Manufacturing equipment for composite materials, molds, and methods for manufacturing composite materials.

Abstract

When pressing the sheet against the substrate to bond it, the sheet is evenly bonded to the substrate while preventing lifting between the sheet and the substrate. [Solution] The manufacturing apparatus 100 for a substrate with a functional layer comprises a mold 13 having a recess 25 and a sheet contact surface 27, a sheet fixing part 17 that fixes the end of a sheet 15 placed over the recess 25 to the mold 13 to form a first chamber CB1, an opposing mold 19 that is provided opposite the mold 13 to the sheet 15 to form a second chamber CB2, and a sheet driving part 21 that flexes the sheet 15. A gap CR is provided between the end face of the substrate 11 housed in the recess 25 and the inner wall surface 25b of the recess 25. In a cross-sectional view of the mold 13, the bottom-side tangent along the bottom surface 25a at the intersection of the bottom surface 25a and the inner wall surface 25b of the recess 25 and the contact-side tangent along the sheet contact surface 27 at the intersection of the sheet contact surface 27 and the inner wall surface 25b intersect each other.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing a composite material, a mold, and a method for manufacturing a composite material.

Background Art

[0002] In order to impart a desired function to the entire surface or a part of glass or other substrates, there is a method of bonding a sheet to the glass or substrate. For example, a method of adhering a sheet having a functional layer to the surface of a substrate, and further, a method of transferring the adhered functional layer to the substrate and peeling off only the sheet are known. In recent years, in displays such as in-vehicle display devices, a design having a curved surface may be adopted for the purpose of improving visibility and design, and accordingly, the demand for cover glass having a curved surface is also increasing. Patent Document 1 describes a method for manufacturing a cover glass for a display device in which a sheet (transfer member) having a functional layer (coloring layer) is adhered to a substrate (glass substrate) having such a complex shape with a curved surface, and the coloring layer of the sheet is transferred onto the substrate.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the method for manufacturing a cover glass described in Patent Document 1, the colored layer is transferred to the substrate by vacuum pressure forming. The general procedure for this vacuum pressure forming method involves placing the substrate on a base inside a chamber, arranging a sheet with a functional layer so that the main surface of the substrate and the sheet surface on the functional layer side face each other, and fixing the ends of the sheet. This divides the chamber into two spaces by the sheet: one space and the other space which does not contain the substrate. Then, with the sheet and functional layer heated and softened, the air pressure in one space is made lower than that in the other space, causing the sheet to adhere to the main surface of the substrate. This causes the functional layer of the sheet to adhere tightly to the substrate. The base is also provided with a sheet contact surface outside the outer edge of the substrate, which supports the adhered sheet so that it is flush with the main surface of the substrate. When the substrate and sheet are brought into close contact in this way, the softened functional layer deforms along the main surface of the substrate and adheres to it.

[0005] In order to fix the base body 71 described above to the base 73, generally, as shown in Figure 17, a recess (recess 75) equal to the thickness of the base body 71 is provided in the base 73, and the base body 71 is placed in this recess 75. However, since the actual base body 71 has a dimensional difference from the design shape, in order to reliably accommodate the base body 71 in the recess 75, the shape of the recess 75 must be designed to be slightly larger than the design shape of the base body 71. As a result, when the base body 71 is placed in the recess 75, a gap CR is generated between the base body 71 and the inner wall surface 75a of the recess 75. When the sheet 77 is pressed against the base body 71 by differential pressure in this state, the sheet 77 deforms so as to sink into the area of ​​the gap CR.

[0006] Because the deformed sheet 77 has a continuous sheet shape, even though it is subjected to a load w due to the pressure difference, the end 79 on the gap CR side between the base body 71 and the base 73 does not follow the main surface 71a of the base body 71 and the sheet contact surface 73a of the base 73, resulting in lifting 81. As a result, the functional layer provided on the sheet 77 is not transferred to the base body 71 in the areas where lifting 81 occurs, and there were instances where the functional layer was not transferred to the end of the base body 71.

