WO2017110618A1 - Resin sheet, method for manufacturing resin sheet, and method for manufacturing multilayer resin substrate - Google Patents

Abstract

A resin sheet (101) has a first surface (81) and a second surface (82) on the reverse side therefrom, and comprises mainly a thermoplastic resin. Were the resin sheet (101) to be bisected in the thickness direction, and the region closer to the first surface (81) designated as a first region, and the region closer to the second surface (82) designated as a second region, the porosity of the first region would be greater than 0, and the porosity of the second region would be greater than the porosity of the first region.

Description

Resin sheet, method for producing resin sheet, and method for producing resin multilayer substrate

The present invention relates to a resin sheet, a resin sheet manufacturing method, and a resin multilayer substrate manufacturing method.

A technique relating to a method for producing a yarn composed of polymer nanofibers is described in JP-A-2011-214170 (Patent Document 1). In Patent Document 1, a polymer material solution that is a raw material for polymer nanofibers is ejected from a nozzle, and a high voltage is applied between the nozzle and the collector. Thereby, polymer nanofiber accumulates on a collector and a sheet-like nonwoven fabric is obtained. In patent document 1, the sheet-like nonwoven fabric which consists of polymer nanofiber is manufactured in this way, and the strip | belt-shaped nonwoven fabric is manufactured by cut | disconnecting this. By passing this strip-shaped nonwoven fabric through a series of devices, yarns made of polymer nanofibers are continuously produced. In Patent Document 1, polymer nanofibers are fused and bonded only in a limited region of the yarn by irradiating a laser beam in the middle of the yarn made of the polymer nanofiber thus manufactured. A dot is formed.

JP-A-2007-268717 (Patent Document 2) describes that a thermoplastic polyimide resin film is obtained by melt extrusion molding of a thermoplastic polyimide resin.

JP 2011-214170 A JP 2007-268717 A

In order to carry out the technique of Patent Document 1, it is necessary to produce a sheet-like nonwoven fabric having self-supporting properties with polymer nanofibers. For this purpose, it is first necessary to prepare polymer nanofibers. Since the material of the fiber is ejected from the nozzle to be a fiber, it must be dissolved in a solvent. Further, the conditions for forming the fibers and the sheets are complicated and cannot be realized easily.

When the production method of Patent Document 2 was carried out, the obtained film was a solid body, and a film having a high specific surface area could not be obtained.

Therefore, the present invention does not require the solubility of the material in a solvent, does not require prior self-supporting ability, can be produced by a simple method, and can have a higher specific surface area than a resin sheet or surface. An object of the present invention is to provide a resin sheet having a high internal porosity and a method for producing them. Moreover, it aims at providing the manufacturing method of the resin multilayer substrate which can reduce the level | step difference of an outermost surface.

In order to achieve the above object, a resin sheet according to the present invention is a resin sheet having a first surface and a second surface that are opposite to each other, and a thermoplastic resin as a main material, and is 2 etc. in the thickness direction. When the region closer to the first surface is the first region and the region closer to the second surface is the second region, the porosity of the first region is greater than 0, The porosity of the two regions is larger than the porosity of the first region.

According to the present invention, a resin sheet having a high specific surface area or a resin sheet having a higher internal void ratio than the surface can be obtained, and this resin sheet does not require solubility in a solvent of the material, and is a thermoplastic resin. It can be easily produced using the powder or fibrillated product.

It is a flowchart of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is explanatory drawing of the 2nd process of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is 1st explanatory drawing of the 3rd process of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is 2nd explanatory drawing of the 3rd process of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is explanatory drawing of the 4th process of the manufacturing method of the resin sheet in Embodiment 1 based on this invention. It is a SEM photograph of the 2nd surface of the resin sheet obtained by the manufacturing method of the resin sheet in Embodiment 1 based on the present invention. It is a SEM photograph of the 1st surface of a resin sheet obtained by the manufacturing method of a resin sheet in Embodiment 1 based on the present invention. It is explanatory drawing of a mode that the resin sheet in Embodiment 2 based on this invention is equally divided into two in the thickness direction. It is a flowchart of the manufacturing method of the resin sheet in Embodiment 3 based on this invention. It is 1st explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 3 based on this invention. It is 2nd explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 3 based on this invention. It is explanatory drawing of the 2nd process of the manufacturing method of the resin sheet in Embodiment 3 based on this invention. It is explanatory drawing of a mode that the resin sheet in Embodiment 4 based on this invention is equally divided into 3 in the thickness direction. It is explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 5 based on this invention. It is 1st explanatory drawing of the 2nd process of the manufacturing method of the resin sheet in Embodiment 5 based on this invention. It is 2nd explanatory drawing of the 2nd process of the manufacturing method of the resin sheet in Embodiment 5 based on this invention. It is explanatory drawing of the 3rd process of the manufacturing method of the resin sheet in Embodiment 5 based on this invention. It is the SEM photograph which looked at the edge of the resin sheet obtained by the manufacturing method of the resin sheet in Embodiment 5 based on this invention from the side. It is a SEM photograph of the 2nd surface of the resin sheet obtained by the manufacturing method of the resin sheet in Embodiment 5 based on the present invention. It is a SEM photograph of the 1st surface of the resin sheet obtained by the manufacturing method of the resin sheet in Embodiment 5 based on the present invention. It is a SEM photograph in the state where the section of the resin sheet in Embodiment 6 based on the present invention was exposed. It is a SEM photograph in the state where the section of the resin sheet in Embodiment 7 based on the present invention was exposed. It is 1st explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 8 based on this invention. It is 2nd explanatory drawing of the 1st process of the manufacturing method of the resin sheet in Embodiment 8 based on this invention. It is typical sectional drawing of the resin sheet in Embodiment 9 based on this invention. It is a flowchart of the manufacturing method of the resin sheet in Embodiment 10 based on this invention. It is 1st explanatory drawing of the manufacturing method of the resin sheet in Embodiment 10 based on this invention. It is 2nd explanatory drawing of the manufacturing method of the resin sheet in Embodiment 10 based on this invention. It is 1st explanatory drawing of the manufacturing method of the resin sheet in Embodiment 11 based on this invention. It is 2nd explanatory drawing of the manufacturing method of the resin sheet in Embodiment 11 based on this invention. It is a flowchart of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 1st process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 2nd process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 3rd process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 4th process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 5th process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 6th process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 7th process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention. It is explanatory drawing of the 8th process of the manufacturing method of the resin multilayer substrate in Embodiment 12 based on this invention.

