Manufacturing method for functional member

Abstract

To provide a manufacturing method for a functional member that is excellent in environmental performance.SOLUTION: The manufacturing method for a functional member comprises: an applying step of applying powder resin and conductive particles to a base material; and a heating step of induction-heating the conductive particles by making the conductive particles generate inductive currents so that the powder resin is melted and the conductive particles are fixed to the base material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for producing a functional member. [Background technology]

[0002] Many methods for producing functional members such as polishing members have been proposed (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 05-253851 [Patent Document 2] Japanese Patent Application Laid-Open No. 2005-144628 Summary of the Invention [Problem to be solved by the invention]

[0004] For example, functional materials are manufactured by applying a binder resin to a substrate and then adhering specific particles to the binder resin. Organic solvents are used in this type of binder resin. These organic solvents have a significant impact on the environment because they are released into the atmosphere during the manufacturing process.

[0005] Therefore, an object of the present invention is to provide a method for producing a functional member that is environmentally friendly. [Means for solving the problem]

[0006] The above object can be achieved by a method for manufacturing a functional component, which includes a coating step of coating a substrate with powder resin and conductive particles, and a heating step of inductively heating the conductive particles by generating an induced current in the conductive particles so that the powder resin melts and the conductive particles are fixed to the substrate.

[0007] The applying step may include applying the powder resin to the base material, applying the conductive particles toward the powder resin on the base material, and applying the powder resin again toward the conductive particles on the base material.

[0008] The coating step may coat the base material with a mixture of the powder resin and the conductive particles.

[0009] The conductive particles may be ferrous metals, non-ferrous metals, graphite, or alloys thereof.

[0010] The substrate may be a sheet, a film, or a continuous strip-shaped member.

[0011] The powder resin may be thermosetting and contain at least one of epoxy-based, epoxy polyester-based, polyester-based, acrylic-based, and fluororesin-based powders.

[0012] The powder resin may be thermoplastic and may contain powder of at least one of vinyl chloride, polyethylene, and nylon.

[0013] The powder resin may be thermoplastic and may include powder of an engineering plastic.

[0014] The engineering plastic may be PPS, PEEK, or PI.

[0015] The substrate may be any one of a plastic film, paper, nonwoven fabric, woven fabric, and metal plate.

[0016] The metal plate may be stainless steel. [Effects of the Invention]

[0017] According to the present invention, it is possible to provide an environmentally friendly method for producing a functional member. [Brief explanation of the drawings]

[0018] [Figure 1] 1A to 1C are explanatory diagrams of a method for producing a functional member. DETAILED DESCRIPTION OF THE INVENTION

[0019] FIG. 1 is an explanatory diagram of the manufacturing method of a functional member of this embodiment. The substrate W is wound into a roll. One end of the substrate W is transported to the right in FIG. 1 by a roller or the like (not shown). The coating devices 10, 20, and 30 are installed facing the substrate W in the order of the transport direction of the substrate W. The coating devices 10, 20, and 30 are arranged at a predetermined interval from each other in the transport direction of the substrate W. Furthermore, an induction heating coil 41 is installed between the coating devices 20 and 30, as will be described in detail later. An induction heating coil 42 is installed downstream of the coating device 30. The coils 41 and 42 are installed to surround the substrate W so that the substrate W passes through them.

[0020] The coating device 10 applies powder resin to the upper surface of the substrate W. The process performed by the coating device 10 is a so-called undercoating process. Next, the coating device 20 applies conductive particles to the surface of the substrate W coated with the powder resin. Next, an alternating current flows through the coil 41, causing an induced current to flow through the conductive particles coated on the substrate W, resulting in induction heating. This causes the conductive particles to reach a high temperature in a short period of time, melting the powder resin. Next, the coating device 30 applies powder resin again to the surface of the substrate W coated with the conductive particles. The process performed by the coating device 30 is a so-called topcoating process. Next, an alternating current flows through the coil 42, causing the conductive particles to be induction heated again, melting the reapplied powder resin. Note that the specific coating method used by the coating devices 10, 20, and 30 may be a coating method using compressed air, or may be electrostatic coating using, for example, an electrostatic gun.

[0021] Thereafter, when the substrate W is separated from the coil 42, the temperature of the conductive particles on the substrate W drops, and the powder resin on the substrate W solidifies. In this way, the conductive particles applied to the substrate W are fixed to the substrate W. Thereafter, the substrate W is cut to a desired size, and, for example, a sheet-shaped functional member is manufactured.

[0022] As described above, this manufacturing method is environmentally friendly because it does not use organic solvents. Furthermore, compared to when organic solvents are used, when powder resins are used, maintenance and management are easier. Therefore, the manufacturing of functional components using this manufacturing method can be carried out unmanned.

