CN114466703A

CN114466703A - Method for forming coating pattern, method for producing laminate, program for forming coating pattern, and resin coating device

Info

Publication number: CN114466703A
Application number: CN202080069605.XA
Authority: CN
Inventors: 北浦英二
Original assignee: Dow Corning Toray Co Ltd
Current assignee: DuPont Toray Specialty Materials KK
Priority date: 2019-09-05
Filing date: 2020-08-13
Publication date: 2022-05-10
Also published as: TW202114786A; WO2021044818A1; KR20220054400A; JPWO2021044818A1

Abstract

The invention aims to provide a method for determining the coating amount required by forming a coating pattern. The method for forming a coating pattern of the present invention includes: determining the coating amount of the resin based on the density (D) of the resin and the coating thickness (T) when the resin is uniformly coated on the whole coating surface; a step of determining a coating pattern in the coated side; and a step of applying the resin of which the application amount is determined to the application surface according to the application pattern.

Description

Method for forming coating pattern, method for producing laminate, program for forming coating pattern, and resin coating device

Technical Field

The present invention relates to a method for forming a coating pattern, a method for manufacturing a laminate, a program for forming a coating pattern, and a resin coating apparatus.

Background

In a manufacturing process of a display device, an electronic apparatus, a touch panel, or the like, when different components are bonded to each other with an adhesive, air bubbles may be mixed between the components. In particular, when bonding optical components such as a display device, the occurrence of bubbles may cause a problem because of adverse effects such as a reduction in visibility of the bonded components.

In order to prevent the occurrence of unfilled portions such as air bubbles in the above-described manufacturing process, in patent document 1, when the transparent resin filler is discharged from the supply means, the two panels are arranged so that the transparent resin filler comes into contact with the two panels, i.e., the image display panel and the front panel, thereby preventing the air bubbles from being mixed in. However, in the method disclosed in patent document 1, since the interval between the two panels is narrow, it takes time to apply the transparent resin filler to the entire panel, and the manufacturing cost increases.

Patent document 2 describes a method for manufacturing a member for a display device in which a pair of workpieces are bonded together with an adhesive, and when a liquid crystal panel and a panel cover are bonded together with an adhesive layer, the pressure inside a chamber is reduced. The depressurization of the inside of the chamber is related to the reduction of bubbles generated between the panels, but on the other hand, a device for depressurization is required, and the number of manufacturing processes increases, thereby increasing the manufacturing cost.

On the other hand, in patent documents 3 and 4, the pasting step is performed under atmospheric pressure in order to reduce the manufacturing cost. Further, in patent documents 3 and 4, the adhesive resin is applied in a dot pattern along a bidirectional Y-shaped line pattern in the protective plate. However, in patent documents 3 and 4, since the bidirectional Y-shaped line pattern and the dot pattern can take various shapes in accordance with the aspect ratio of the part coated with the adhesive resin, the aspect ratio of the part cannot be uniquely determined independently.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2015-052795

Patent document 2: japanese laid-open patent publication No. 2015-194727

Patent document 3: japanese patent laid-open publication No. 2011-150331

Patent document 4: japanese patent laid-open publication No. 2013-152289

Disclosure of Invention

Problems to be solved by the invention

The present invention has been made in view of the above-described problems, and an object thereof is to provide a method for determining a coating amount required for forming a coating pattern.

Another object of the present invention is to provide a method for forming a coating pattern that prevents the occurrence of unfilled portions such as air bubbles when forming a laminate.

Another object of the present invention is to provide a method for manufacturing a laminated body in which bonding of a pair of works is performed under atmospheric pressure.

Further, an object of the present invention is to provide a resin coating apparatus that automatically calculates an optimal coating pattern.

Means for solving the problems

In order to achieve the above object, the following means is provided.

In one embodiment of the present invention, there is provided a method of forming a coating pattern, including:

determining the coating amount of the resin based on the density (D) of the resin and the coating thickness (T) when the resin is uniformly coated on the whole coating surface;

a step of determining a coating pattern in the coated side; and

and a step of applying the resin of which the application amount is determined to the application surface according to the application pattern.

In one embodiment of the present invention, there is provided a method for producing a laminate,

the method for manufacturing a laminate uses a pair of workpieces constituting a display device, and includes:

a step of forming a coating pattern on at least one of the pair of workpieces by the above coating pattern forming method;

a step of bonding the pair of workpieces via the coating pattern; and

a step of curing the resin contained in the coating pattern.

The step of bonding the pair of workpieces may be performed under atmospheric pressure (without reduced pressure).

In one embodiment of the present invention, there is provided a process for forming a coating pattern,

the program for forming a coating pattern causes a computer to function as:

a coating amount determination unit that determines the amount of resin to be applied, based on the density (D) of the resin and the coating thickness (T) when the resin is uniformly applied to the entire surface to be coated;

a coating pattern determining section that determines a coating pattern in the coating surface; and

and a resin coating part for coating the resin with the determined coating amount on the coating surface according to the coating pattern.

In one embodiment of the present invention, there is provided a resin coating apparatus including:

a computer including a program for forming the coating pattern; and

and a coating device for coating the resin on the coating surface according to the coating amount and/or the coating pattern determined by the program.

The resin coating apparatus may further include:

a detection unit for obtaining a precursor of a laminate by bonding a pair of workpieces constituting a display device via a coating pattern, and sensing leakage of a resin or non-filling of the resin from the precursor of the laminate after bonding; and

and a learning unit that, when the detection unit detects a resin leak or a resin non-filling, re-determines the amount of application and/or the application pattern so that the amount of application and/or the application pattern are optimized so that the resin leak or the resin non-filling does not occur in the laminated body precursor.

Advantageous effects

The present invention can provide a method for determining the amount of resin applied required for the formation of a coating pattern according to the above solution. This can minimize the amount of resin applied, which leads to cost reduction.

