Method of producing glass laminate, and glass laminate

Abstract

To improve product yield by allowing positioning of an outer peripheral end part of a plate-like structure and an outer peripheral end part of a glass plate to be carried out after bonding both to reduce a generation rate of defective products.SOLUTION: A method of producing a glass laminate 1 obtained by bonding glass plates 4, 6 to a plate-like structure 2 through adhesive layers 3, 5 includes: a preparation process of preparing a plate-like structure capable of deforming by crushing at least an outer peripheral part 2c from an outer peripheral side as the plate-like structure 2; a bonding process of bonding the glass plates 4, 6 to main surfaces 2d, 2c facing each other of the plate-like structure 2 through the adhesive layers 3, 5 so that the outer peripheral part 2c of the plate-like structure 2 prepared by the preparation process is protruded from outer peripheral end parts 4a, 6a of the glass plates 4, 6; and a crushing process of crushing the outer peripheral part 2c of the plate-like structure 2 from the outer peripheral side after the bonding process.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to a method for producing a glass laminate in which a glass plate and a plate-like structure are bonded together, and to a glass laminate. [Background technology]

[0002] In recent years, glass laminates in which a glass plate (including a glass film) is attached to a plate-like structure have been attempted to be used or put into practical use as light-transmitting members constituting windows, doors, etc. of buildings. As the plate-like structure, various types of structures are used, such as plate-like resin structures and metal structures having a plurality of through holes in the thickness direction.

[0003] As one example, Patent Document 1 discloses that a plate-shaped honeycomb structure made of stainless steel or the like is used as a plate-shaped structure, and a glass plate is attached to this honeycomb structure via an adhesive layer to obtain a glass laminate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 8-25564 Summary of the Invention [Problem to be solved by the invention]

[0005] In the glass laminate disclosed in Patent Document 1, if the outer peripheral end of the honeycomb structure and the outer peripheral end of the glass plate are attached in a state where there is a misalignment between them during manufacturing, it is difficult to correct the misalignment. Therefore, when manufacturing the glass laminate, it is necessary to attach the outer peripheral end of the honeycomb structure and the outer peripheral end of the glass plate while aligning them precisely. However, since the honeycomb structure is difficult to process and has low dimensional accuracy, it is difficult to match the side dimensions of the honeycomb structure and the side dimensions of the glass plate, and further to match the positions of their outer peripheral ends. For this reason, it has been difficult to manufacture a glass laminate with a high yield using conventional techniques.

[0006] The above-mentioned problems may occur similarly when a glass laminate is manufactured using a plate-like structure other than a honeycomb structure.

[0007] From the above viewpoints, an object of the present invention is to obtain, with a good yield, a glass laminate in which the side dimensions of a plate-like structure and a glass plate match and the positions of the peripheral ends of both are aligned. [Means for solving the problem]

[0008] (1) A first aspect of the present invention devised to solve the above problems is a manufacturing method for a glass laminate in which a glass plate is attached to a plate-like structure via an adhesive layer, and is characterized by comprising: a preparation step of preparing a plate-like structure as the plate-like structure, at least a peripheral portion of which can be deformed by crushing from the peripheral side; a bonding step of bonding a glass plate via the adhesive layer to at least one main surface of the plate-like structure prepared in the preparation step such that the peripheral portion of the plate-like structure protrudes from the peripheral end of the glass plate; and a crushing step of, after the bonding step, deforming the peripheral portion of the plate-like structure protruding from the peripheral end of the glass plate by crushing from the peripheral side.

[0009] According to this configuration, in the bonding step, the plate-like structure and the glass plate are bonded together with the outer peripheral portion of the plate-like structure protruding from the outer peripheral end of the glass plate, and then in the crushing step, the protruding portion of the plate-like structure is crushed from the outer peripheral side to deform it. In this case, the outer peripheral end of the portion deformed by crushing the plate-like structure corresponds to the outer peripheral end of the plate-like structure, so by performing the crushing step, it is possible to match the side dimensions of the plate-like structure and the side dimensions of the glass plate, and further align the outer peripheral end of the plate-like structure and the outer peripheral end of the glass plate. Since this crushing step is performed after the bonding step, it is possible to easily deform the outer peripheral dimensions and shape of the plate-like structure to match the outer peripheral dimensions and shape of the bonded glass plate. This reduces the rate of defective products and improves the product yield.

[0010] (2) In the above configuration (1), in the bonding step, a glass plate is bonded to each of the two opposing main surfaces of the plate-like structure via an adhesive layer, and in the crushing step, the peripheral portions of the plate-like structure protruding from the peripheral ends of the glass plates may be crushed from the peripheral side to deform them.

[0011] In this way, it is possible to align the outer peripheral edges of the glass plates attached to both main surfaces of the plate-like structure with the side dimensions of the plate-like structure, while also aligning the outer peripheral edges of the glass plates with the outer peripheral edge of the plate-like structure, thereby obtaining essentially the same effect as in the configuration (1) above.

[0012] (3) In the above-mentioned configuration (1) or (2), after the crushing step, a cover layer may be provided on the outer periphery of the portion of the plate-like structure that has been deformed by crushing.

[0013] In this way, the deformed portion of the plate-like structure caused by crushing is covered with the cover layer, so that the deformed portion is protected by the cover layer and the appearance is improved.

[0014] (4) In any of the above configurations (1) to (3), the plate-like structure may be a metal structure having a thickness of 5 to 25 mm and a plurality of through-holes penetrating in the thickness direction.

[0015] In this way, the strength of the glass laminate can be increased and translucency can be ensured, in comparison with a case where the plate-like structures are resin structures or the like.

[0016] (5) In any of the above configurations (1) to (4), the metal structure may be an aluminum honeycomb structure.

[0017] In this way, the weight of the glass laminate can be reduced and translucency can be ensured, in comparison with a case in which the metal structure is made of stainless steel or the like.

[0018] (6) In any one of the above configurations (1) to (5), in the attaching step, the adhesive layer may be caused to bite into openings of the plurality of through holes in the metal structure.