[0007] Therefore, the present invention aims to provide a composite material manufacturing apparatus, a mold, and a method for manufacturing a composite material that can uniformly bond a sheet to a substrate while preventing the sheet from lifting up between the sheet and the substrate when the sheet is pressed and bonded to the substrate. [Means for solving the problem]

[0008] This invention consists of the following configuration. (1) A manufacturing apparatus for composite materials that presses a sheet against a substrate via an adhesive layer to bond them together, A mold having a recess for supporting the substrate, and a sheet contact surface formed from the inner wall surface of the recess toward the outside of the recess, A sheet fixing portion is provided, which fixes the end of the sheet, which is positioned to cover the recess of the mold, to the mold, thereby forming a first chamber that is an airtight space on the mold side of the sheet, An opposing mold is provided on the opposite side of the mold from the sheet fixed to the mold, forming a second chamber that becomes an airtight space, A seat drive unit that causes the seat to flex by creating a pressure difference between the first chamber and the second chamber, Equipped with, A gap is provided between the end face of the base body housed in the recess and the inner wall surface of the recess facing the end face. In a cross-sectional view of the substrate of the mold in the thickness direction, the bottom-side tangent line along the bottom surface at the intersection of the bottom surface of the recess and the inner wall surface, and the contact-side tangent line along the sheet contact surface at the intersection of the sheet contact surface and the inner wall surface, intersect each other. Manufacturing equipment for composite materials. (2) The mold used in the composite material manufacturing apparatus described in (1), A molding die having surfaces where the bottom surface of the recess and the sheet contact surface intersect with each other. (3) A method for manufacturing a composite material, wherein the sheet is bonded to the substrate using the composite material manufacturing apparatus described in (1), The base body is placed in the recess of the mold, The sheet is fixed to the sheet fixing part, The air pressure in the first chamber is made higher than the air pressure in the second chamber, causing the sheet to bend toward the mold, and the sheet is pressed against the substrate and bonded to the substrate. A method for manufacturing composite materials. [Effects of the Invention]

[0009] According to the present invention, when pressing the sheet against the substrate, it is possible to uniformly adhere the sheet to the substrate while preventing lifting between the sheet and the substrate. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is an overall diagram showing the schematic configuration of the composite material manufacturing apparatus. [Figure 2A] Figure 2A is a step-by-step process diagram (part 1) illustrating the manufacturing procedure for composite materials using a cross-sectional view of the molding apparatus. [Figure 2B] Figure 2B is a process diagram (part 2) illustrating the manufacturing procedure for composite materials step by step using a cross-section of the molding apparatus. [Figure 3] Figure 3 is an enlarged cross-sectional view of section K shown in Figure 2B. [Figure 4] Figure 4 is an explanatory diagram illustrating a schematic model showing the deformation of the sheet shown in Figure 3. [Figure 5] Figure 5 is a schematic diagram illustrating the displacement of the sheet that has lifted. [Figure 6] Figure 6 is an explanatory diagram showing the displacement of the sheet along the mold to the right of intersection Q in Figure 5. [Figure 7] Figure 7 is an explanatory diagram showing a free field diagram for the case 0 ≤ x ≤ j. [Figure 8] Figure 8 is an explanatory diagram showing the free field diagram for the case j ≤ x ≤ k. [Figure 9] Figure 9 is an explanatory diagram showing the case where the load applied to the sheet is small. [Figure 10] Figure 10 is an explanatory diagram showing the sheet shown in Figure 5 rotated so that the main surface of the base is horizontal. [Figure 11]Figure 11 is a cross-sectional view showing a sheet being pressed against a base, which is a curved plate placed in a recess of a mold. [Figure 12] Figure 12 is an enlarged explanatory diagram showing the arrangement of the substrate and the sheet contact surface of the mold shown in Figure 11. [Figure 13] Figure 13 is an explanatory diagram showing a molding die that curves the sheet in the opposite direction to that shown in Figure 4 when the sheet is brought into close contact with the substrate. [Figure 14] Figure 14 is a schematic plan view of a mold with multiple recesses. [Figure 15] Figure 15 is a schematic plan view of a mold in which a recess for accommodating an irregularly shaped base is formed. [Figure 16A] Figure 16A is a partially enlarged plan view showing the shape of the sheet contact surface at the corner of the recess in the molding die. [Figure 16B] Figure 16B is a partially enlarged plan view showing the shape of the sheet contact surface at the corner of the recess in the molding die. [Figure 17] This is an explanatory diagram showing the deformation of a sheet pressed against a substrate, as in the conventional method. [Modes for carrying out the invention]