Further, the present invention can provide a method for forming a coating pattern that prevents the generation of unfilled portions such as bubbles when a laminate is formed. This prevents the occurrence of unfilled portions such as air bubbles in the laminate, thereby improving the adhesion between the members of the laminate and improving the appearance of the laminate.

The present invention can also provide a method for manufacturing a laminate in which bonding of a pair of workpieces is performed under atmospheric pressure. This eliminates the need for a vacuum apparatus, and thus reduces the manufacturing cost.

Further, the present invention can provide a resin coating apparatus that automatically calculates an optimal coating pattern. Thus, it is not necessary to determine an optimum coating pattern by trial and error, and therefore the cost associated with the production can be suppressed.

Drawings

Fig. 1 is a diagram showing a first embodiment of the present invention.

Fig. 2 is a diagram showing a second embodiment of the present invention.

Detailed Description

The present invention will be described in detail below with reference to the drawings. The drawings used in the following description are for convenience only and will be partially enlarged to show the features of the present invention. Therefore, the dimensional ratios of the respective components shown in the drawings and the like may be different from those of the actual components. The materials, dimensions, and the like shown in the following description are examples, and the present invention is not limited to these, and can be implemented by being appropriately changed within a range in which the effects thereof are exhibited.

[ method for Forming coating Pattern ]

The present invention discloses a method of forming a coating pattern in one embodiment. The method for forming the coating pattern includes: the method comprises the steps of determining the coating amount of resin, determining a coating pattern in a coating surface, and coating the resin on the coating surface according to the coating pattern.

< amount of coating >

The coating amount is determined based on the density (D) of the resin to be coated and the coating thickness (T) in the case where the resin is uniformly coated on the entire coating surface. Thus, the resin used may be in a minimum amount required, which is advantageous in terms of cost.

In the step of applying the resin to the application surface in accordance with the application pattern, the resin may be applied to at least a part of the application pattern. Preferably, the resin may be coated over the entire coating pattern. More preferably, the resin may be continuously applied over the entire coating pattern. Since the resin is continuously applied over the entire application pattern, there is no resin isolated from other resins, and bubbles are less likely to be generated when the resin is used for subsequent lamination in laminate production.

The density (D) of the resin is determined according to the kind of the resin used. The coating thickness (T) in the case of uniformly coating the resin on the entire coating surface is not particularly limited as long as it is a thickness adopted in the above-mentioned technical field. For example, in the case of applying a preferred resin (liquid resin) in the present invention, the resin can be applied favorably with an application thickness (T) of 10 μm or more, and a resin-filled layer that suppresses the generation of unfilled portions such as air bubbles and has practically sufficient adhesion can be formed, and the application thickness (T) can be designed to be less than 10 μm as needed. When the coating thickness (T) is required to be designed to be thick, the amount of resin used may be simply increased, or a thick coating layer may be formed by repeatedly coating resins by the method of the present invention.

< coating Pattern >

'Square shape'

Fig. 1 shows a coating pattern according to a first embodiment of the present invention. In the case where the coated surface 1 is a square having a length W of one side, the coating pattern in the coated surface 1 is determined in a radial shape as shown in fig. 1.

The constituent elements for providing the coated surface 1 are not particularly limited, but may be a rigid panel such as a glass panel, a resin plate made of an acrylic resin or a polycarbonate resin, or a metal plate.

The coated surface 1 has: an edge portion extending from the outer periphery of the application surface 1 by [ alpha ] W and not forming an application pattern; and an effective coated surface 10 surrounded by the edge portion.

The effective coated surface 10 is a square having a length W 'of one side, and the length W' is W-2. alpha.W (wherein. alpha. is 0.01. ltoreq. alpha. is 0.1).

The coating pattern has:

the intersection 20 of the diagonals;

a first whisker 24 extending from the intersection 20 of the diagonal lines toward the center of the first side 11; and

a second whisker 25 extends from the intersection 20 of the diagonal lines towards the center of the second side 12. The first and

second whiskers

24 and 25 each have a length of β W'/2 (where 0 < β ≦ 1).

Further, the coating pattern has:

a first branch line 31 and a second branch line 32 extending from the intersection point 20 of the diagonal lines to both ends of the first side 11; and

the third branch line 33 and the fourth branch line 34 extend from the intersection 20 of the diagonal lines to both ends of the second side 12. The length Lb of each of the first branch line 31, the second branch line 32, the third branch line 33, and the fourth branch line 34 is W'/√ 2.

Further, the coating pattern further has:

a first rib portion 41 extending from the intersection point 20 of the diagonal lines toward the center of the third side 13; and

the second rib portion 42 extends from the intersection point 20 of the diagonal lines toward the center of the fourth side 14. The first rib portion 41 and the second rib portion 42 each have a length of β W'/2 (where 0 < β ≦ 1). When the application surface 1 is square, the total length of the first whiskers 24 and the second whiskers 25 is equal to the total length of the first rib portion 41 and the second rib portion 42.

Alpha can be 0.01-0.1. Alpha is preferably 0.15. ltoreq. alpha.ltoreq.0.85, more preferably 0.3. ltoreq. alpha.ltoreq.0.7, and most preferably 0.4. ltoreq. alpha.ltoreq.0.6. In the case of α < 0.01, the ends of the four branch lines 31 to 34 are close to the four corners of the coated surface 1, and therefore, the resin applied near the ends of the four branch lines 31 to 34 is likely to leak to the outside of the coated surface 1 at the time of resin application and/or at the time of laminate production. As a result, unnecessary resin is used, and the cost may increase. When α > 0.1, the end portions of the four branch lines 31 to 34 are distant from the four corners of the coated surface 1, and therefore unfilled portions such as air bubbles may be present near the four corners of the coated surface 1, which may reduce the adhesive strength or deteriorate the appearance.