[0019] In this way, the adhesive layer bites into the openings of the plurality of through holes, thereby increasing the attachment strength of the glass laminate and improving durability.

[0020] (7) In any one of the above configurations (1) to (6), the wall portion constituting the through hole in the metal structure may have a thickness of 5 to 200 μm.

[0021] In this way, since the thickness of the wall portion is small, the adhesive layer can easily penetrate into the wall portion, and the attachment strength of the glass laminate can be further increased.

[0022] (8) In any of the above configurations (1) to (7), the adhesive layer may have a thickness of 100 μm or more.

[0023] In this way, the adhesive layer can be made thicker, so that the adhesive layer can penetrate into the opening by a larger amount, thereby further increasing the bonding strength of the glass laminate.

[0024] (9) In any of the above configurations (1) to (8), the bonding step includes a first step of preparing a glass plate with an adhesive layer, which is formed by bonding the upper surface of an adhesive layer having a release paper attached to its lower surface to the lower surface of a glass plate, placing a plate-like structure on a surface plate so that one of its main surfaces is the upper surface, and positioning and temporarily placing the glass plate with an adhesive layer on the upper surface of the plate-like structure, and a second step of contacting the upper surface of the glass plate with an adhesive layer with a support film that is stretched across the space above the glass plate with an adhesive layer and has an adhesive area formed on at least a part of its lower surface for temporarily bonding the glass plate with an adhesive layer, with the upper surface of the glass plate with an adhesive layer, so that the upper surface of the glass plate with an adhesive layer is bonded to the adhesive area on the lower surface of the support film. a second step of temporarily adhering the support film to the glass plate with the adhesive layer in a state in which the glass plate with the adhesive layer is supported by the temporary adhesion; a third step of temporarily retracting, after the second step, the support film with the glass plate with the adhesive layer, together with the glass plate with the adhesive layer, upward together with the glass plate with the adhesive layer, and further peeling off the release paper from the adhesive layer; a fourth step of moving, after the third step, the support film together with the glass plate with the adhesive layer downward while pressing them against the plate-like structure, thereby adhering the glass plate with the adhesive layer from which the release paper has been peeled off, to the plate-like structure; and a fifth step of releasing the temporary adhesion between the support film and the glass plate with the adhesive layer, thereby obtaining a first glass laminate in which a glass plate is attached to the upper surface of the plate-like structure via the adhesive layer.

[0025] This allows the attachment process to be carried out efficiently and also promotes automation of the process.

[0026] (10) In the above configuration (9), in the first step, the lower and upper surfaces of the plate-like structure are each covered with a protective sheet, and the original outer peripheral end portion of the plate-like structure is surrounded by a guide member, and in the third step, the protective sheet covering the upper surface of the plate-like structure may be removed.

[0027] In this way, in the first step, the upper and lower surfaces of the plate-like structure are protected by the protective sheet, and defects such as scratches or defects on these upper and lower surfaces are avoided. In addition, in the first step, the original outer peripheral end of the plate-like structure (the outer peripheral end before the crushing step) is surrounded by the guide member, and defects such as undue deformation and even scratches or defects on the original outer peripheral end of the plate-like structure are avoided, and the guide member can position the plate-like structure on the surface plate. In addition, in the third step, the protective sheet covering the upper surface of the plate-like structure is removed, and in the fourth step, the adhesive layer from which the release paper has been peeled off can be directly bonded to the exposed upper surface of the plate-like structure.

[0028] (11) In the above configuration (9) or (10), the adhesive strength of the adhesive area formed on the support film to the glass plate may be weaker than the adhesive strength of the adhesive layer to the glass plate and the plate-like structure, so that the temporary adhesion is released in the fifth step.

[0029] In this way, the temporary adhesion can be released easily and efficiently in the fifth step.

[0030] (12) In any of the configurations (9) to (11) above, the support film has one end fixed to the front end of the base plate and is stretched across the space above the glass plate with an adhesive layer so as to slope upward toward the rear side of the base plate. In a second step, the upper surface of the support film is pressed toward the upper surface of the glass plate with an adhesive layer by a laminating roller, while the laminating roller and the base plate are moved relatively in the front-to-rear direction of the base plate, thereby temporarily adhering the upper surface of the glass plate with an adhesive layer to the lower surface of the support film. In a third step, the laminating roller is moved upward, thereby temporarily retracting the glass plate with an adhesive layer and the support film upward. In a fourth step, the laminating roller is pressed against the upper surface of the support film by the laminating roller, while the laminating roller and the base plate are moved relatively in the front-to-rear direction of the base plate, thereby adhering the glass plate with an adhesive layer from which the release paper has been peeled off to the plate-like structure.

[0031] In this way, by using the laminating roller in the laminating step, the work in the laminating step can be performed more efficiently and the automation of the work can be further promoted.

[0032] (13) In any of the configurations (9) to (12) above, the base plate may be configured to be movable in a forward / backward direction, the lamination roller may be configured to be movable in a vertical direction, and in a second step, the base plate may move forward from the rear moving end, in a third step, the base plate may move backward from the front moving end, and in a fourth step, the base plate may move forward from the rear moving end.

[0033] Here, if the lamination roller is moved in the front-rear direction, the mechanism for moving the lamination roller needs to be provided in the work space, which may cause layout problems such as interference with other mechanisms provided in the work space. According to the configuration here, since the base plate is moved in the front-rear direction, the mechanism for moving the base plate can be provided below the work space, which makes it difficult for layout problems to occur. This makes it possible to smoothly carry out the second, third, and fourth steps.

[0034] (14) In any of the above configurations (9) to (13), the platen may be made of metal and have a resin film attached to its upper surface.

[0035] In this way, since the surface plate is made of metal, it can always be moved stably in the forward and backward directions. In addition, since a resin film is attached to the upper surface of the surface plate, it is possible to perform appropriate work while reliably preventing scratches on the plate-like structure and the glass plate. Furthermore, by replacing the resin film, it is possible to use the surface plate for a long period of time, and durability is improved.