The dimensional ratios shown in the drawings do not always faithfully represent the actual ones, and the dimensional ratios may be exaggerated for convenience of explanation. In the following description, when referring to a concept above or below, it does not mean absolute above or below, but rather relative above or below in the illustrated posture. .

(Embodiment 1)
With reference to FIGS. 1 to 8, a method for producing a resin sheet in the first embodiment based on the present invention will be described. FIG. 1 shows a flowchart of a method for manufacturing a resin sheet in the present embodiment. In the flowchart of FIG. 1, step S4 is not shown, but steps S1, S2, S3, and S5 are shown.

The method for producing a resin sheet in the present embodiment includes a step S1 of preparing a base material having a main surface, a step S2 of applying a thermoplastic resin powder to the main surface to form an application layer, and the application Irradiating a flash lamp from the opposite side of the substrate toward the layer to fuse a part of the coating layer including the surface on the side far from the substrate; In the step S3 of fusing, including the step S5 of separating from the material and taking it out alone, the coating layer is equally divided into two in the thickness direction, and the region far from the main surface is defined as the first region, When the region closer to the surface is the second region, the porosity of the first region is greater than 0, the porosity of the second region is greater than the porosity of the first region, and the application The powder is at least partially in the form of the powder Fusing enough to integrate the whole of the coating layer while leaving.

Each step included in the resin sheet manufacturing method in the present embodiment will be described in more detail with reference to the drawings.

First, as step S1, a base material 1 having a main surface 1u is prepared as shown in FIG. The substrate 1 may be made of, for example, PET (polyethylene terephthalate). Next, as step S2, as shown in FIG. 3, a powder of thermoplastic resin is applied to the main surface 1u to form the coating layer 10. The application is preferably performed by applying a paste-like resin dispersion obtained by dispersing thermoplastic resin powder in a dispersion medium. This is because a stable coating film can be obtained. The same applies to the other embodiments described below.

As step S3, as shown in FIG. 4, a part of the coating layer 10 including the surface far from the substrate 1 by irradiating the flash lamp 4 from the side opposite to the substrate 1 toward the coating layer 10 To fuse. The flash lamp 4 emits light 4a with a high light amount over a very short time. By performing step S3, the state shown in FIG. 5 is obtained. In FIG. 5, the coating layer 20 is formed. Part of the coating layer 20 including the surface on the side far from the substrate 1 has already been fused, so that the original shape of the powder is somewhat broken, and it is difficult to understand the original shape as the powder. There are also parts.

As step S5, as shown in FIG. 6, the coating layer 20 is separated from the substrate 1 and taken out alone. Step S5 may be performed by peeling off the coating layer 20 from the substrate 1. Step S5 may be performed by removing the substrate 1 by some means while leaving the coating layer 20. Thus, the resin sheet 101 can be obtained. The resin sheet 101 has a first surface 81 and a second surface 82 that face opposite sides. The first surface 81 is a surface fused by irradiation of the flash lamp 4. The second surface 82 is a surface that is in contact with the main surface 1 u of the substrate 1.

FIG. 7 and FIG. 8 show SEM (Scanning Electron Microscope) photographs of the surface of the resin sheet 101 produced by the inventors as prototypes. FIG. 7 is a view of the second surface 82, and FIG. 8 is a view of the first surface 81. In FIG. 7, fine particles of the powder can be seen, but in FIG. 8, the particles are fused to form a large shape.

In Step 3 described with reference to FIGS. 4 to 5, as shown in FIG. 9, the coating layer 20 is equally divided into two in the thickness direction, and the region far from the substrate 1 is defined as the first region 20a. When the region closer to 1 is the second region 20b, the porosity of the first region 20a is greater than 0, the porosity of the second region 20b is greater than the porosity of the first region 20a, and the application The layer 20 is fused so as to be integrated as a whole of the coating layer 20 while leaving at least a part of the powder form.

In this embodiment, the example using the powder of the thermoplastic resin has been described. However, as described later in the fifth embodiment, a fibrillated product of the thermoplastic resin may be used instead of the powder of the thermoplastic resin. .

In this embodiment, even if the material has no self-supporting property and can not be handled as a film or sheet by itself, fine particles or nanofibers can be fused together by flash lamp irradiation and handled as an independent sheet. be able to. By fusing only the vicinity of the outermost surface with a flash lamp, the adhesion between the base material and the material does not increase and can be easily peeled off.

In the present embodiment, the resin sheet having a high specific surface area can be obtained by a simple method without requiring the solubility of the material in the solvent and without requiring prior self-supporting property.

In this embodiment, by controlling the depth of the portion to be fused with respect to the coating thickness of the fine particles, the flash lamp irradiation surface can be fused and formed into a sheet, and the back surface can leave the fine particle shape. is there. A resin sheet as a high specific surface area film can be obtained from a desired material, and the properties of the material can be utilized to the maximum.

(Embodiment 2)
With reference to FIG. 6 to FIG. 9, a resin sheet according to the second embodiment of the present invention will be described. FIG. 6 shows a schematic cross-sectional view of the resin sheet in the present embodiment. The photograph of the 2nd surface of the resin sheet in this Embodiment is shown in FIG. 7, and the photograph of the 1st surface is shown in FIG.

As shown in FIG. 6, the resin sheet 101 in the present embodiment is a resin sheet having a first surface 81 and a second surface 82 that are opposite to each other and mainly made of a thermoplastic resin. As shown in FIG. 9, when the region closer to the first surface 81 divided into two in the thickness direction is the first region 20 a and the region closer to the second surface 82 is the second region 20 b, The porosity of the 1 area | region 20a is larger than 0, and the porosity of the 2nd area | region 20b is larger than the porosity of the 1st area | region 20a.

The resin sheet 101 in the present embodiment has a high specific surface area, and can be easily manufactured by using the thermoplastic resin powder by the manufacturing method described in the first embodiment. In carrying out the production method, the solubility of the material in the solvent is not necessary.

(Embodiment 3)
With reference to FIGS. 10 to 13, a method for manufacturing a resin sheet according to the third embodiment of the present invention will be described. FIG. 10 shows a flowchart of the resin sheet manufacturing method in the present embodiment.