Beta can be more than 0 and less than or equal to 1. When β is 1, the lengths of the first whisker 24 and the second whisker 25 are W'/2, respectively, and reach the outer periphery of the effective application surface. Further, as in the first embodiment, when the application surface 1 is square, the lengths of the first rib portion 41 and the second rib portion 42 are W'/2, respectively, and reach the outer periphery of the effective application surface. Beta may be preferably 0 < beta.ltoreq.0.75, and more preferably 0 < beta.ltoreq.0.5. When β, which is not included in the present invention, is 0, unfilled portions such as air bubbles may be present in the region surrounded by the first side 11, the first branch line 31, and the second branch line 32 during the production of the laminate, and the adhesive strength may be reduced or the appearance may be impaired. In the case where β > 1, an unnecessary resin is used, and the cost may increase.

According to the forming method of the coating pattern of the present invention, the shape of the coating pattern in fig. 1 is uniquely determined.

< coordinates >

The step of determining the coating pattern in the coated side 1 in fig. 1 comprises: a step of determining each coordinate in the coating pattern.

When the coordinate of one of the four corners of the square-shaped coated surface 1 is (0, 0) and the coordinate of the intersection 20 of the two diagonal lines in the square is (W/2 ),

the coordinates of the end of the first hair line 24 are ((W-. beta.W')/2, W/2);

the coordinates of the end of the second whisker 25 are ((W +. beta. W')/2, W/2);

the coordinates of the end of the first branch 31 are ((W-W ')/2, (W + W')/2);

the coordinates of the end of the second branch line 32 are ((W-W ')/2, (W-W')/2);

the coordinates of the end of the third branch line 33 are ((W + W ')/2, (W + W')/2);

the coordinates of the end of the fourth branch line 34 are ((W + W ')/2, (W-W')/2);

the coordinates of the end of the first rib 41 are (W/2, (W + β W')/2);

the coordinates of the end of the second rib 42 are (W/2, (W-. beta.W')/2).

According to the forming method of the coating pattern of the present invention, the coordinates of the coating pattern in fig. 1 are uniquely determined. In fig. 1, the coordinates of the lower left corner of the application surface, that is, the intersection of the first side 11 and the fourth side 14 are set as the origin (0, 0), but in the actual formation of the application pattern, the upper left corner of the application surface may be set as the origin (0, 0) based on the arrangement of the application device, and the application pattern may be determined by setting the other corners as the origin.

Rectangle

Fig. 2 shows a coating pattern according to a second embodiment of the present invention. In the case where the coated surface 1 is a rectangle having a width W and a length L (where W.ltoreq.L), the coating pattern in the coated surface 1 is determined to be a shape as shown in FIG. 2 (hereinafter, referred to as a fishbone pattern shape). In the present specification, a rectangle is a concept including a square, and is described as W.ltoreq.L instead of W < L.

The effective coated side 10 has a width W '(where 0.01 < alpha < 0.1) of W-2 alpha W and a length L' of L-2 alpha W.

The fishbone pattern has:

a center line portion 23 that intersects a first intersection point 21 where bisectors of two angles sandwiching the first side 11 having the width W intersect with a second intersection point 22 where bisectors of two angles sandwiching the second side 12 having the width W intersect;

a first hair line 24 extending from the first intersection 21 to a midpoint of the first side 11; and

and a second whisker line 25 extending from the second intersection 22 towards the midpoint of the second side 12. The first and

second whiskers

24 and 25 each have a length of β W'/2 (where 0 < β ≦ 1).

Further, the fishbone pattern has:

a first branch line 31 and a second branch line 32 extending from the first intersection 21 to both ends of the first side 11; and

the third branch line 33 and the fourth branch line 34 extend from the second intersection 22 to both ends of the second side 12. The length Lb of each of the first branch line 31, the second branch line 32, the third branch line 33, and the fourth branch line 34 is W'/√ 2.

Further, the fishbone pattern has:

a first rib portion 41 having Nrib/2 number extending perpendicularly to the central line portion 23 from the central line portion 23 to the third edge 13 having the length L; and

the second rib portions 42 extend perpendicularly to the center line portion 23 from the center line portion 23 to the fourth side 14 having the length L, and have Nrib/2. The first rib portion 41 and the second rib portion 42 each have a length Lc.

The method for solving the length Lc and the number Nrib of rib portions is described in detail below.

The length Lc of the first rib portion 41 and the second rib portion 42 in the fishbone pattern and the total number Nrib of the first rib portion 41 and the second rib portion 42 are obtained as follows. What is important is the relationship between the length of the coating pattern and the area of the effective coated side 10. In the case of a square, the length of the coating pattern required per unit area of the effective coated surface 10 is calculated, and then the length of the coating pattern required for the area when the square is changed to a rectangle is calculated, thereby calculating Lc and Nrib.

When fig. 1 and 2 are compared, fig. 1 is a square shape with respect to the coated surface 1, whereas fig. 2 is a rectangular shape.

First, the coated side of the squareThe overall length of the coating pattern in 1 is 4(W '/√ 2 +. beta. W '/2), and the area of the effective coated surface 10 is W '². Therefore, the length of the coating pattern required per unit area is 4(W '/√ 2+ β W '/2)/W '²。

Here, when the length of one side of the square in fig. 1 is equal to the length of the short side of the rectangle in fig. 2, the length of the rectangle in fig. 2 is increased by L ' -W ' as compared with the square in fig. 1, and therefore the area of the effective coated surface 10 is increased by (L ' -W ') W '.