[0036] (15) In any of the above configurations (9) to (14), the support film may be wound around the support roller so as to slope upward toward the rear, and a tensioning member may be provided to apply tension to the stretched portion of the support film extending from the front end of the base plate to the support roller.

[0037] In this way, it is possible to prevent the attachment work from becoming difficult due to the stretched portion of the support film becoming loose.

[0038] (16) In the above configuration (15), the tension applying member may be a weight attached to a portion of the support film hanging vertically downward from the rear side of the portion of the support film that is wound around the support roller.

[0039] In this way, since the weight serving as the tension-applying member is attached to the support film, there is no need to provide a separate device for applying tension to the stretched portion of the support film, making the entire apparatus smaller and simpler.

[0040] (17) In any of the above configurations (1) to (16), the support roller may be configured to move upward as the laminating roller moves upward, and to move downward as the laminating roller moves downward.

[0041] In this way, the angle of the support film, which is inclined upward toward the rear from the laminating roller, can be adjusted to an appropriate angle by the support roller.

[0042] (18) In the configuration of (9) above, after the fifth step of the bonding process and before the crushing step, the method may further include a step of placing the first glass laminate upside down on a table so that the other main surface of the plate-like structure is the upper surface, and a step of performing the first to fifth steps on the first glass laminate instead of the plate-like structure to bond a glass plate with an adhesive layer to the other main surface of the plate-like structure, thereby obtaining a second glass laminate in which glass plates are bonded via an adhesive layer to each of two opposing main surfaces of the plate-like structure.

[0043] In this way, a glass laminate in which glass plates are bonded via adhesive layers to the two opposing main surfaces of a plate-like structure can be efficiently produced.

[0044] (19) A second aspect of the present invention, which has been invented to solve the above problems, is a glass laminate comprising a plate-like structure, an adhesive layer provided on a main surface of the plate-like structure, and a glass plate attached to the plate-like structure via the adhesive layer, characterized in that a deformed portion is provided on the outer periphery, including the outer peripheral end, of the plate-like structure, formed by crushing the plate-like structure from the outer periphery.

[0045] According to this glass laminate, during its production, substantially the same effects as those in the case of the above configuration (1) can be obtained.

[0046] (20) In the above configuration (19), the plate-like structure may be a metal structure having a thickness of 5 to 25 mm and a plurality of through holes penetrating in the thickness direction, and a glass plate may be attached to each of the two opposing main surfaces of the plate-like structure via an adhesive layer.

[0047] In this way, substantially the same effects as those in the above cases (2) and (4) can be obtained.

[0048] (21) In the above configuration (19) or (20), a cover layer may be further provided for covering the outer peripheral end of the deformed portion of the plate-like structure.

[0049] In this way, the outer peripheral edge of the plate-like structure is protected by the cover layer, and the appearance of the glass laminate is improved.

[0050] (22) In any of the above configurations (19) to (21), the cover layer may cover the outer periphery of the glass plate and the outer periphery of the plate-like structure.

[0051] In this way, not only the outer peripheral edge of the plate-like structure but also the outer peripheral edge of the glass plate are protected by the cover layer, and the appearance of the glass laminate is further improved. Effect of the Invention

[0052] According to the present invention, it becomes possible to align the outer peripheral edge of the plate-like structure with the outer peripheral edge of the glass plate after the two are attached, thereby reducing the occurrence of defective products and improving product yield. [Brief description of the drawings]

[0053] [Figure 1] FIG. 2 is an exploded perspective view of components of a glass laminate according to an embodiment of the present invention. [Diagram 2]1 is a longitudinal sectional front view in which a main part of a plate-like structure (honeycomb structure) which is a component of a glass laminate according to an embodiment of the present invention is broken away. [Diagram 3] FIG. 2 is a plan view showing a state in which a bonding step is being performed in the manufacturing method of the glass laminate according to the embodiment of the present invention. [Figure 4] 4 is a longitudinal sectional front view taken along line ZZ in FIG. 3. [Diagram 5] FIG. 2 is an enlarged longitudinal sectional front view of a main part illustrating a state in which a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 6] FIG. 2 is a vertical sectional front view showing a state in which a crushing step is being performed in the manufacturing method of the glass laminate according to the embodiment of the present invention. [Figure 7] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 8] FIG. 2 is a bottom view of a support film used in carrying out a bonding step in the manufacturing method for a glass laminate according to an embodiment of the present invention, as viewed from below. [Figure 9] FIG. 2 is a plan view showing a main part of a bonding step in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 10] FIG. 2 is a vertical sectional front view showing a main part of a bonding step in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 11] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 12] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 13] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 14]FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 15] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 16] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. [Figure 17] FIG. 2 is a vertical sectional front view showing a state in which a part of a bonding step is being performed in the manufacturing method for a glass laminate according to the embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] Hereinafter, a method for producing a glass laminate and a glass laminate according to an embodiment of the present invention will be described with reference to the accompanying drawings.

[0055] The manufacturing method of the glass laminate according to the embodiment of the present invention includes a preparation step. FIG. 1 is a perspective view in which each component of the glass laminate 1 prepared in the preparation step is disassembled and arranged. In detail, in the preparation step, a plate-like structure 2 arranged in the center in the vertical direction in the figure, a first adhesive layer 3 and a first glass plate 4 arranged above the plate-like structure 2, and a second adhesive layer 5 and a second glass plate 6 arranged below the plate-like structure 2 are prepared. All of these components 2 to 6 have a rectangular outline. In addition, in the preparation step, an outer tape 7 is also prepared as a cover layer illustrated to surround the outer periphery of the plate-like structure 2 in the figure. Note that each of the components 2 to 7 shown in the figure exists before the glass laminate is manufactured, but for convenience, the reference number "1" used for the manufactured glass laminate is written in the figure and the above description.