[0011] Embodiments of the present invention will be described in detail below with reference to the drawings. The composite material manufacturing apparatus according to the present invention is an apparatus for manufacturing composite materials by bonding sheets to a substrate via an adhesive layer using vacuum forming or pressure forming. In this apparatus, the shape of each part such as the chamber, which is an airtight space formed between the sheets, and the mold, as well as the sheet drive mechanism, are not limited to the configuration examples described below and can be modified as appropriate. Also, the dimensions of the components shown in the drawings described below do not necessarily correspond to the actual dimensions.

[0012] <Configuration of the manufacturing apparatus for substrates with functional layers> Figure 1 is an overall diagram showing the schematic configuration of the composite material manufacturing apparatus 100. The composite material manufacturing apparatus 100 (hereinafter also referred to as the "manufacturing apparatus") comprises a mold 13 that supports the base body 11, a sheet 15, a sheet fixing part 17, an opposing mold 19, a sheet driving part 21, and a control unit 23.

[0013] The base body 11 is, for example, a flat plate-shaped member having a main surface 11a and a main surface 11b on the opposite side, and is supported by the mold 13 with the main surface (base body opposing surface) 11a facing the sheet 15. As will be described in detail later, the base body 11 is not limited to a flat plate, but may also be other shapes such as a curved plate having at least a part of a concave or convex curved surface, or a block body. Examples of materials for the base body 11 include glass, resin, and metal, but are not particularly limited.

[0014] In Figure 1, the direction of the main surface 11a of the base body 11, which is placed in the recess 25 of the mold 13, is defined as the horizontal direction, and this is referred to as the X direction. The vertical direction, which is the normal direction of the base body 11, is defined as the Y direction.

[0015] The mold 13 has a recess 25 having a planar shape capable of accommodating the entire base body 11, and a sheet contact surface 27. The recess 25 shown here has a flat bottom surface 25a and an inner wall surface 25b surrounding the bottom surface 25a.

[0016] The sheet contact surface 27 is formed extending from the inner wall surface 25b of the recess 25 toward the outside of the recess 25. The sheet contact surface 27 shown here is inclined such that its height in the Y direction decreases toward the recess 25. That is, the sheet contact surface 27 is formed in an annular shape surrounding the recess 25 and is an inclined surface that protrudes in the opposite direction to the bottom surface 25a of the recess 25 as it moves away from the recess 25. Furthermore, it is preferable that the sheet contact surface 27 is formed as a smooth continuous surface along the inner wall surface 25b of the recess 25.

[0017] The recess 25 is formed to be slightly larger than the size of the base 11 in a plan view in the thickness direction of the base 11, so that it can be reliably accommodated even if the base 11 has a dimensional difference from the design dimensions. Therefore, a gap CR exists between the inner wall surface 25b of the recess 25 that accommodates the base 11 and the base 29, and the side surface of the base 11 that faces the inner wall surface 25b.

[0018] The base 11 is placed on the bottom surface 25a of the recess 25 via a flat base 29. The base 29 is formed to be the same size as the recess 25 in the plan view described above, and absorbs the height of the base 11 from the bottom surface 25a, changes in the thickness of the base 11, etc. By preparing multiple types of bases 29, bases 11 of different thicknesses can be set in the same mold 13, increasing versatility. Details regarding the height of the base 11 in the Y direction housed in the recess 25 will be described later. The mold 13 may also be configured to place the base 11 directly on the bottom surface 25a of the recess 25 without using the base 29.

[0019] The sheet 15 is positioned to cover the recess 25 of the mold 13 and has flexibility that allows for displacement in the Y direction toward the mold 13 and the opposing mold 19. The sheet fixing part 17 securely fixes the end 15a of the sheet 15 to the mold 13, thereby forming a first chamber CB1 which is an airtight space on the mold 13 side of the sheet 15. The sheet fixing part 17 can employ a structure that clamps the end 15a of the sheet 15 to the mold 13 via, for example, a rubber gasket. The sheet 15 may have a functional layer 30 provided on its outer surface facing the mold 13. Alternatively, the sheet 15 itself may function as a functional layer.