The resin sheet manufacturing method in the present embodiment has many steps in common with the resin sheet manufacturing method in the first embodiment, but unlike the resin sheet manufacturing method in the first embodiment, the process before step S5 is performed. Includes S4.

In the method for producing a resin sheet in the present embodiment, the substrate 1 has translucency. As the substrate 1, for example, a PET film is used. Further, in this manufacturing method, before the step S5 of separating the coating layer from the base material 1 and taking it out alone, the light 4a is transmitted through the base material 1 and enters the coating layer 20 as shown in FIG. The process S4 which fuse | melts a part including the surface of the side close | similar to the base material 1 among the application layers 20 by irradiating the flash lamp 4 is included.

10 to 11, it has been described that the process S4 is performed after the process S3 is performed, but actually, the process S3 and the process S4 may be performed in parallel. Or it is good also as performing process S3 after performing process S4. In that case, it will be performed in order of process S4, S3, S5.

FIG. 12 shows a state after both steps S3 and S4 are completed regardless of which of steps S3 and S4 is performed first. In FIG. 12, the coating layer 21 is formed. Of the coating layer 21, a part including the surface on the side far from the base material 1 and a part including the surface on the side close to the base material 1 are fused together, and the original shape of the powder is destroyed. On the other hand, in the middle part, the original shape of the powder is relatively maintained.

As step S5, as shown in FIG. 13, the coating layer 21 is separated from the substrate 1 and taken out alone. In this way, the resin sheet 102 can be obtained. The resin sheet 102 has a first surface 81 and a second surface 82 that face opposite sides.

In this embodiment, even if the material has no self-supporting property and can not be handled as a film or sheet by itself, fine particles or nanofibers can be fused together by flash lamp irradiation and handled as an independent sheet. be able to. By fusing only the vicinity of the outermost surface with a flash lamp, the adhesion between the base material and the material does not increase and can be easily peeled off.

In the present embodiment, the upper and lower surfaces of the coating layer are fused by flash lamp irradiation, so that the state as a single resin sheet after separation from the substrate 1 can be further stabilized. According to the present embodiment, a resin sheet having a higher internal porosity than the surface can be easily obtained.

(Embodiment 4)
With reference to FIGS. 13 to 14, a resin sheet according to Embodiment 4 of the present invention will be described. FIG. 13 shows a schematic cross-sectional view of the resin sheet in the present embodiment.

As shown in FIG. 13, the resin sheet 102 in the present embodiment is a resin sheet having a first surface 81 and a second surface 82 that are opposite to each other and mainly made of a thermoplastic resin. 14, the region closest to the first surface 81 divided into three equal parts in the thickness direction is defined as a first region 21a, the region closest to the second surface 82 is defined as a second region 21b, and the first region 21a and the first region When the region sandwiched between the two regions 21b is the third region 21c, the porosity of the first region 21a is greater than 0, and the porosity of the third region 21c is greater than the porosity of the first region 21a. In addition to the resin sheet 102 shown in FIGS. 13 to 14, the resin sheet 101 shown in FIG. 6 also satisfies this condition.

Also in the present embodiment, the same effect as in the second embodiment can be obtained. According to the present embodiment, since it is a resin sheet having a higher internal porosity than the surface, it can be a resin sheet that can be significantly compressed in the thickness direction as necessary. Therefore, this resin sheet can be used, for example, as a so-called step absorption sheet.

Note that the porosity of the third region 21c is preferably larger than the porosity of the second region 21b. The resin sheet 102 shown in FIGS. 13 to 14 satisfies this condition.

(Embodiment 5)
With reference to FIGS. 15 to 22, a method for producing a resin sheet in the fifth embodiment according to the present invention will be described. In the first embodiment, each process is illustrated and described for a method of manufacturing a resin sheet using a thermoplastic resin powder. In the present embodiment, instead of the thermoplastic resin powder, a thermoplastic resin powder is used. Each process is illustrated and demonstrated about the manufacturing method of the resin sheet using a fibrillation thing. The flowchart of the resin sheet manufacturing method in the present embodiment is the same as that shown in FIG.

The manufacturing method of the resin sheet in the present embodiment includes a step S1 of preparing a base material having a main surface, a step S2 of forming a coating layer by applying a fibrillated product of a thermoplastic resin to the main surface, and the coating Irradiating a flash lamp from the opposite side of the substrate toward the layer to fuse a part of the coating layer including the surface on the side far from the substrate; And step S4 of separating from the material and taking it out alone. In the fusion bonding step S3, when the coating layer is equally divided into two in the thickness direction, a region far from the main surface is defined as a first region, and a region near the main surface is defined as a second region. The porosity of the first region is greater than 0, the porosity of the second region is greater than the porosity of the first region, and the coating layer remains at least partially in the form of the fibrillated product. The coating layer is fused so as to be integrated as a whole.

Each step included in the resin sheet manufacturing method in the present embodiment will be described in more detail with reference to the drawings.

Step S1 is the same as that described in the first embodiment.
As step S2, as shown in FIG. 15, a fibrillated product of a thermoplastic resin is applied to the main surface 1u to form a coating layer 30.

As step S3, as shown in FIG. 16, a part of the coating layer 30 including the surface far from the substrate 1 by irradiating the flash lamp 4 from the side opposite to the substrate 1 toward the coating layer 30. To fuse. The flash lamp 4 emits light 4a with a high light amount over a very short time. By performing step S3, the state shown in FIG. 17 is obtained. In FIG. 17, the coating layer 40 is formed. A part of the coating layer 40 including the surface on the side far from the base material 1 is fused, so that the original form of the fibrillated product is somewhat broken, and the original form as the fibrillated product is difficult to understand. There is also a part.

As step S5, as shown in FIG. 18, the coating layer 40 is separated from the substrate 1 and taken out alone. Step S5 may be performed by peeling the coating layer 40 from the substrate 1. Step S5 may be performed by removing the substrate 1 by some means while leaving the coating layer 40. In this way, the resin sheet 103 can be obtained. The resin sheet 103 has a first surface 81 and a second surface 82 that face opposite sides. The first surface 81 is a surface fused by irradiation of the flash lamp 4. The second surface 82 is a surface that is in contact with the main surface 1 u of the substrate 1.