[0056] The plate-like structure 2 is a honeycomb structure having a plurality of through holes 2a penetrating in the thickness direction. The opening shape (shape in plan view) of these through holes 2a is polygonal (hexagonal in the illustrated example). The honeycomb structure 2 is made of aluminum and has a thickness T1 of 5 to 25 mm (preferably 8 to 20 mm). The dimensions of the honeycomb structure 2 in the vertical direction (direction AA in the figure) and in the horizontal direction (direction BB in the figure) are both 200 to 1500 mm (preferably 300 to 1200 mm). Furthermore, as shown in FIG. 2, the thickness T2 of the wall portion 2b constituting the plurality of through holes in the honeycomb structure 2 is 5 to 200 μm (preferably 5 to 100 μm, 5 to 50 μm, or 10 to 20 μm). Because the thickness T2 of the wall portion 2b is small in this manner, the honeycomb structure 2 can be deformed by crushing the outer peripheral portion 2c corresponding to the four sides and four corner portions shown in Figure 3 from the outer periphery side around the entire circumference.

[0057] With reference to FIG. 1, the first adhesive layer 3 and the second adhesive layer 5 each have a thickness of 100 μm or more (preferably 200 μm or more). The upper limit of this thickness is 400 μm (preferably 300 μm). The vertical and horizontal dimensions of these adhesive layers 3 and 5 are both shorter than the vertical and horizontal dimensions of the above-mentioned honeycomb structure 2. Examples of materials for these adhesive layers 3 and 5 include acrylic adhesives, silicone adhesives, rubber adhesives, ultraviolet-curable acrylic adhesives, ultraviolet-curable epoxy adhesives, thermosetting epoxy adhesives, thermosetting melamine adhesives, thermosetting phenol adhesives, ethylene vinyl acetate (EVA) resin adhesives, and polyvinyl butyral (PVB) resin adhesives. In this embodiment, the first adhesive layer 3 and the second adhesive layer 5 have the same thickness, material, vertical dimension, and horizontal dimension.

[0058] The first glass plate 4 and the second glass plate 6 each have a thickness of 10 to 700 μm (preferably 100 to 500 μm), which is a thickness that provides flexibility in this embodiment. The thicknesses of these glass plates 4 and 6 are substantially the same as or smaller than the thicknesses of the first and second adhesive layers 3 and 5 described above. Furthermore, the vertical and horizontal dimensions of these glass plates 4 and 6 are both shorter than the vertical and horizontal dimensions of the honeycomb structure 2 described above. It is preferable to use alkali-free glass or chemically strengthened glass as these glass plates 4 and 6. Here, the "alkali-free glass" refers to glass that does not substantially contain an alkali component (alkali metal oxide), and specifically, glass in which the weight ratio of the alkali component is 1000 ppm or less. The weight ratio of the alkali component is preferably 500 ppm or less, more preferably 300 ppm or less. In this embodiment, the first glass plate 4 and the second glass plate 6 are identical in thickness, material, vertical dimension, and horizontal dimension. Furthermore, the glass plates 4, 6 and the above-mentioned adhesive layers 3, 5 are substantially identical in vertical dimension and horizontal dimension.

[0059] The thickness of the outer tape 7 as the cover layer is, for example, 50 to 500 μm (preferably 80 to 120 μm). The thickness of the outer tape 7 is substantially the same as or smaller than the thickness of the adhesive layers 3 and 5 and the glass plates 4 and 6. The longitudinal dimension of the outer tape 7 is substantially the same as or longer than the dimension of one circumference of the outer periphery of the plate-like structure 2. Metals such as aluminum, its alloys, and stainless steel are typically used as the material for the outer tape 7. Note that other materials that can be used for the outer tape 7 include paper, cloth (chemical fiber, glass fiber), synthetic resin (polypropylene, polyethylene, cellophane, polyvinyl chloride, polyester), rubber, or composite materials thereof.

[0060] The method for manufacturing a glass laminate according to this embodiment includes, as steps subsequent to the above-mentioned preparation step, a bonding step and a squeezing step.

[0061] 3 and 4, the bonding step is generally performed by bonding a first glass plate 4 to one main surface 2d of the honeycomb structure 2 via a first adhesive layer 3 so that the peripheral portion 2c of the honeycomb structure 2 protrudes from the peripheral end 4a (peripheral end 4a corresponding to the four sides) of the first glass plate 4. Similarly, a second glass plate 6 is bonded to the other main surface 2e of the honeycomb structure 2 via a second adhesive layer 5 so that the peripheral portion 2c of the honeycomb structure 2 protrudes from the peripheral end 6a (peripheral end 6a corresponding to the four sides) of the second glass plate 6. In this case, the bonding position of the first glass plate 4 to one main surface 2d of the honeycomb structure 2 and the bonding position of the second glass plate 6 to the other main surface 2e of the honeycomb structure 2 are the same position when viewed along the thickness direction. The dimensions T3, T4 of the honeycomb structure 2 protruding from the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6 are 2 to 20 mm (preferably 3 to 10 mm) over the entire periphery.

[0062] 5, in the attaching step, due to the large thickness of the first and second adhesive layers 3, 5 and the small thickness T2 of the wall portion 2b of the honeycomb structure 2, both ends 2ba, 2bb in the thickness direction of the wall portion 2b are respectively embedded in the first and second adhesive layers 3, 5. In other words, the first and second adhesive layers 3, 5 are respectively embedded in the openings 2aa on both sides in the thickness direction of the multiple through holes 2a in the honeycomb structure 2.

[0063] In the crushing process, the outer peripheral portion 2c of the honeycomb structure 2 shown in FIG. 3, that is, the portion of the honeycomb structure 2 protruding from the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6, is crushed from the outer peripheral side in the direction indicated by the arrow X in the figure to deform it. When the protruding portion 2c of the honeycomb structure 2 is crushed and deformed, the dimensions of the four sides of the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6 are matched to the dimensions of the four sides of the outer peripheral end 2f of the honeycomb structure 2, as shown in FIG. 6. At the same time, the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6 are aligned with the outer peripheral end 2f of the honeycomb structure 2. Then, by performing the above-mentioned size adjustment and alignment, a deformed portion 2h formed by crushing from the outer peripheral side is provided in the outer peripheral portion 2g including the outer peripheral end 2f of the honeycomb structure 2.