When the length L '-W' of the central line portion 23, which increases when the square shape of fig. 1 is changed to the rectangular shape of fig. 2, is taken into consideration, the length x of the coating pattern to be added to the area of the increased portion is x + L '-W'. When the length of the coating pattern required per unit area is the same as in the case of a square, (x + L ' -W ')/(L ' -W ') W '/4 (W '/√ 2+ betaw '/2)/W,²the relationship of (1) holds. Thus, x ═ (L '-W') (2 β +2 √ 2-1) was calculated.

Here, the first rib part 41 and the second rib part 42 in fig. 1 are determined to intersect at the intersection point 20 of the diagonal lines, but the first rib part 41 in fig. 2 is determined not to intersect with the first intersection point 21 and the second rib part 42 is also determined not to intersect with the second intersection point. Accordingly, in order to complement the total length β W ' of the first rib portion 41 and the second rib portion 42 in fig. 1 with respect to the area (L ' -W ') W ' increased in the change from the square shape to the rectangular shape in fig. 2, β W ' needs to be added in addition to the length x. Thus, when the square of fig. 1 is transformed into the rectangle of fig. 2, the length total c to be added is calculated as β W ' + (L ' -W ') (2 β +2 √ 2-1).

Next, a total number Nrib of the first rib part 41 and the second rib part 42 in fig. 2 is calculated. The number of the first rib portions 41 and the second rib portions 42 may be equal. That is, the number of the first rib parts 41 and the number of the second rib parts 42 may be Nrib/2, respectively.

The total number Nrib of the first rib portion 41 and the second rib portion 42 in fig. 2 is calculated based on the width W' of the effective coated surface corresponding to how many portions of the length total c that needs to be added. In practice, the total c/W' is often a decimal number. Thus, only one of the rib portions has a different length. To avoid this, the total c/W' is rounded up to an integer value, and the integer value is doubled, thereby matching the number of the first rib parts 41 and the number of the second rib parts 42. Nrib is calculated by the following equation.

[ mathematical formula 1]

(where [ ] is a round-up function)

Next, the lengths Lc of the first rib portion 41 and the second rib portion 42 in fig. 2 are calculated. Lc is calculated by dividing the length total c to be added by Nrib. Lc is calculated by the following equation.

[ mathematical formula 2]

When the value of total c/W 'is an integer, the length Lc of the rib part is W'/2, and when the value of total c/W 'is not an integer, Lc < W'/2.

α and β are as described in the first embodiment.

According to the method of forming the coating pattern of the present invention, the shape of the fishbone in fig. 2 is uniquely determined.

The step of determining the coating pattern in the coated side 1 in fig. 2 comprises: and determining each coordinate in the coating pattern.

When the coordinates of one of the four corners of the rectangular coated surface 1 are (0, 0) and the coordinates of the intersection of the two diagonal lines in the rectangle are (L/2, W/2),

the coordinates of the first intersection point 21 are set to (W/2 );

the coordinates of the second intersection 22 are set to (L-W/2, W/2);

the coordinates of the end of the second whisker 25 are set to (L- (W-beta W')/2, W/2);

the coordinates of the end of the first branch 31 are ((L-L ')/2, (W + W')/2);

the coordinates of the end of the second branch line 32 are ((L-L ')/2, (W-W')/2);

the coordinates of the end of the third branch line 33 are ((L + L ')/2, (W + W')/2);

the coordinates of the end of the fourth branch line 34 are ((L + L ')/2, (W-W')/2);

coordinates in the central line portion 23 of the first rib portion 41 and the second rib portion 42 which are kth (where 1 < k ≦ Nrib/2) from the first intersection point 21 in the first rib portion 41 and the second rib portion 42 of Nrib/2 are set to (W/2+ (L-W) × (2k-1)/Nrib, W/2), respectively;

the coordinates of the end of the kth first rib 41 are (W/2+ (L-W) × (2k-1)/Nrib, W/2+ Lc);

the coordinates of the end of the kth second rib 42 are (W/2+ (L-W) × (2k-1)/Nrib, W/2-Lc).

According to the method of forming the coating pattern of the present invention, the coordinates of the fishbone in fig. 2 are uniquely determined.

As is apparent from the determined coordinates, the distance from the first intersection 21 to the intersection of the 1 st first rib portion 41 and the center line portion 23 is (L-W)/Nrib. Further, the distance from the k-th first rib part 41 to the (k + 1) -th first rib part 41 is 2 × (L-W)/Nrib.

The resin used in the method for forming a coating pattern of the present invention can function as an adhesive at the time of bonding, and the type and curing system (cure system) thereof are not particularly limited, but from the viewpoint of curability and physical properties of the resulting laminate, one or more selected from a curable silicone resin composition, a curable acrylic resin composition, a curable vinyl resin composition, and a curable epoxy resin composition are preferable, and a curable silicone resin composition which can be cured to form an adhesive resin member is particularly preferable. Further, the method for curing these curable resin compositions may be selected from the following methods depending on the curing agent and curing system thereof: heat curing at 50 ℃ or higher, room temperature curing, photo-curing by irradiation with high-energy rays such as ultraviolet rays (UV light), and a combination of these curing methods. From the viewpoint of enabling room temperature curing in a short time, particularly, in the case where the laminated body constitutes a display device, without adversely affecting each member, it is preferable to select, as a curing system, a curing method mainly involving a hydrosilylation curing reaction at room temperature, a condensation curing reaction at room temperature, or photocuring by irradiation with UV light.