19 to 21 show SEM photographs of the resin sheet 103 prototyped by the inventors. FIG. 19 shows the end of the resin sheet 103 as viewed from the side. In FIG. 19, the white arrow points to the fused surface, that is, the first surface 81. In FIG. 19, it is shown upside down compared to FIG. In FIG. 19, the upper side is the second surface 82 and the lower side is the first surface 81. FIG. 20 shows the second surface 82 as seen. FIG. 21 shows the first surface 81 as viewed. In FIG. 20, a fine fibrous shape of the fibrillated product can be seen, but in FIG. 21, the fibrillated products are fused to form a large-sized shape.

FIG. 22 shows a state in which the resin sheet 103 prototyped by the inventor is embedded with another resin so that the gap is filled with the other resin, and then the section is exposed by cutting and observed with an SEM. . In FIG. 22, the upper and lower sides of the coating layer 40 are shown upside down as compared with FIG. In FIG. 22, the upper surface of the coating layer 40 is a surface in contact with the main surface 1 u of the substrate 1. In step 3 described with reference to FIGS. 16 to 17, as shown in FIG. 22, the coating layer 40 is equally divided into two in the thickness direction, and a region far from the substrate 1 is defined as a first region 40a. When the region close to 1 is the second region 40b, the porosity of the first region 40a is greater than 0, the porosity of the second region 40b is greater than the porosity of the first region 40a, and the application The layer 40 is fused so as to be integrated as a whole of the coating layer 40 while leaving the form of the fibrillated product at least partially.

Also in the present embodiment, the same effect as in the first embodiment can be obtained. In this embodiment, since the fibrillated product is used instead of the powder used in Embodiment 1, the specific surface area can be made extremely high. Since the fibrillated product is intertwined with each other even before the surface is fused, the fibrillated product is less likely to scatter than the powder and is easy to handle. The fibrillated product has a smaller true volume than the apparent volume and, as a result, a smaller heat capacity. Therefore, even when the same amount of energy is applied for fusing, the fibrillated product is fused compared to the powder. It's easy to do.

(Embodiment 6)
With reference to FIGS. 18 to 22, a resin sheet according to the sixth embodiment of the present invention will be described. A schematic cross-sectional view of the resin sheet in the present embodiment is shown in FIG. A photograph of the cross section of the resin sheet in the present embodiment is shown in FIG. The photograph of the 2nd surface of the resin sheet in this Embodiment is shown in FIG. 20, and the photograph of the 1st surface is shown in FIG.

As shown in FIG. 18, the resin sheet 103 in the present embodiment is a resin sheet having a first surface 81 and a second surface 82 that are opposite to each other and mainly made of a thermoplastic resin. 22, when the region closer to the first surface 81 divided into two in the thickness direction is the first region 40a, and the region closer to the second surface 82 is the second region 40b, The porosity of the 1st area | region 40a is larger than 0, and the porosity of the 2nd area | region 40b is larger than the porosity of the 1st area | region 40a.

The resin sheet 103 in the present embodiment has a high specific surface area, and can be easily produced using a fibrillated product of a thermoplastic resin by the manufacturing method described in the fifth embodiment. In carrying out the production method, the solubility of the material in the solvent is not necessary.

(Embodiment 7)
With reference to FIG. 18 and FIG. 23, the resin sheet in Embodiment 7 based on this invention is demonstrated. FIG. 23 is obtained by changing the region dividing method in FIG. Therefore, in FIG. 23, the top and bottom of the coating layer 40 are shown upside down compared to FIG.

As shown in FIG. 18, the resin sheet 103 in the present embodiment is a resin sheet having a first surface 81 and a second surface 82 that are opposite to each other and mainly made of a thermoplastic resin. 23, the region closest to the first surface 81 divided into three in the thickness direction is defined as a first region 40ax, the region closest to the second surface 82 is defined as a second region 40bx, and the first region 40ax and the first region When the region sandwiched between the two regions 40bx is the third region 40cx, the porosity of the first region 40ax is greater than 0, and the porosity of the third region 40cx is greater than the porosity of the first region 40ax.

Also in the present embodiment, the same effect as described in the sixth embodiment can be obtained.

Note that the porosity of the third region 40cx is preferably larger than the porosity of the second region 40bx.

(Embodiment 8)
With reference to FIGS. 24 to 26, a resin sheet manufacturing method according to Embodiment 8 of the present invention will be described. Although this embodiment has many steps that are common to the resin sheet manufacturing method of the fifth embodiment, unlike the resin sheet manufacturing method of the first embodiment, step S4 is included before step S5. The flowchart of the resin sheet manufacturing method in the present embodiment is the same as that shown in FIG.

In the method for producing a resin sheet in the present embodiment, the substrate 1 has translucency. Further, in this manufacturing method, before the step S5 of separating the coating layer from the base material 1 and taking it out alone, the light 4a is transmitted through the base material 1 and enters the coating layer 40 as shown in FIG. Step S4 is included in which a part of the coating layer 40 including the surface close to the substrate 1 is fused by irradiating the flash lamp 4.

10 and 24, it has been described that the process S4 is performed after the process S3 is performed, but actually, the process S3 and the process S4 may be performed in parallel. Or it is good also as performing process S3 after performing process S4. In that case, it will be performed in order of process S4, S3, S5.

FIG. 25 shows a state after both steps S3 and S4 are completed regardless of which of steps S3 and S4 is performed first. In FIG. 25, the coating layer 41 is formed. Of the coating layer 41, a part including the surface far from the base material 1 and a part including the surface near the base material 1 are fused together, and the original form of the fibrillated product is destroyed. On the other hand, in the middle part, the original shape of the fibrillated product is relatively maintained.

As step S5, as shown in FIG. 26, the coating layer 41 is separated from the substrate 1 and taken out alone. Thus, the resin sheet 104 can be obtained. The resin sheet 104 has a first surface 81 and a second surface 82 that face opposite sides.

According to the present embodiment, a resin sheet having a higher internal porosity than the surface can be obtained using the fibrillated product. Since fibrillated material is used in place of the powder, the internal porosity can be made extremely high. Since such a sheet can be greatly compressed in the thickness direction as necessary, it can be used, for example, as a so-called step absorbing sheet.

(Embodiment 9)
With reference to FIG. 26, the resin sheet in Embodiment 9 based on this invention is demonstrated. FIG. 26 shows a schematic cross-sectional view of the resin sheet in the present embodiment.