[0064] In the illustrated example, the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6 and the outer peripheral end 2f of the honeycomb structure 2 are aligned in the thickness direction, but it is sufficient if they are substantially aligned in the thickness direction. Here, "substantially aligned in the thickness direction" means that even if any of these outer peripheral ends 4a, 6a, 2f protrudes from the other outer peripheral ends, it is sufficient if an operation for adjusting the dimensions of these four sides and an operation for aligning the positions of these outer peripheral ends 4a, 6a, 2f have been performed.

[0065] In this case, the work is performed, for example, by pressing a plate material from the outer periphery against the protruding portion 2c of the honeycomb structure 2, or by pressing the surface of a roller that moves while rotating against the outer periphery, or by pressing the hand (fingers, etc.) of a worker against the outer periphery.

[0066] Thereafter, an outer tape 7 is attached across the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6, the outer peripheral ends 3a, 5a of the first and second adhesive layers 3, 5, and the outer peripheral end 2f of the honeycomb structure 2, thereby obtaining a finished product, the glass laminate 1.

[0067] Next, the above-mentioned bonding process will be described in detail. This bonding process is carried out using a bonding device 8 shown in FIG.

[0068] As shown in the figure, the laminating device 8 includes a surface plate 9, a laminating roller 10, a support roller 11, a support film 12, and a tension applying member 13.

[0069] The surface plate 9 is made of metal, and has a resin film 9a attached to its upper surface. The surface plate 9 is equipped with running wheels 9b that run along rails 14, and is configured to move in the front-rear direction. In the following description, the direction indicated by arrow C in the figure is the front, and the direction indicated by arrow D is the rear. Note that the figure shows the surface plate 9 at the rear end of its movement.

[0070] The laminating roller 10 is disposed behind the front end 9c of the base plate 9. The laminating roller 10 is configured to move in the up-down direction but not in the front-rear direction. The laminating roller 10 is configured to rotate idly around a shaft 10a. At least the surface of the laminating roller 10 is formed of an elastic material such as rubber or resin.

[0071] The support roller 11 is disposed behind the laminating roller 10. The support roller 11 is configured to move in the up-down direction but not in the front-rear direction. The support roller 11 preferably rotates idly around the shaft 11a, but does not have to rotate idly. The surface of the support roller 11 is preferably not elastically deformable and is preferably smooth.

[0072] The support film 12 is wound around the support roller 11, and one end (front end) 12a is fixed to the front end 9c of the base plate 9. The support film 12 is inclined upward toward the support roller 11. The support film 12 has a hanging portion 12b that hangs down vertically from the rear side of the support roller 11. As shown in FIG. 8, an adhesive region 15 (a cross-hatched region in the figure) is formed on the lower surface of the support film 12. This adhesive region 15 is positioned so as not to interfere with the support roller 11. The lamination roller 10 is positioned above a stretching portion 12c that extends from the front end 12a of the support film 12 to the support roller 11.

[0073] 7, tension applying member 13 applies tension to stretching portion 12c of support film 12. Specifically, tension applying member 13 is a weight attached to the lower end of hanging portion 12b of support film 12.

[0074] The laminating device 8 having the above-mentioned configuration performs the laminating process as described below. Specifically, the laminating process includes a first step to a fifth step, and the above-mentioned squeezing step is performed after the fifth step.

[0075] In the first step, first, as shown in FIG. 7, a lower protective sheet 16 is laid on a surface plate 9, and the honeycomb structure 2 is placed on the lower protective sheet 16 so that one of the main surfaces 2d faces upward. After this placement, the original peripheral end 2j (the peripheral end 2j before the pressing step is performed) of the honeycomb structure 2 is surrounded by guide members 17. More specifically, as shown in FIG. 9, the original peripheral end 2j of the honeycomb structure 2 is surrounded by four guide members 17. Then, the inner surfaces 17a of these guide members 17 position the honeycomb structure 2 when they come into contact with the original peripheral end 2j of the honeycomb structure 2. The vertical dimension of these guide members 17 is the same as the thickness T1 of the honeycomb structure 2. Thereafter, in the first step, as shown in FIG. 7, the honeycomb structure 2 and the four guide members 17 are covered with an upper protective sheet 18.

[0076] Furthermore, in the first step, a glass plate 19 with an adhesive layer as shown in Fig. 10 is prepared. This glass plate 19 with an adhesive layer is formed by adhering the upper surface of a first adhesive layer 3, which has a release paper 20 attached to its lower surface, to the lower surface of a first glass plate 4. Then, in the first step, this glass plate 19 with an adhesive layer is temporarily placed on an upper protective sheet 18 as shown in Fig. 11.

[0077] Next, in the second step, as shown in Fig. 12, the lamination roller 10 presses the upper surface of the support film 12 downward while the platen 9 moves forward from the rear moving end. At this time, the support roller 11 gradually moves downward. As a result, the adhesive region 15 on the lower surface of the support film 12 abuts against the upper surface of the adhesive-layered glass plate 19, and the upper surface of the adhesive-layered glass plate 19 and the lower surface of the support film 12 are temporarily bonded together. The above-mentioned adhesive region 15 is repeatedly used for subsequent temporary bonding.

[0078] Thereafter, in the third step, as shown in FIG. 13, the laminating roller 10 and the support roller 11 move upward, and the support film 12 moves upward. At this time, the base plate 9 moves from the front moving end to the rear moving end. At this point, the glass plate 19 with the adhesive layer temporarily moves upward in a state where it is temporarily adhered to the support film 12. Furthermore, in the third step, under this condition, as shown in FIG. 14, the release paper 20 of the glass plate 19 with the adhesive layer is peeled off and the upper protective sheet 18 is removed. As a result, the lower surface of the first adhesive layer 3 of the glass plate 19a with the adhesive layer from which the release paper 20 has been peeled off is exposed, and one main surface (upper surface) 2d of the honeycomb structure 2 is exposed.