[0023] As described above, the powder resin is applied to the base material W before the conductive particles are applied, and then the powder resin is again applied to the base material W after the conductive particles are applied, thereby improving the fixation of the conductive particles.

[0024] The applicators 10, 20, and 30 are spaced apart from one another. Therefore, even if, for example, the powder resin sprayed from the applicator 10 or 30 falls off the substrate W, and the conductive particles sprayed from the applicator 20 fall off the substrate W, the powder resin and the conductive particles are prevented from mixing around the applicators 10, 20, and 30. As a result, the powder resin and the conductive particles can be easily collected separately. The collected powder resin and the conductive particles can be reused. In this way, the material reuse rate is improved. The powder resin and the conductive particles may be mixed in advance, and the mixture may be applied to the substrate W. In this case, the number of applications is reduced.

[0025] The functional member produced by the above method includes a base material and a resin layer containing conductive particles, and therefore the above manufacturing method is suitable for producing, for example, an electrode member that requires electrical conductivity or a cooling member that requires high thermal conductivity as the functional member.

[0026] The above manufacturing method is not limited to the manufacture of components that require electrical conductivity or thermal conductivity. For example, when manufacturing a polishing member as a functional component, conductive particles that can be used as abrasive particles may be applied to a substrate. Alternatively, abrasive particles may be applied to a substrate together with the conductive particles.

[0027] The conductive particles are, for example, ferrous metals (Fe, SS, SUS, etc.), non-ferrous metals (brass, gold, platinum, nickel, lead, copper, aluminum, etc.), graphite (carbon), or alloys thereof.

[0028] The powder of the powder resin may be thermosetting or thermoplastic. Thermosetting powders include epoxy-based powder resins, polyester-based powder resins, epoxy-polyester-based powder resins, fluororesin-based powder resins, and acrylic-based powder resins. Thermoplastic powders include vinyl chloride, polyethylene, nylon, and the like.

[0029] The powder resins applied by the application devices 10 and 30 may be the same or different types of powder resins. The amounts of the powder resins applied by the application devices 10 and 30 may be the same or different.

[0030] The shape of the substrate is not limited, and may be a sheet, a film, a strip, or a plastic film, paper, a nonwoven fabric, a woven fabric, or a metal.

[0031] As described above, the conductive particles are used as a heating element for induction heating, and therefore, by adjusting the particle size of the conductive particles and the amount of conductive particles applied relative to the amount of powder resin applied, it is possible to adjust the amount of heat applied from the conductive particles to the powder resin.

[0032] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to such specific embodiments, and various modifications and variations are possible within the scope of the gist of the present invention as defined in the claims. [Explanation of symbols]

[0033] W Base material 10, 20, 30 Coating equipment 41, 42 Coils

Claims

1. a coating step of coating a base material with powder resin and conductive particles; a heating step of inductively heating the conductive particles by generating an induced current in the conductive particles so that the powder resin melts and the conductive particles are fixed to the base material; A method for manufacturing a functional member comprising the steps of:

2. 2. The method for manufacturing a functional member according to claim 1, wherein the coating step includes coating the powder resin onto the substrate, coating the conductive particles toward the powder resin on the substrate, and then coating the powder resin again toward the conductive particles on the substrate.

3. The method for producing a functional member according to claim 1 , wherein the coating step comprises coating the base material with a mixture of the powder resin and the conductive particles.

4. 4. The method for producing a functional member according to claim 1, wherein the conductive particles are made of an iron-based metal, a non-ferrous metal, graphite, or an alloy thereof.

5. 4. The method for producing a functional member according to claim 1, wherein the substrate is a sheet, a film, or a continuous strip-shaped member.

6. 4. The method for manufacturing a functional member according to claim 1, wherein the powder resin is thermosetting and contains at least one of epoxy-based, epoxy polyester-based, polyester-based, acrylic-based, and fluororesin-based powders.

7. 4. The method for manufacturing a functional member according to claim 1, wherein the powdered resin is thermoplastic and contains at least one powder of vinyl chloride, polyethylene, or nylon.

8. 4. The method for manufacturing a functional member according to claim 1, wherein the powdered resin is thermoplastic and includes a powder of an engineering plastic.

9. The method for producing a functional member according to claim 8 , wherein the engineering plastic is PPS, PEEK, or PI.

10. 4. The method for producing a functional member according to claim 1, wherein the substrate is any one of a plastic film, paper, a nonwoven fabric, a woven fabric, and a metal plate.

11. The method for producing a functional member according to claim 10, wherein the metal plate is made of stainless steel.

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