As shown in FIG. 26, the resin sheet 104 in the present embodiment is a resin sheet having a first surface 81 and a second surface 82 that are opposite to each other and mainly made of a thermoplastic resin, and has a thickness. A region that is equally divided into three in the direction and is closest to the first surface 81 is a first region, a region that is closest to the second surface 82 is a second region, and a region sandwiched between the first region 21a and the second region 21b is When the third region is used, the porosity of the first region is greater than 0, and the porosity of the third region is greater than the porosity of the first region.

According to the present embodiment, since the resin sheet has a higher internal porosity than the surface, the resin sheet can be compressed significantly in the thickness direction as necessary. Therefore, this resin sheet can be used, for example, as a so-called step absorption sheet.

Note that the porosity of the third region is preferably larger than the porosity of the second region. The resin sheet 104 shown in FIG. 26 satisfies this condition.

(Embodiment 10)
With reference to FIGS. 27 to 29, a resin sheet manufacturing method according to the tenth embodiment of the present invention will be described. FIG. 27 shows a flowchart of a method for manufacturing a resin sheet in the present embodiment.

The method for producing a resin sheet in the present embodiment includes a step S1 of preparing a base material having a main surface, a step S2 of forming a coating layer by applying a thermoplastic resin powder to the main surface, Irradiating a flash lamp so as to pass through the base material and enter the coating layer, thereby fusing a part of the coating layer including a surface close to the base material, and the coating layer; And step S5 for separating the substrate from the substrate and taking it out alone. In the fusion bonding step S4, when the coating layer is equally divided into two in the thickness direction, a region far from the main surface is defined as a first region, and a region near the main surface is defined as a second region. The porosity of the second region is greater than 0, the porosity of the first region is greater than the porosity of the second region, and the coating layer leaves the powder form at least partially. The coating layer is fused so as to be integrated as a whole.

Each step included in the resin sheet manufacturing method in the present embodiment will be described in more detail with reference to the drawings.

Since steps S1 and S2 are the same as those described in the first embodiment, description thereof will not be repeated.

As step S4, as shown in FIG. 28, a part of the coating layer 10 including the surface near the substrate 1 is melted by irradiating the flash lamp 4 toward the coating layer 10 from the substrate 1 side. Put on. In other words, by irradiating the flash lamp 4 so that the light 4a passes through the substrate 1 and enters the coating layer 10, a part of the coating layer 10 including the surface close to the substrate 1 is fused. . By performing step S4, the state shown in FIG. 29 is obtained. In FIG. 29, the coating layer 22 is formed. Part of the coating layer 22 including the surface on the side close to the base material 1 is fused, so that the original shape of the powder is somewhat collapsed, and the original shape as the powder becomes difficult to understand. There is also a part.

Since step S5 is the same as that described in the first embodiment, description thereof will not be repeated. By completing step S5 in this way, a resin sheet in which the resin sheet 101 shown in FIG. 6 is turned upside down is obtained.

Also in the present embodiment, the same effect as in the first embodiment can be obtained.
(Embodiment 11)
With reference to FIG. 30 to FIG. 31, a method for manufacturing a resin sheet according to the eleventh embodiment of the present invention will be described. The flowchart of the resin sheet manufacturing method in the present embodiment is the same as that shown in FIG.

The method for producing a resin sheet in the present embodiment includes a step S1 for preparing a base material having a main surface, a step S2 for forming a coating layer by applying a fibrillated thermoplastic resin to the main surface, Irradiating a flash lamp so as to pass through the base material and enter the coating layer, thereby fusing a part of the coating layer including a surface close to the base material, and the coating layer; In step S4 for separating and separating the substrate from the base material, and in the step S4 for fusing, the coating layer is divided into two equal parts in the thickness direction, and the region far from the main surface is defined as the first region. When the region closer to the main surface is the second region, the porosity of the second region is greater than 0, the porosity of the first region is greater than the porosity of the second region, and The coating layer is at least partially Fusing enough to integrate the whole of the coating layer while leaving the form of the fibril product.

Each step included in the resin sheet manufacturing method in the present embodiment will be described in more detail with reference to the drawings.

Since steps S1 and S2 are the same as those described in the fifth embodiment, description thereof will not be repeated.

As step S4, as shown in FIG. 30, a part of the coating layer 30 including the surface near the substrate 1 is melted by irradiating the flash lamp 4 from the substrate 1 side toward the coating layer 30. Put on. In other words, by irradiating the flash lamp 4 so that the light 4a passes through the substrate 1 and enters the coating layer 30, a part of the coating layer 30 including the surface close to the substrate 1 is fused. . By performing step S4, the state shown in FIG. 31 is obtained. In FIG. 31, the coating layer 32 is formed. Part of the coating layer 32 including the surface on the side close to the base material 1 is fused, so that the original shape of the powder is somewhat collapsed, and the original shape as the powder becomes difficult to understand. There is also a part.

Since step S5 is the same as that described in the first embodiment, description thereof will not be repeated. By completing step S5 in this way, a resin sheet in which the resin sheet 103 shown in FIG. 18 is turned upside down is obtained.

Also in the present embodiment, the same effect as in the fifth embodiment can be obtained.
In some of the embodiments described so far, the method for producing a resin sheet has been described. In these resin sheet producing methods, the thermoplastic resin preferably contains a liquid crystal polymer.

In some embodiments so far, resin sheets have been described, but in these resin sheets, the thermoplastic resin preferably includes a liquid crystal polymer.

Specific application examples of the resin sheet and the manufacturing method thereof described so far are shown below.
(Application example 1) Regardless of the type of material, by impregnating the above-mentioned resin sheet having a high specific surface area with another type of resin, a polymer alloy with an anchor effect can be easily produced. Moreover, since the contact area is large, a composite material having excellent interfacial adhesion can be obtained. By using LCP or polyimide as a material, a substrate having high heat resistance, low dielectric constant, high strength, and high adhesion can be manufactured.

(Application example 2) Since a low-density sheet including an air layer is obtained, this sheet can be used as a step absorption sheet. By appropriately selecting and using materials such as LCP, polyimide, PEEK, etc. according to the material of the multilayer substrate and the press temperature as the step absorption sheet of the multilayer substrate, without impairing the heat resistance and electrical characteristics of the finished substrate, A flat multilayer substrate can be manufactured by filling the step portion of the circuit.