The resin used in the coating pattern forming method of the present invention may be a curable resin composition which is cured to form an elastomer (elastomer) resin member or a gel-like resin member, and the penetration (hereinafter, simply referred to as "penetration") defined in JIS K2220 of the cured silicone resin member or acrylic resin member may be in the range of 5 to 70 at 25 ℃, and the penetration may be in the range of 10 to 60 or in the range of 20 to 50. Such a silicone resin member or acrylic resin member has appropriate flexibility and durability, and is excellent in adhesion/close holding property and follow-up property between members, and therefore, when a laminate including a pair of works constituting a display device is formed using the application pattern of the present invention, a reliable paste-seam effect can be achieved. The curable resin composition may be a resin which has adhesiveness after curing and forms a resin member in which deformation of a sample at the maximum adhesive strength is sufficiently large. For example, the tensile shear adhesion strength (hereinafter referred to as "shear adhesion strength") of the cured silicone resin member or acrylic resin member measured according to JIS K6850 may be 0.05MPa or more, 0.05 to 10MPa, or practically 0.1 to 5MPa at 25 ℃. In the case of measuring the amount of displacement in tensile shear with respect to the thickness of the sample at the peak of the tensile shear bond strength (maximum bond strength), the ratio of displacement may be 1000% or more, and practically, the ratio may be in the range of 1000 to 6000%.

In the coating pattern forming method of the present invention, since the formed coating pattern is used for bonding a pair of workpieces, appropriate fluidity of the resin is required. The viscosity of the resin used in the method for forming a coating pattern of the present invention at 25 ℃ is preferably 100 to 100000 mPas, and more preferably 500 to 10000 mPas. When the viscosity of the resin at 25 ℃ is in the above range, a satisfactory filling layer having a coating thickness (T) of 10 μm or more can be formed. On the other hand, if the viscosity at 25 ℃ is less than 100mPa · s, the resin excessively spreads over a wide range from the coating portion, and the target coating thickness may not be obtained. When the viscosity at 25 ℃ exceeds 100000 mPas, the resin cannot spread properly from the coating pattern, and there may be an unfilled portion such as bubbles in the production of the laminate.

Examples of usable resins include, but are not limited to, the following curable silicone resin compositions containing:

(A) one or more polyorganosiloxanes having a curing-reactive functional group in a molecule; and

(B) a catalyst for the curing reaction, and a curing reaction,

the viscosity of the curable silicone resin composition at 25 ℃ is in the range of 500 to 10000 mPas.

In particular, the resin which can be used in the present invention may be an optically transparent resin (hereinafter referred to as "OCR (optically Clear resin)") or a curable silicone adhesive, and these may preferably be OCR and curable silicone adhesives proposed and used by the present applicant in Japanese patent application No. 2018-0861179 and International application No. PCT/JP 2019/017859.

In addition, the resin needs to be in a liquid state when forming a coating pattern, and a certain usable time needs to be ensured. The usable time can be designed or controlled by, for example, selecting the kind and amount of an inhibitor for a curing system contained in the resin (for example, a curing inhibitor for a curing system including a hydrosilylation reaction). For example, in the case where the component (A) is subjected to a curing reaction at 25 ℃ in the presence of the component (B), the amount of the inhibitor for the component (B) is increased to ensure a required pot life. On the other hand, the time until the composition is cured can be shortened by not adding an inhibitor to the component (B) or by setting the minimum amount to ensure the pot life.

In the case where the resin is a multicomponent resin such as a two-component resin, the components are stored separately before forming a coating pattern, and the components are mixed at the time of coating, whereby the time required for curing can be increased. The components may be mixed by a mixer or the like immediately before application, and are preferably used immediately after mixing in order to suppress occurrence of problems such as clogging of the apparatus and discharge failure. In addition, when the resin is a multicomponent resin such as a two-component resin, a dispenser including: a liquid raw material tank is physically provided with a partition; and a mechanism for mixing the liquid raw materials supplied from the raw material tanks to the discharge part by a predetermined amount. By using such a dispenser provided with a mechanism for separately filling the raw material liquid and a mixing mechanism, the components of the composition can be filled into physically separated tanks, and can be mixed by a predetermined amount at a time of dispensing and applied.

In the step of determining the amount of resin applied, γ [% ] (wherein 0 < γ ≦ 100) may be more than the amount determined based on the density (D) of the resin applied and the coating thickness (T). Thus, even if some resin leaks from the coated surface when the coated surface coated with the resin is bonded to other elements, a sufficient amount of resin can be secured to spread over the entire coated surface.

For γ [% ], it may be 0 < γ ≦ 100. In terms of γ [% ], γ is preferably 10. ltoreq. γ.ltoreq.90, and more preferably 20. ltoreq. γ.ltoreq.80. If γ [% ] exceeds 100%, the amount of resin applied increases, which is disadvantageous in terms of cost.

As described above, the forming method of the coating pattern disclosed in the present specification may determine the coating amount based on the density (D) of the coated resin and the above-described coating thickness (T). Further, the forming method of the coating pattern disclosed in the present application can uniquely determine the shape and coordinates of the coating pattern. Thus, the bonding process can be designed efficiently without specifying the application pattern by trial and error. The amount of resin applied may be as small as necessary, which leads to cost reduction.

[ method for producing laminate ]

In one embodiment, the present invention discloses a method for manufacturing a laminated body using a pair of workpieces constituting a display device.

The method for manufacturing a laminate includes: forming a coating pattern on at least one of the pair of workpieces by the coating pattern forming method; a step of bonding a pair of workpieces via a coating pattern; and a step of curing the resin contained in the coating pattern.

The step of forming a coating pattern in at least one of the pair of workpieces may also include: and forming a coating pattern on the coating surfaces of the pair of workpieces. In this case, the resin pattern formed on the pair of workpieces can be adjusted so that the shape and/or coordinates of at least a part of the resin pattern coincide with each other when the pair of workpieces are bonded to each other.

The step of bonding the pair of works via the application pattern may be performed under atmospheric pressure (without reduced pressure). Thus, a vacuum process with high cost is not required, and the cost can be reduced.

The step of attaching a pair of workpieces via a coating pattern may be performed using a method known in the art.