[0020] The functional layer 30 is not particularly limited, but examples include a colored layer, an AR (Anti-Reflection) layer, and an AFP (Anti-Finger-Print) layer. The functional layer 30 may function as an adhesive layer itself, or an adhesive layer may be provided on the outer surface of the functional layer 30.

[0021] The opposing mold 19 is provided opposite the sheet 15, which is fixed to the mold 13, on the side opposite to the mold 13, and facing the sheet 15. The opposing mold 19 is hermetically fixed to the sheet fixing portion 17 or the end portion 15a of the sheet 15. This forms a second chamber CB2 which is an airtight space. The opposing mold 19 may also be equipped with a heater 31 for heating the sheet 15. The heater 31 generates heat according to the supplied energy and heats the sheet 15, which is the object to be heated, to a desired temperature distribution. In addition to the resistance heating element provided in the opposing mold 19, the heater 31 may be of other heating methods such as induction heating, dielectric heating, heating with hot air, infrared irradiation, superheated steam, or contact with a hot plate.

[0022] The seat drive unit 21 creates a pressure difference between the first chamber CB1 and the second chamber CB2, causing the seat 15 to flex in the Y direction. The seat drive unit 21 may include, for example, a pump 33 and a pressure adjustment unit 35 that adjusts the air pressure generated by the pump 33, with the pressure adjustment unit 35 adjusting the pressure in the first chamber CB1 and the second chamber CB2 through pressure lines 37 that communicate with each of them.

[0023] The control unit 23 controls each part, including the seat drive unit 21 and the heater 31. The control unit 23 is composed of hardware, such as an information processing device like a PC (Personal Computer). The functions of the control unit 23 are realized by a processor such as a CPU (Central Processing Unit) or MPU (Micro Processor Unit), or a control device such as a dedicated circuit, reading a program with a specific function stored in a storage device (not shown) and executing it. Examples of storage devices include volatile memory areas such as RAM (Random Access Memory), non-volatile memory areas such as ROM (Read Only Memory), and storage devices such as HDDs (Hard Disk Drives) and SSDs (Solid State Drives). In addition to the above-described configuration, the control unit 23 may also be another computer remotely connected to the manufacturing device 100 via a network or the like.

[0024] <Method for molding composite materials> Next, we will outline the procedure for bonding the functional layer provided on the sheet 15 to the substrate 11 using the manufacturing apparatus 100 for the substrate with the functional layer described above. Although the control unit 23 controls each part comprehensively, manual control is also permitted.

[0025] Figures 2A and 2B are process diagrams illustrating the manufacturing procedure of a substrate with a functional layer, shown step-by-step in cross-section of the manufacturing apparatus 100. In the following explanation, the same reference numerals are used for the same components and parts, and their explanations will be omitted or simplified. First, as shown in Figure 2A, the substrate 11 is placed in the recess 25 of the mold 13, and the sheet 15 having the functional layer is fixed with the sheet fixing part 17. Then, the heater 31 is heated to make the air pressure in the first chamber CB1 higher than the air pressure in the second chamber CB2, causing the sheet 15 to bend toward the opposing mold 19. When the sheet 15 comes into contact with the heated opposing mold 19, the sheet 15 and the functional layer 30 are heated and softened.

[0026] Then, as shown in Figure 2B, the air pressure in the first chamber CB1 is lowered to be lower than the air pressure in the second chamber CB2, causing the sheet 15 to bend toward the mold 13. This causes the heated sheet 15 to be pressed against the base body 11, and the functional layer 30 to adhere closely to the base body 11. By pressing the sheet 15 against the base body 11 using vacuum pressure forming, the sheet 15 deforms to conform to the shape of the base body 11, resulting in good adhesion between the functional layer 30 and the base body 11. It is preferable to heat the base body 11 using an appropriate heating means before pressing the sheet 15 against it.