(Application Example 3) Since a low density sheet containing a large amount of air layer can be obtained, a sheet having a lower dielectric constant including the air layer can be obtained by using a low dielectric constant material such as LCP as the material. .

(Application Example 4) By using a resin having a small surface tension such as a fluorine resin as a material, a resin sheet having a super water-repellent surface can be obtained due to a lotus effect due to surface irregularities.

The sheet obtained by performing irradiation with a flash lamp only on one side maintains a high specific surface area on the surface opposite to the irradiated surface, so that a polymer alloy substrate sheet, a step absorption sheet, When used for applications such as super water-repellent sheets, good performance is easily obtained. On the other hand, a sheet obtained by irradiating both sides with a flash lamp is easy to obtain a self-supporting property even if the film thickness is large, and is suitable for an application requiring a large film thickness. When used for a step-absorbing sheet, a heat insulating sheet containing an air layer, or a low dielectric sheet, good performance is easily obtained.

(Embodiment 12)
With reference to FIGS. 32 to 40, a method for manufacturing a resin multilayer substrate in accordance with the twelfth embodiment of the present invention will be described. FIG. 32 shows a flowchart of the method for manufacturing the resin multilayer substrate in the present embodiment.

The manufacturing method of the resin multilayer substrate in the present embodiment includes a step S101 for preparing a first thermoplastic resin layer having a conductor pattern disposed on the surface, a step S102 for preparing a second thermoplastic resin layer, and so far. Step S103 of preparing the resin sheet described in any of the embodiments, the resin sheet is in contact with the conductor pattern, and the resin sheet is the first thermoplastic resin layer and the second thermoplastic resin. Step S104 for obtaining a laminate by stacking at least the first thermoplastic resin layer, the second thermoplastic resin layer, and the resin sheet so as to be sandwiched between layers, and applying heat and pressure to the laminate, Step S105 for integrating the laminated body.

Each step included in the method for manufacturing a resin multilayer substrate in the present embodiment will be described in more detail with reference to the drawings.

First, step S101 for preparing a first thermoplastic resin layer is performed. For this purpose, first, as shown in FIG. 33, a resin sheet 12 with a conductor film is prepared. The resin sheet with a conductor film 12 includes a resin layer 2 and a conductor layer 17. The conductor layer 17 is disposed so as to cover one surface of the resin layer 2. The conductor layer 17 is, for example, a metal layer. The metal layer here may be, for example, a copper layer. As shown in FIG. 34, a resist pattern 13 is formed on one surface of the resin sheet 12 with a conductor film. By etching the conductor layer 17 using the resist pattern 13 as a mask, the conductor pattern 7 is formed as shown in FIG. By removing the resist pattern 13, a first thermoplastic resin layer 51 is obtained as shown in FIG. This is step S101.

Step S102 for preparing the second thermoplastic resin layer is performed. As shown in FIG. 37, the second thermoplastic resin layer 52 may have the same conductor pattern 7 as the first thermoplastic resin layer 51. The second thermoplastic resin layer 52 may have a conductor pattern 7 different from that of the first thermoplastic resin layer 51. The second thermoplastic resin layer 52 may have no conductor pattern at all. When the 2nd thermoplastic resin layer 52 has a certain conductor pattern, it is good also as obtaining the 2nd thermoplastic resin layer 52 of a desired structure by performing the operation | work similar to process S101.

Step S103 for preparing the resin sheet described in any of the above embodiments is performed. Step S103 may be performed by the resin sheet manufacturing method described above. Here, as an example, a resin sheet 103 is prepared as shown in FIG. The resin sheet 103 has been described in the sixth embodiment with reference to FIG. In FIG. 38, the resin sheet 103 is simplified and displayed. The first surface 81 of the resin sheet 103 may face either up or down.

Processes S101, S102, and S103 may be performed in any order, and may be performed in parallel. After all of steps S101, S102, and S103 are completed, step S104 for obtaining a laminate is performed. In step S104, as shown in FIG. 39, the resin sheet 103 abuts on the conductor pattern 7, and the resin sheet 103 is sandwiched between the first thermoplastic resin layer 51 and the second thermoplastic resin layer 52. At least the first thermoplastic resin layer 51, the second thermoplastic resin layer 52, and the resin sheet 103 are stacked to obtain a laminate 85. In FIG. 39, the laminated body 85 is obtained by combining and stacking sheets in addition to the above-described three sheets.

After step S104, step S105 for integrating the laminate is performed. In step S105, the laminated body 85 is integrated by applying heat and pressure to the laminated body 85. A gap portion is formed in the portion overlapping the conductor pattern 7 in the resin sheet 103 (the lower resin sheet 103 in FIG. 39) sandwiched between the first thermoplastic resin layer 51 and the second thermoplastic resin layer 52 through the step S105. As a result, the material of the resin sheet 103 is accommodated in a portion where the conductor pattern 7 is not present. That is, the resin sheet 103 functions as a step absorption sheet. In this way, the resin multilayer substrate 201 can be obtained as shown in FIG.

In the present embodiment, a resin sheet produced using a thermoplastic resin powder or fibrillated product is sandwiched between thermoplastic resin layers as a step-absorbing sheet to form a laminate, thereby producing a resin multilayer substrate. Therefore, it is possible to obtain a resin multilayer substrate in which the step on the outermost surface is reduced. In addition, it is more preferable to use the same material for the resin layer having a conductor pattern formed on the surface and the resin sheet as the step absorption sheet, since the material characteristics of each other are equal.

(Experimental result)
Hereinafter, the results of actual experiments by the inventors will be described.

(Experiment 1)
As Experiment 1, a resin sheet was prototyped by the manufacturing method described in the first embodiment.

LCP powder was used as the powder. First, in order to obtain LCP powder, a LCP biaxially stretched film having a thickness of 125 μm was prepared as a raw material of LCP powder. This film was primarily ground using a rotary cutter mill. In the primary pulverization, only those pulverized to such an extent that they passed through a 3 mm diameter sieve were collected. The primary pulverized film piece was subjected to secondary pulverization using a freeze pulverizer to obtain LCP powder. Of the obtained LCP powder, only those passing through 40 mesh were collected. The LCP powder thus obtained was hereinafter referred to as “LCP1”. LCP1 was added to butanediol at a weight ratio of 25% and stirred to obtain a paste-like LCP dispersion. This was called “LCP dispersion 1”.