The step of attaching the pair of workpieces via the coating pattern may further include: and a step of bonding the pair of workpieces by gradually shortening the distance from a state where the pair of workpieces face each other in parallel. By arranging the pair of workpieces in parallel with each other, bubbles are less likely to be generated at the time of bonding.

The step of curing the resin contained in the coating pattern may be performed using a method known in the art. The step of curing the resin may also include a thermosetting step, a photo-curing step, and the like curing steps known to those skilled in the art.

The size and thickness of the laminate are not particularly limited, and are determined according to the use of the laminate. For example, the laminate can be used for applications selected from display devices, electronic devices, and touch panels. The pair of workpieces may be used for a purpose selected from elements constituting a display device, an electronic device, a touch panel, and the like.

As described above, in the method for producing a laminate disclosed in the present specification, the occurrence of unfilled portions such as air bubbles in the laminate is prevented when the pair of works are bonded due to the coating pattern shape unique to the present application, and therefore, the adhesive strength is improved and the appearance of the laminate is excellent. In addition, since the bonding of the pair of workpieces is performed under the atmospheric pressure without reducing the pressure, the cost reduction is associated.

[ procedure ]

The present invention discloses a process for forming a coating pattern of a resin on a coated surface in one embodiment.

A program for causing a computer to function as:

a coating amount determination unit that determines the amount of resin applied based on the density (D) of the resin and the coating thickness (T) when the resin is uniformly applied to the entire surface to be coated;

a coating pattern determining section that determines a coating pattern on the coating surface; and

and a resin coating part for coating the resin with determined coating amount on the coating surface according to the coating pattern.

The coating amount determining section can determine the coating amount so that γ [% ] (where 0 < γ ≦ 100) is more than the amount determined based on the density (D) of the resin to be coated and the coating thickness (T).

The coating pattern determining section may employ a radial coating pattern on a square as shown in fig. 1; and a fishbone pattern on a rectangle as shown in fig. 2 as the determined coating pattern.

The resin coating section determines a coating amount of a resin determined in advance, based on a coating pattern, to be applied to the coating surface. The discharge speed of the resin, the scanning speed of the coating device, and the like can be appropriately set by those skilled in the art according to the resin used and the coating surface.

[ resin coating apparatus ]

The invention discloses a resin coating device with a computer including the program.

The resin coating apparatus may include the following coating apparatuses: the resin is applied to the coated surface in accordance with the coating amount and/or coating pattern determined by the program.

The coating device may use a coating device known in the art. The coating device may include a discharge unit for discharging the resin. The resin can be discharged from the discharge portion at a constant speed and at a constant discharge amount. The coating device may have a general configuration of a resin coating device other than the computer including the program, and is not particularly limited.

[ resin applying apparatus having automatic learning function ]

The invention also discloses a resin coating device provided with a detection part and a learning part.

The detection unit obtains a precursor of a laminate by bonding a pair of workpieces constituting a display device via a coating pattern, and detects leakage of a resin or non-filling of the resin from the precursor.

The leakage of the resin or the non-filling of the resin can be determined by image detection. The image detection may also use methods known in the art.

The learning unit re-determines the amount of resin applied and/or the application pattern when the detection unit detects that the resin has leaked or the resin has not been filled, thereby optimizing the amount of resin applied and/or the application pattern so that the resin does not leak or the resin has not been filled in the laminated body precursor.

Unfilled refers to a concept that includes the following areas: a region partially surrounded by the resin and the other part opened to the outer periphery of the application face 1; and a region entirely surrounded by the resin, that is, air bubbles.

The re-determination of the coating amount and/or the coating pattern is achieved by independently changing α, β, and γ, respectively, based on the information of leakage and non-filling obtained by image detection.

α is correlated with the width α W (where 0.01. ltoreq. α. ltoreq.0.1) of the edge portion where no coating pattern is formed in the coated surface 1 in FIGS. 1 and 2. The increase or decrease of α affects the expansion of the resin in the following portions: after bonding, that is, after the formation of the laminate precursor, the edge portion of the coated surface 1, particularly the four corners of the coated surface 1. Therefore, in the case where the non-filling of the resin is mainly generated at the edge portion of the coated surface 1, α is redetermined to be reduced. Thus, the unfilled portion formed at the edge portion can be eliminated. On the other hand, when the leakage of the resin occurred mainly at the four corners of the coated surface 1, α was determined to increase again. Thereby, the leakage in the four corners of the coated surface 1 can be reduced.

Beta is associated with the length beta W'/2 of the first whisker 24 and the second whisker 25 in FIGS. 1 and 2 (where 0 < beta. ltoreq.1). The increase or decrease of β affects the expansion of the resin in the following areas: the end portions of the first and

second hair lines

24 and 25 in fig. 2 after bonding, that is, the regions surrounded by the first side 11, the first branch line 31, and the second branch line 32 and the regions surrounded by the second side 12, the third branch line 33, and the fourth branch line 34 in fig. 2. Therefore, in the case where the non-filling of the resin is mainly generated in the vicinity of the end portions of the first whiskers 24 and the end portions of the second whiskers 25, β is redetermined to increase. Thus, the unfilled portions generated in the vicinity of the ends of the first whiskers 24 and the ends of the second whiskers 25 can be eliminated. On the other hand, in the case where the leakage of the resin is generated in the vicinity of the end of the first whisker wire 24 and the end of the second whisker wire 25, B is re-determined to be increased. This reduces leakage in the vicinity of the ends of the first whiskers 24 and the ends of the second whiskers 25 on the coated surface 1.