[0079] Next, in the fourth step, as shown in Fig. 15, the laminating roller 10 again presses the upper surface of the support film 12 downward and moves, while the platen 9 moves forward from the rear moving end. At this time, the support roller 11 gradually moves downward. As a result, the lower surface of the first adhesive layer 3 of the adhesive-layered glass plate 19a temporarily adhered to the support film 12 is pressed against one main surface (upper surface) 2d of the honeycomb structure 2, and the adhesive-layered glass plate 19 and the honeycomb structure 2 are adhered to each other.

[0080] After that, in the fifth step, as shown in FIG. 16, the laminating roller 10 and the support roller 11 move upward again, so that the support film 12 moves upward. At this time, the surface plate 9 moves to the rear moving end. At this time, the adhesive strength of the adhesive region 15 of the support film 12 to the first glass plate 4 is weaker than the adhesive strength of the first adhesive layer 3 to the first glass plate 4 and the honeycomb structure 2, so that the temporary adhesion between the adhesive layer-attached glass plate 19a and the support film 12 is released. Also, at this time, the four guide members 17 are removed. As a result, on the lower protective sheet 16, a first glass laminate 1a is obtained in which the first glass plate 4 is attached to one main surface (upper surface) 2d of the honeycomb structure 2 via the first adhesive layer 3. In this case, the peripheral portion 2c of the honeycomb structure 2 protrudes from the peripheral end 4a of the first glass plate 4 (see the peripheral structure of the first glass plate 4 in FIG. 3 and FIG. 4 described above).

[0081] After the first to fifth steps are performed as described above, the first glass laminate 1a is placed upside down on the lower protective sheet 16 as shown in FIG. 17. Then, as in the first step described above, the guide member 17 and the upper protective sheet 18 are arranged. The guide member 17 used in this case is longer in the vertical direction by the thickness of the first glass plate 4 and the first adhesive layer 3 than the guide member 17 described above. Thereafter, the first to fifth steps described above are performed in the order shown in FIG. 11 to FIG. 16. In this case, the second adhesive layer 5 and the second glass plate 6 are used as the adhesive layer and the glass plate of the adhesive layer-attached glass plate 19. For convenience, FIG. 17 illustrates an embodiment corresponding to FIG. 13 described above.

[0082] This results in a second glass laminate in which the first and second glass plates 4, 6 are bonded to two opposing main surfaces 2d, 2e of the honeycomb structure 2 via the first and second adhesive layers 3, 5, respectively. In the second glass laminate obtained here, the peripheral portion 2c of the honeycomb structure 2 protrudes from the peripheral ends 4a, 6a of the first and second glass plates 4, 6, as shown in Figures 3 and 4 described above. Therefore, thereafter, a crushing step and bonding of the outer tape 7 in the manner shown in Figure 6 are performed to obtain a finished glass laminate 1.

[0083] According to the glass laminate 1 having the above-described configuration and the manufacturing method thereof, the following advantageous effects can be obtained.

[0084] Since the pressing process is performed after the bonding process, the outer periphery of the honeycomb structure 2 can be easily deformed to match the outer periphery of the bonded first and second glass plates 4 and 6. This reduces the rate of defective products and improves the product yield.

[0085] The honeycomb structure 2 is made of aluminum, and the thickness of the wall portions 2b constituting the multiple through holes 2a of the honeycomb structure 2 is 5 to 200 μm, preferably 5 to 100 μm, 5 to 50 μm, or 10 to 20 μm, thereby achieving a significant reduction in the weight of the glass laminate 1.

[0086] Since the first and second adhesive layers 3, 5 respectively fit into the openings 2aa on both sides of the plurality of through holes 2a in the thickness direction, the adhesive strength of the glass laminate 1 is increased, and durability is improved.

[0087] Since the thickness of the adhesive layer is 100 μm or more and the thickness of the wall portion 2b is small, the first and second adhesive layers 3, 5 can each penetrate into the opening 2aa by a large amount, thereby further increasing the adhesion strength of the glass laminate 1.

[0088] After the crushing step, the outer surface tape 7 is applied to the outer periphery of the portion 2h of the honeycomb structure 2 that has been deformed by crushing, so that the deformed portion 2h is protected and the appearance is improved.

[0089] Since the bonding process includes the first to fifth steps as described above, the work in the bonding process is performed efficiently and automation of the work is promoted.

[0090] In the first step of the lamination process, the two opposing main surfaces 2d, 2e of the honeycomb structure 2 are protected by two protective sheets 16, 18, thereby avoiding defects such as scratches or defects on these main surfaces 2d, 2e when the lamination roller 10 is pressed against them.

[0091] In the first step of the lamination process, the original outer peripheral end 2j of the honeycomb structure 2 is surrounded by the guide member 17, so that defects such as undue deformation of the original outer peripheral end 2j and even scratches or defects caused by the lamination roller 10 being pressed against it are avoided.

[0092] In the fifth step of the attachment process, the adhesive strength of the adhesive region 15 to the glass plate 4(6) is weaker than the adhesive strength of the adhesive layer 3(5) to the glass plate 4(6) and the honeycomb structure 2, so that the temporary adhesion between the support film 12 and the adhesive-layer-coated glass plate 19a is released, and the temporary adhesion can be released easily and efficiently.

[0093] In the laminating process, the base plate 9 moves in the front-rear direction, but the laminating roller 10 does not move in the front-rear direction, so a mechanism for moving the base plate 9 in the front-rear direction can be provided below the work space. Therefore, compared to a case where a mechanism for moving the laminating roller 10 in the front-rear direction is provided inside the work space, layout problems are less likely to occur.

[0094] The surface plate 9 is made of metal, more specifically, SUS, so that it can always be moved stably in the forward and backward directions. In addition, a resin film 9a is attached to the upper surface of the surface plate 9, so that appropriate work can be performed while reliably preventing scratches on the honeycomb structure 2 and the glass plate 4 (6). Furthermore, by replacing the resin film 9a, the surface plate 9 can be used for a long period of time, and its durability is improved.