As step S1, a PET substrate was prepared. As Step S2, LCP dispersion 1 was applied on a PET substrate by a screen printing method to form a coating film. For this screen printing, a screen mesh of 70 lines / inch and an opening of 263 μm was used. Furthermore, the sheet | seat in which the coating film about 30 micrometers thick consisting of LCP powder (LCP1) was formed by drying on 130 degreeC on a hotplate for 3 minutes conditions. This sheet corresponds to that shown in FIG. The coating film having a thickness of about 30 μm corresponds to the coating layer 10 in FIG. As step S3, a flash lamp irradiation treatment was performed on the side of the sheet having the coating film using PulseForge (R) 1300 manufactured by NovaCentrix with a pulse width of 0.5 milliseconds and an output of 300V. Thus, at least a part of the coating film was fused. As step S5, the coating film was peeled off from the PET substrate to obtain an LCP sheet having a film thickness of 25 μm. As a result of observing the LCP sheet with SEM, it was found that the surface irradiated with the flash lamp was fused and integrated, and the surface peeled from the PET base material was fused while maintaining the powder shape. It was. The specific surface area of the LCP sheet thus obtained was measured using Macsorb (R) HM manufactured by Mountec Co., Ltd. As a result, the specific surface area was 2 g / m ² .

From this experiment, even if it is a powder that does not have self-holding properties, the surface of the coating layer formed thereby can be fused to give the whole layer self-supporting properties while leaving a part of the shape of the powder. It was confirmed that the sheet obtained by peeling off the coating layer can be handled as an independent sheet. In this method, it is possible to form a sheet while partially leaving the powder shape, so that a resin sheet as a high specific surface area sheet can be obtained. The material to be used as the high specific surface area sheet does not need to be completely dissolved in the solvent, and may be simply applied as a dispersion. Therefore, a resin having high solvent resistance can be used as the material.

The LCP sheet obtained from LCP1 in Experiment 1 was embedded with Stricus Specifix-20, cut so that the cross-section was exposed, and then observed with SEM (VE7800 manufactured by Keyence Corporation). The ratio of voids (embedded resin) to the ratio of LCP resin in the image obtained by observation was determined. The porosity (void area / viewing area) was 33% on the irradiated surface side when the total film thickness was divided into two equal parts, and 69% on the non-irradiated surface side. When the irradiation surface porosity / non-irradiation surface porosity was defined as the porosity ratio, the porosity ratio was 0.48. The measurement results are shown in Tables 1 to 3.

(Experiment 2)
As Experiment 2, a resin sheet was prototyped by the manufacturing method described in the fifth embodiment.

The second pulverization is performed using a freeze pulverizer to obtain LCP powder, which is the same as described in Experiment 1. Of the LCP powder obtained by secondary pulverization, those passing through 150 mesh were collected. The LCP powder thus obtained was fibrillated with a high-pressure wet crusher. Thus, a fibrillated product of LCP was obtained. This is hereinafter referred to as “LCP2”. LCP2 was added to butanediol (viscosity: about 90 mPa · s) at a weight ratio of 5% and stirred to obtain a paste-like LCP dispersion. This was called “LCP dispersion 2”.

Steps S1 and S2 were performed as in Experiment 1. However, in Step S2, coating was performed using the LCP dispersion 2 instead of the LCP dispersion 1 of Experiment 1. The obtained sheet corresponds to that shown in FIG. The coating film corresponds to the coating layer 30 in FIG. Furthermore, the resin sheet was manufactured by performing process S3, S5 similarly to the experiment 1. FIG. About the obtained resin sheet, the specific surface area and the porosity were measured. The measurement results are shown in Tables 1 to 3.

(Experiment 3)
As Experiment 3, a resin sheet was manufactured by replacing the powder material of Experiment 1 with another type.

As the powder, a thermoplastic polyimide resin powder (hereinafter referred to as “PI powder”) was used. In order to obtain PI powder, pellets of Aurum (R) (AURUM) PL450C manufactured by Mitsui Chemicals were prepared, and the pellets were pulverized using a freeze pulverizer. In this way, PI powder was obtained. Of the obtained PI powder, a powder passing through 40 mesh was added to butanediol at a weight ratio of 30% and stirred to obtain a paste-like PI dispersion. Using this PI dispersion, a resin sheet was obtained by the production method shown in the first embodiment. About the obtained resin sheet, the specific surface area and the porosity were measured. The measurement results are shown in Tables 1 to 3.

(Experiment 4)
In Experiment 4, a resin sheet was made by replacing the powder material of Experimental Example 1 with another type.

As the powder, a PEEK resin powder (hereinafter referred to as “PEEK powder”) was used. PEEK 150XF (powder) manufactured by Victrex was used as the PEEK powder, and 25% by weight was added to butanediol, followed by stirring to obtain a paste-like PEEK dispersion. Using this PEEK dispersion, a resin sheet was obtained by the production method shown in the first embodiment. About the obtained resin sheet, the specific surface area and the porosity were measured. The measurement results are shown in Tables 1 to 3.

(Experiment 5)
In Experiment 5, a resin sheet was made by replacing the powder material of Experiment 1 with another type.

As the powder, cyclic olefin polymer (COP) resin powder (hereinafter referred to as “COP powder”) was used. ZEONEX (R) RS420 made by Nippon Zeon was pulverized using a freeze pulverizer to obtain COP powder. Among the obtained COP powders, those passing through 40 mesh were added to butanediol in a weight ratio of 30% and stirred to obtain a paste-like COP dispersion. Using this dispersion, a resin sheet was obtained by the production method shown in the first embodiment. About the obtained resin sheet, the specific surface area and the porosity were measured. The measurement results are shown in Tables 1 to 3.

(Experiment 6)
As Experiment 6, using the LCP dispersion liquid 1 of Experiment 1, a resin sheet was prototyped by the manufacturing method described in Embodiment 3.

