有率は、前記発熱フィルム全体基準で15%以上25%以下である、請求項12~22のいずれか1項に記載の発熱フィルム。
- 前記炭素フィラーは、炭素繊維である、請求項12~23のいずれか1項に記載の発熱フィルム。
- 前記樹脂は、フッ素樹脂を含んで成る、請求項12~24のいずれか1項に記載の発熱フィルム。
- 前記発熱フィルムの膜厚が5μm以上400μm以下である、請求項12~25のいずれか1項に記載の発熱フィルム。
- 平面視において前記発熱フィルムの外側の輪郭が円形で中央に孔を有する、請求項12~26のいずれか1項に記載の発熱フィルム。
- 前記発熱フィルムの裏面に電極を備えている、請求項12~27のいずれか1項に記載の発熱フィルム。
- 前記電極の厚みは、5μm以上50μm以下である、請求項28のいずれか1項に記載の発熱フィルム。
- 請求項12~29のいずれか1項に記載の発熱フィルムを備えたレンズであって、
前記発熱フィルムが前記レンズと直接的に接している、レンズ。 - 請求項30に記載のレンズを備えて成る、車載カメラ。
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