[0095] In the bonding step, a weight is used as the tension applying member 13 that applies tension to the stretched portion 12c of the support film 12, so that the bonding device 8 as a whole can be made compact and simple.

[0096] In the lamination process, the support roller 11 moves upward as the laminating roller 10 moves upward, and moves downward as the laminating roller 10 moves downward, so that the angle of the support film 12 inclined upward from the laminating roller 10 toward the rear can always be maintained at an appropriate angle.

[0097] Although an embodiment of the present invention has been described above, the embodiment of the present invention is not limited to this, and various modifications are possible without departing from the gist of the present invention.

[0098] For example, in the above embodiment, the honeycomb structure 2 made of aluminum is used as the plate-like structure, but a honeycomb structure made of other metals such as stainless steel or made of resin may be used. A hollow lattice structure in which holes having an opening shape of any shape other than honeycomb (hexagonal) may be arranged may be used. For example, a lattice structure having an opening shape of any polygon such as a triangle or a square, a circle, an ellipse, or a combination of these may be used. The plate-like structure may be a plate-like structure other than a honeycomb structure as long as at least the outer periphery of the plate-like structure can be crushed from the outer periphery and deformed.

[0099] In the bonding process of the above embodiment, the base plate 9 is moved in the front-rear direction while the laminating roller 10 is not moved in the front-rear direction. However, the base plate 9 may be moved in the front-rear direction while the laminating roller 10 is placed in a fixed position.

[0100] The glass laminate 1 of the above embodiment has glass plates 4 and 6 attached to two opposing main surfaces 2d and 2e of a honeycomb structure 2 via adhesive layers 3 and 5, respectively, but it may also be that a glass plate is attached to only one of the main surfaces of the honeycomb structure 2 via an adhesive layer.

[0101] In the glass laminate 1 according to the above embodiment, only one glass plate 4 (6) is attached to one main surface 2d (2e) of the honeycomb structure 2 via an adhesive layer 3 (5). However, two or more glass plates may be attached to the main surface 2d (2e) of the honeycomb structure 2 via an adhesive layer 3 (5). In this case, an adhesive layer is interposed between the two or more glass plates.

[0102] Although each of the components 2 to 6 of the glass laminate 1 according to the above embodiment has a rectangular outline, the outlines of all or some of these components may be other shapes, such as a polygonal, circular or elliptical shape.

[0103] Although the cover layer of the glass laminate 1 according to the above embodiment is constituted by the outer tape 7, it may be constituted by a non-tape-shaped film, a rubber sealer, a coating film, or the like.

[0104] The cover layer of the glass laminate 1 in the above embodiment is attached across the outer peripheral ends 4a, 6a of the first and second glass plates 4, 6, the outer peripheral ends 3a, 5a of the first and second adhesive layers 3, 5, and the outer peripheral end 2f of the honeycomb structure 2, but it may be attached only to the outer peripheral end 2f of the honeycomb structure 2, or it may be attached only to the outer peripheral ends 3a, 5a of the first and second adhesive layers 3, 5 and the outer peripheral end 2f of the honeycomb structure 2. [Explanation of symbols]

[0105] 1 Glass laminate 1a First Glass Laminate 2 Plate-shaped structure (honeycomb structure) 2a Through hole 2aa Opening of through hole 2b Wall portion constituting the through hole 2c Outer periphery of plate-shaped structure (honeycomb structure) 2d One of the main surfaces of the plate-like structure (honeycomb structure) 2e The other main surface of the plate-like structure (honeycomb structure) 2f: Outer edge of plate-shaped structure (honeycomb structure) 2g outer periphery 2h Deformation section 3 First adhesive layer 4 First Glass Pane 4a Outer peripheral edge of first glass plate 5 Second adhesive layer 6 Second Glass Pane 6a Outer peripheral edge of second glass plate 7 Outer Tape 9. Fixed Plate 9a Resin film 9c Front end of surface plate 10 Laminating roller 11 Support roller 12 Support film 12a Front end of support film 12b Hanging part of supporting film 12c Support film attachment section 13 Tensioning member 15 Adhesive area 16 Lower protective sheet 17 Guide member 18 Upper protective sheet 19 Glass plate with adhesive layer 19a Glass plate with adhesive layer from which the release paper has been removed 20 Release paper

Claims

1. A method for producing a glass laminate in which a glass plate is attached to a plate-like structure via an adhesive layer, comprising the steps of: a preparation step of preparing a plate-like structure having at least an outer peripheral portion capable of being crushed and deformed from the outer peripheral side as the plate-like structure; a bonding step of bonding the glass plate to at least one main surface of the plate-like structure via the adhesive layer so that the outer peripheral portion of the plate-like structure prepared in the preparation step protrudes from an outer peripheral end of the glass plate; a crushing step of crushing, from the outer periphery, the outer peripheral portion of the plate-like structure protruding from the outer periphery edge of the glass plate, to deform the outer peripheral portion after the bonding step.

2. 2. The method for manufacturing a glass laminate according to claim 1, wherein in the bonding step, the glass plates are bonded to each of two opposing main surfaces of the plate-like structure via the adhesive layer, and in the crushing step, the peripheral portions of the plate-like structure protruding from the peripheral ends of the glass plates are crushed from the peripheral side to deform them.

3. 3 . The method for producing a glass laminate according to claim 1 , further comprising providing, after the crushing step, a cover layer on an outer periphery of a portion of the plate-like structure that has been deformed by the crushing. 4 .

4. 3. The method for producing a glass laminate according to claim 1, wherein the plate-like structure is a metal structure having a thickness of 5 to 25 mm and a plurality of through holes penetrating in the thickness direction.

5. The method for producing a glass laminate according to claim 4, wherein the metal structure is an aluminum honeycomb structure.