The LCP dispersion 1 was applied onto a PET substrate using a doctor blade to form a coating film. Then, it dried on 130 degreeC * 10 minute conditions on the hotplate, and obtained the sheet | seat which formed the coating film about 100 micrometers thick which consists of LCP powder. The coating surface of this sheet was subjected to flash lamp irradiation treatment using PulseForge (R) 1300 manufactured by NovaCentrix with a pulse width of 1 millisecond and an output of 380V. Subsequently, a flash lamp irradiation process was performed from the PET substrate side with a pulse width of 1 millisecond and an output of 390V. The coating film was peeled off from the PET substrate to obtain an LCP sheet having a thickness of about 80 μm. As a result of observing the LCP sheet with SEM, it was found that the surface on the side in contact with the substrate and the surface on the opposite side were fused and integrated. The specific surface area of the LCP sheet thus obtained was measured using Macsorb (R) HM manufactured by Mountec Co., Ltd. As a result, the specific surface area was 2.4 g / m ² .

About the obtained resin sheet, the porosity was measured. The measurement results are shown in Tables 2 to 3.
(Experiment 7)
As Experiment 7, using the PI dispersion liquid of Experiment 3, a resin sheet was prototyped by the manufacturing method described in the third embodiment. About the obtained resin sheet, the specific surface area and the porosity were measured. The measurement results are shown in Tables 2 to 3.

Table 1 shows the results obtained by dividing the resin sheet obtained in each of Experiments 1 to 5 into two portions in the thickness direction in the manner shown in FIG. 9 and measuring the porosity for each of these two regions.

Tables 2 to 3 show the results of measuring the porosity of each of these three regions by dividing the resin sheets obtained in Experiments 1 to 7 into three equal parts in the thickness direction in the manner shown in FIG. Tables 2 and 3 are the contents that should originally be one table connected in the left-right direction, but are divided into two tables for the convenience of display space.

The material of the substrate 1 used in the resin sheet manufacturing method is not particularly limited. However, when the manufacturing method includes a step of irradiating a flash lamp so that light passes through the base material 1 and enters the coating layer, the base material 1 needs to have translucency. In other cases, the substrate 1 may be formed of a material that does not have translucency.

In addition, you may employ | adopt combining suitably two or more among the said embodiment.
In addition, the said embodiment disclosed this time is an illustration in all the points, Comprising: It is not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

1 substrate, 1u main surface, 2 resin layer, 3 powder, 3e fibrillated product, 4 flash lamp, 4a light, 7 conductor pattern, 10 (powder) coating layer, 12 resin sheet with conductor film, 13 resist pattern , 17 conductor layer, 20 coating layer (derived from powder and fused on top), 20a, 21a, 40a, 40ax first region, 20b, 21b, 40b, 40bx second region, 21c, 40cx third region, 21 Coating layer (derived from powder and fused on both sides), 22 coating layer (derived from powder and fused on lower surface), coating layer (30 of fibrillated material), 32 (derived from fibrillated material and fused on lower surface) Coating layer, 40 (derived from fibrillated product and fused on top) 41, coated layer (derived from fibrillated and fused on both sides), 51 first thermoplastic resin layer 52 second thermoplastic resin layer, 81 first surface 82 second surface 85 laminate, 101-104 resin sheet, 201 a resin multilayered substrate.

Claims (9)

A resin sheet having a first surface and a second surface that are opposite to each other and made of a thermoplastic resin as a main material. A region closer to the first surface is divided into two equal parts in the thickness direction. When a region close to the second surface is a second region, the porosity of the first region is greater than 0, and the porosity of the second region is greater than the porosity of the first region , Resin sheet. A resin sheet having a first surface and a second surface that are opposite to each other and made of a thermoplastic resin as a main material. The region closest to the first surface is divided into three equal parts in the thickness direction. When the region closest to the second surface is the second region, and the region sandwiched between the first region and the second region is the third region, the porosity of the first region is greater than zero. A resin sheet in which the porosity of the third region is larger than the porosity of the first region. The resin sheet according to claim 2, wherein the porosity of the third region is larger than the porosity of the second region. The resin sheet according to any one of claims 1 to 3, wherein the thermoplastic resin includes a liquid crystal polymer. Preparing a base material having a main surface;
Applying a thermoplastic resin powder or fibrillated product to the main surface to form a coating layer;
Fusing a part of the coating layer including a surface far from the substrate by irradiating a flash lamp from the opposite side of the substrate toward the coating layer;
Separating the coating layer from the substrate and taking it out alone,
In the step of fusing, when the coating layer is equally divided into two in the thickness direction, a region far from the main surface is a first region, and a region near the main surface is a second region, The porosity of the first region is greater than 0, the porosity of the second region is greater than the porosity of the first region, and the coating layer is at least partially in the form of the powder or the fibrillated product. The manufacturing method of the resin sheet | seat which is made to fuse | melt so that it may integrate as the whole of the said application layer, leaving behind. The substrate has translucency,
The manufacturing method includes:
Before the step of separating the coating layer from the substrate and taking it out alone,
Irradiating a flash lamp so that light is transmitted through the substrate and incident on the coating layer, thereby fusing a part of the coating layer including a surface closer to the substrate. Item 6. A method for producing a resin sheet according to Item 5. Preparing a base material having a main surface;
Applying a thermoplastic resin powder or fibrillated product to the main surface to form a coating layer;
Irradiating a flash lamp so that light is transmitted through the substrate and incident on the coating layer, thereby fusing a part of the coating layer including a surface close to the substrate;
Separating the coating layer from the substrate and taking it out alone,
In the step of fusing, when the coating layer is equally divided into two in the thickness direction, a region far from the main surface is a first region, and a region near the main surface is a second region, The porosity of the second region is greater than 0, the porosity of the first region is greater than the porosity of the second region, and the coating layer is at least partially in the form of the powder or the fibrillated product. The manufacturing method of the resin sheet | seat which is made to fuse | melt so that it may integrate as the whole of the said application layer, leaving behind. The method for producing a resin sheet according to any one of claims 5 to 7, wherein the thermoplastic resin includes a liquid crystal polymer. Preparing a first thermoplastic resin layer having a conductor pattern disposed on the surface;
Preparing a second thermoplastic resin layer;
Preparing the resin sheet according to any one of claims 1 to 4,
At least the first thermoplastic resin layer, the first thermoplastic resin layer, and the second thermoplastic resin layer so that the resin sheet is in contact with the conductor pattern and the resin sheet is sandwiched between the first thermoplastic resin layer and the second thermoplastic resin layer. 2 stacking the thermoplastic resin layer and the resin sheet to obtain a laminate;
And a step of applying heat and pressure to the laminate to integrate the laminate.

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