γ [% ] (wherein, 0 < γ ≦ 100) means an excess ratio with respect to the coating amount determined based on the density (D) of the coated resin and the above coating thickness (T). The increase or decrease of γ affects the spread of the resin on the entire applied surface 1 after bonding. Therefore, in the case where the non-filling of the resin is generated in the entirety of the coated face 1, γ is re-determined to be increased. This eliminates the occurrence of unfilled portions on the entire coated surface 1. On the other hand, the portion where the resin actually leaks from the application surface 1 is the peripheral edge portion of the application surface 1, but when the leakage of the resin mainly occurs in the entire application surface 1, γ is determined to be reduced again. This reduces the leakage of the entire coated surface 1.

As described above, the resin application device provided with the detection unit and the learning unit disclosed in the present specification can optimize the amount of resin applied and the application pattern by sensing the state of resin leakage and non-filling from the image detected with respect to the state of resin after the bonding of the pair of workpieces, and repeating the re-determination of the parameters α, β, and γ so that resin leakage and non-filling do not occur.

The invention provides a resin coating device capable of automatically calculating an optimal coating pattern. This can suppress the cost due to the trial and error, and thus contributes to cost reduction.

Hereinafter, the method for forming a coating pattern according to the present invention will be described in detail with reference to examples. However, the present invention is not limited to the description of the following examples. In addition, although the laminate composed of a pair of works manufactured by the following examples is included in the scope of the present invention, the laminate and the display device of the present invention are not limited to the description of the following examples. The resin coating apparatus using the method for forming a coating pattern of the present invention is not limited to the following examples.

[ examples ]

An ultraviolet curable resin DOWSIL manufactured by DOW/TORAY Co., Ltd^TMVE-2001 UV Optical Bonding was carried out by preparing a bonded sample having a thickness of 0.3mm in a thickness of a Bonding resin layer from a float glass plate (148X 210X 1.7mm) and a polycarbonate plate (153X 215X 1.0mm) having one surface (Bonding surface) thereof subjected to an antireflection coating. In the present example, in order to apply the curable resin to a polycarbonate plate and bond a float glass plate from above the polycarbonate plate, the coordinate position of the application of the curable resin was set based on the following coordinates (in mm): based on polycarbonate platesIn fig. 2, the point of intersection of the first side 11 and the third side 13 on the upper left side of the polycarbonate plate is defined as the origin (0, 0), the long side is defined as the x-axis, and the short side is defined as the y-axis. The x-axis is a positive direction from the origin to the intersection of the second side 12 and the third side 13, and the y-axis is a positive direction from the origin to the intersection of the first side 11 and the fourth side 14. 1. Determination of the coating weight, the coating edge and the linear length ratio of the whisker and calculation of the parameters

DOWSIL^TMVE-2001 UV Optical Bonding has a viscosity of 3600 mPas and a specific gravity of 1.120g/cm³In order to form a layer having a thickness of 0.3mm on the entire surface of the glass, it is necessary to coat 148X 210X 0.3/1000 (9.324 cm)³(10.443 g). In actual trial production, as a general practice, + 5% of the above calculated coating amount was left coated. The coating edge α was set to 10% of the short side of the polycarbonate sheet, and the linear length ratio B of the whiskers was set to 60%.

According to the present invention, the variables required for drawing the coating pattern were calculated as shown in table 1 below.

[ Table 1]

2. Drawing of coating patterns based on the above parameters

The drawing speed linear density is derived by dividing the actual resin coating amount by the total drawing line length. The resin discharge amount was set to 8 g/min and the pattern drawing speed was set to 9.03 mm/sec (drawing line density: 10 × 8/60/9.03 ═ 0.148g/cm) so as to obtain the drawn line density at the drawing speed described above on the polycarbonate sheet using SHOT mini 300SX, ML-606GX and TCU-02 manufactured by Musashi engineering co. The coordinate points are shown in table 2. As described above, each coordinate is a coordinate (unit is mm) in which the upper left of the coated polycarbonate sheet is the origin (0, 0), the long side is the x-axis, and the short side is the y-axis (using a coordinate system of SHOT mini 300SX manufactured by Musashi engineering co.

[ Table 2]

3. Application of float glass to polycarbonate sheet based on coating pattern

The polycarbonate plate on which the resin was drawn along the coating pattern was horizontally left standing, the center of the z-axis of each bonding plate was aligned, the glass plate was placed in a vertical position not in contact with the coating layer, the bonding surfaces were gradually brought close to each other in parallel, the bonding surfaces were bonded to the vicinity of the target film thickness while spreading the coating resin, and 6000mJ/cm of the glass plate was irradiated with a metal halide ultraviolet lamp (metal halide ultraviolet lamp) in this state²The cured product was cured to prepare a bonded sample.

As a result, the curable resin drawn using the application pattern spread over the entire surface of the bonded plate without entrapping air bubbles, and no exposed or unfilled portion from the end of the bonded sample was observed, thereby obtaining a transparent bonded sample having a uniform entire surface.

Description of the reference numerals

1 coating side

10 effective coating side

11 first side

12 second side

13 third side

14 fourth side

Intersection of 20 diagonal lines

21 first intersection point

22 second intersection point

23 center line part

24 first beard line

25 second whisker line

31 first branch line

32 second branch

33 third branch

34 fourth branch

41 first Rib part

42 second rib part

Claims

1. A method of forming a coating pattern, the method comprising:

determining the coating amount of the resin based on the density D of the resin and the coating thickness T when the resin is uniformly coated on the whole coating surface;

a step of determining a coating pattern in the coated side; and

2. The method for forming a coating pattern according to claim 1,

the step of determining a coating pattern in the coated side further comprises: a step of determining the shape of the fishbone pattern,

the coating surface is a rectangle with width W and length L, wherein W is less than or equal to L,

the coated side has: an edge portion extending from the outer periphery of the application surface by [ alpha ] W and not forming the application pattern; and an effective coated surface surrounded by the edge portion,