6. The method for producing a glass laminate according to claim 4 , wherein in the attaching step, the adhesive layer is caused to bite into openings of the plurality of through holes in the metal structure.

7. The method for producing a glass laminate according to claim 6, wherein a thickness of a wall portion constituting the through hole in the metal structure is 5 to 200 μm.

8. The method for producing a glass laminate according to claim 6, wherein the adhesive layer has a thickness of 100 μm or more.

9. The bonding step includes: A first step of preparing a glass plate with an adhesive layer, in which the upper surface of the adhesive layer with a release paper attached to the lower surface is adhered to the lower surface of the glass plate, placing the plate-like structure on a surface plate so that one of the main surfaces is the upper surface, and positioning and temporarily placing the glass plate with the adhesive layer on the upper surface of the plate-like structure; a second step of contacting a support film, which is stretched across a space above the glass plate with an adhesive layer and has an adhesive region formed on at least a portion of its lower surface for temporarily adhering the glass plate with an adhesive layer, with the upper surface of the glass plate with an adhesive layer, thereby temporarily adhering the upper surface of the glass plate with an adhesive layer to the adhesive region on the lower surface of the support film; a third step of temporarily retracting the support film, which is in a state in which the adhesive layer-coated glass plate is supported by temporary adhesion, together with the adhesive layer-coated glass plate upward after the second step, and further peeling off the release paper from the adhesive layer; A fourth step of, after the third step, moving the support film downward together with the glass plate with the adhesive layer and pressing it against the plate-like structure, and adhering the glass plate with the adhesive layer from which the release paper has been peeled off to the plate-like structure; 2. The method for manufacturing a glass laminate according to claim 1, further comprising: a fifth step of, after the fourth step, releasing the temporary adhesion between the support film and the glass plate with the adhesive layer, thereby obtaining a first glass laminate in which the glass plate is attached to an upper surface of the plate-like structure via the adhesive layer.

10. In the first step, the lower surface and the upper surface of the plate-like structure are each covered with a protective sheet, and the original outer peripheral end portion of the plate-like structure is surrounded by a guide member, The method for producing a glass laminate according to claim 9 , wherein in the third step, a protective sheet covering an upper surface of the plate-like structure is removed.

11. 10. The method for manufacturing a glass laminate according to claim 9, wherein the adhesive strength of the adhesive region formed on the support film to the glass plate is weaker than the adhesive strength of the adhesive layer to the glass plate and the plate-like structure, thereby releasing the temporary adhesion in the fifth step.

12. one end of the support film is fixed to a front end of the base plate and is stretched across a space above the adhesive-layer-formed glass plate so as to be inclined upward toward a rear side of the base plate; In the second step, the upper surface of the support film is pressed toward the upper surface of the adhesive layer-formed glass plate by a lamination roller, while the lamination roller and the base plate are moved relative to each other in the front-rear direction of the base plate, thereby temporarily bonding the upper surface of the adhesive layer-formed glass plate to the lower surface of the support film; In the third step, the lamination roller is moved upward to temporarily move the adhesive layer-formed glass plate and the support film upward; 10. The method for manufacturing a glass laminate according to claim 9, wherein in the fourth step, while the lamination roller presses the upper surface of the support film, the lamination roller and the base plate are moved relative to each other in the front-to-rear direction of the base plate, thereby pressing the upper surface of the support film toward the upper surface of the glass plate with the adhesive layer with the lamination roller, and moving the lamination roller and the base plate relative to each other in the front-to-rear direction of the base plate, thereby adhering the glass plate with the adhesive layer from which the release paper has been peeled off to the plate-like structure.

13. The base is configured to be movable in a front-rear direction, The lamination roller is configured to be movable in a vertical direction, In the second step, the platen moves forward from the rear moving end, In the third step, the platen moves rearward from the front moving end, The method for producing a glass laminate according to claim 12, wherein in the fourth step, the platen moves from a rear moving end to a front end.

14. The method for manufacturing a glass laminate according to claim 9, wherein the platen is made of metal and has a resin film attached to an upper surface thereof.

15. The method for manufacturing a glass laminate according to claim 9, characterized in that the support film is wound around a support roller so as to incline upward toward the rear, and a tension applying member is provided to apply tension to a stretched portion of the support film extending from a front end of the base plate to the support roller.

16. 16. The method for manufacturing a glass laminate according to claim 15, wherein the tension applying member is a weight attached to a portion of the support film hanging vertically downward from a rear side of the portion of the support film that is wrapped around the support roller.

17. 17. The method for manufacturing a glass laminate according to claim 15, wherein the support roller moves upward as the laminating roller moves upward, and moves downward as the laminating roller moves downward.

18. After the fifth step of the bonding step and before the squeezing step, the first glass laminate is placed upside down on the platen so that the other main surface of the plate-like structure is an upper surface; 10. The method for producing a glass laminate according to claim 9, further comprising: performing the first to fifth steps on the first glass laminate instead of the plate-like structure, thereby adhering the adhesive layer-attached glass plate to the other main surface of the plate-like structure, to obtain a second glass laminate in which the glass plates are attached via the adhesive layer to each of two opposing main surfaces of the plate-like structure.

19. A plate-like structure; An adhesive layer provided on a main surface of the plate-like structure; A glass plate attached to the plate-like structure via the adhesive layer, A glass laminate comprising: a plate-like structure having a deformed portion formed by crushing the plate-like structure from the outer periphery, the deformed portion being provided on the outer periphery including the outer periphery edge of the plate-like structure.

20. The plate-like structure is a metal structure having a thickness of 5 to 25 mm and a plurality of through holes penetrating in the thickness direction, The glass laminate according to claim 19, wherein the glass plates are attached to two opposing main surfaces of the plate-like structure via the adhesive layer.

21. 21. The glass laminate according to claim 19, further comprising a cover layer that covers an outer peripheral end of the deformed portion of the plate-like structure.

22. 22. The glass laminate according to claim 21, wherein the cover layer covers an outer peripheral edge of the glass plate and an outer peripheral edge of the plate-like structure.

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