the effective coating surface has a width W 'of W-2 alpha W and a length L' of L-2 alpha W, wherein alpha is more than or equal to 0.01 and less than or equal to 0.1,

the fishbone pattern is composed of the following parts:

a center line section that connects a first intersection point at which bisectors of the two corners sandwiching the first side having the width W intersect with a second intersection point at which bisectors of the two corners sandwiching the second side having the width W intersect;

a first whisker line extending from the first intersection point to a midpoint of the first side, having a length β W'/2, wherein β is greater than 0 and less than or equal to 1;

a second whisker, extending from the second intersection to a midpoint of the second side, having a length β W'/2;

a first branch line and a second branch line extending from the first intersection point to both ends of the first side, respectively, and having a length Lb;

a third branch and a fourth branch, each extending from the second intersection to both ends of the second side, and having a length Lb;

a first rib portion extending perpendicularly to the central line portion from the central line portion to a third side having a length L, having a length of Nrib/2, Lc; and

a second rib portion extending perpendicularly to the central line portion from the central line portion to a fourth edge having a length L, having a length of Nrib/2 and a length of Lc,

the Lc is represented by the following formula,

[ mathematical formula 3]

The Nrib is of the formula,

[ mathematical formula 4]

Where [ ] is the round-up function.

3. The method for forming a coating pattern according to claim 2,

the step of determining a coating pattern in the coated side further comprises: a step of determining coordinates of the fishbone pattern,

when the coordinates of one of the four corners in the rectangle is (0, 0) and the coordinates of the intersection of the two diagonal lines in the rectangle is (L/2, W/2),

setting the coordinates of the first intersection point to be (W/2 );

setting the coordinates of the second intersection point to be (L-W/2, W/2);

setting the coordinates of the end of the first beard wire as ((W-beta W')/2, W/2);

setting the coordinates of the end of the second whisker to be (L- (W-beta W')/2, W/2);

setting the coordinates of the end of the first branch line as ((L-L ')/2, (W + W')/2);

setting the coordinates of the end of the second branch line as ((L-L ')/2, (W-W')/2);

setting coordinates of an end of the third branch line to ((L + L ')/2, (W + W')/2);

setting the coordinates of the end of the fourth branch line as ((L + L ')/2, (W-W')/2);

setting coordinates in the central line part of the kth first rib part and the kth second rib part counted from the first intersection point in the Nrib/2 first rib parts and the Nrib parts as (W/2+ (L-W) × (2k-1)/Nrib, W/2), wherein k is more than or equal to 1 and less than or equal to Nrib/2;

setting the coordinates of the end of the kth first rib part as (W/2+ (L-W) × (2k-1)/Nrib, W/2+ Lc);

the coordinates of the end of the kth second rib portion are (W/2+ (L-W) × (2k-1)/Nrib, W/2-Lc).

4. The method for forming a coating pattern according to any one of claims 1 to 3,

the resin comprises a curable silicone resin.

5. The method for forming a coating pattern according to any one of claims 1 to 4,

the step of determining the coating amount of the resin includes: and determining that the coating weight is more than the required amount by gamma percent, wherein gamma is more than 0 and less than or equal to 100.

6. A method of manufacturing a laminated body using a pair of workpieces constituting a display device, the method comprising:

a step of forming a coating pattern in at least one of the pair of workpieces by the method of forming a coating pattern according to any one of claims 1 to 5;

a step of bonding the pair of workpieces via the coating pattern; and

a step of curing the resin contained in the coating pattern.

7. The method for producing a laminate according to claim 6,

the step of bonding the pair of workpieces is performed under atmospheric pressure conditions without a reduced pressure.

8. The method for producing a laminate according to claim 6 or 7, wherein,

the laminate is selected from a display device, an electronic device, or a touch panel.

9. A process of forming a coating pattern,

it causes the computer to function as:

a coating amount determination unit that determines the amount of resin to be coated based on the density D of the resin and the coating thickness T when the resin is uniformly coated on the entire surface to be coated;

10. The program according to claim 9, wherein,

the coating pattern is a fishbone pattern,

the fishbone pattern is composed of the following parts:

a second whisker line extending from the second intersection to a midpoint of the second side and having a length β W'/2;

the Lc is represented by the following formula,

[ math figure 5]

The Nrib is of the formula,

[ mathematical formula 6]

Where [ ] is the round-up function.

11. A resin application apparatus, comprising:

a computer containing the program for forming a coating pattern according to claim 9 or 10; and

12. The resin coating apparatus according to claim 11,

the resin coating device further includes:

a detection unit for obtaining a precursor of a laminate by bonding a pair of works constituting a display device via a coating pattern, and sensing a leakage of a resin or an unfilled resin from the precursor of the laminate after bonding; and

and a learning unit which, when the detection unit detects a resin leak or a resin non-fill, re-determines the amount of application and/or the application pattern so that the resin leak or the resin non-fill does not occur in the laminated laminate precursor, and optimizes the amount of application and/or the application pattern.

13. The resin coating apparatus according to claim 12,

the detection section that senses the leakage of the resin or the non-filling of the resin by the detection section has an image-based detection mechanism,

the coating pattern is a fishbone pattern comprising a variable alpha for determining an edge portion where the coating pattern is not formed and a variable beta for determining a whisker length thereof, wherein 0.01 < alpha < 0.1, 0 < beta < 1, and the coating amount and/or the coating pattern is re-determined by increasing or decreasing at least one variable selected from the following in correspondence with the occurrence of the leakage of the resin or the non-filling of the resin detected by the detection portion, thereby optimizing the coating amount and/or the coating pattern in the learning portion:

i) the variable a;

ii) the variable β;

iii) a variable γ in the case where γ% is increased relative to a calculated value of a required amount in the case where the coating amount of the resin is determined, wherein 0 < γ ≦ 100.