[0027] It is preferable to bond the functional layer 30 to the substrate 11 at a high temperature because this suppresses peeling due to deterioration of the functional layer over time. Alternatively, the functional layer 30 can be bonded to the substrate 11 without heating. For example, if an adhesive layer is provided on the entire surface 11a of the substrate 11 or on a specific area, the functional layer 30 can be selectively bonded to the main surface 11a of the substrate 11 with the adhesive layer by pressing the sheet 15 having the functional layer 30 against the substrate 11. Alternatively, an adhesive layer may be provided in a specific area within the area on the sheet 15 where the functional layer 30 is provided, in which case only the functional layer 30 in the area with the adhesive layer can be selectively bonded to the main surface 11a of the substrate 11. In other words, bonding in a specific pattern becomes possible.

[0028] On the other hand, if the sheet 15 itself is a functional layer, the sheet 15 can be removed from the mold 13 while still attached to the main surface 11a of the base body 11 (as shown in Figure 2B), and any unnecessary parts of the sheet 15 can be cut off as needed. After performing the above process, a composite material with a functional layer 30 provided on the base body 11 is obtained. Alternatively, as shown in Figure 2B above, after the functional layer 30 of the sheet 15 is in close contact with the base body 11, the air pressure in the first chamber CB1 can be made lower than the air pressure in the second chamber CB2, and the sheet 15 can be pulled away from the mold 13 to provide the functional layer 30 on the base body 11.

[0029] In the manufacturing apparatus 100 for a substrate with a functional layer as described above, a gap CR exists between the inner wall surface 25b of the recess 25 of the mold 13 shown in Figure 1 and the side surface of the substrate 11. However, as shown in Figure 2B, when the sheet 15 is pressed against the mold 13, the sheet contact surface 27 is inclined with respect to the main surface 11a of the substrate 11, so the sheet 15 does not lift up from the mold 13. Therefore, the functional layer 30 of the sheet 15 can be uniformly bonded to the substrate 11. The configuration for preventing the sheet 15 from lifting up will be described in detail below.

[0030] <Preventing the sheet from lifting> Figure 3 is an enlarged cross-sectional view of section K shown in Figure 2B. Figure 3 shows a mold 13 in which the base body 11 is housed in the recess 25, in a cross-sectional view in the thickness direction of the base body 11. A gap CR exists between the base body 11 and the inner wall surface 25b of the recess 25. Here, the base body 11 and the base 29 are flat plates with constant thickness, and the bottom surface 25a of the recess 25 and the sheet contact surface 27 are flat surfaces. Therefore, the bottom surface 25a of the recess 25, the base support surface 29a of the base body 11 on the base body 11 side of the base body 11 and the base 29, and the main surface 11a of the base body 11 are parallel to each other. Here, let L1 be the extension of the bottom surface 25a of the recess 25, L2 be the extension of the support surface 29a of the base 29, and L3 be the extension of the base 11's main surface (base-facing surface) 11a. Let L4 be the tangent line on the contact surface side along the sheet contact surface 27 at the intersection P1 of the sheet contact surface 27 and the inner wall surface 25b. The bottom surface 25a of the recess 25 is formed along the X direction, and let L be the length of the gap CR in the X direction.

[0031] The bottom extension line L1 is also the bottom-side tangent line along the bottom surface 25a at the intersection P0 of the bottom surface 25a and the inner wall surface 25b of the recess 25. The bottom extension line L1 and the contact surface side tangent line L4 intersect each other. When the sheet 15 is pressed against the main surface 11a of the base body 11 and the sheet contact surface 27 by the pressure difference between the first chamber CB1 and the second chamber CB2 shown in Figure 1, it contacts point P1 on the inner edge of the sheet contact surface 27 on the gap CR side and point P2 on the outer edge of the main surface 11a of the base body 11 on the gap CR side, and is positioned to span the gap CR. Furthermore, since point P1 is positioned higher in the Y direction than point P2, the sheet 15 is positioned in a curved shape, drawing a smooth curve from the contact surface side tangent line L4 of the sheet contact surface 27 toward line L3 (parallel to the bottom-side tangent line L1) of the main surface 11a of the base body 11. Therefore, compared to the case where the sheet 15 is arranged in a planar manner within the range of points P1 to P2, less deformation is required as the sheet sinks inward into the gap CR, and lifting due to the displacement of the sheet 15 is less likely to occur.

[0032] Next, we will explain the procedure for analytically determining the conditions for preventing the sheet 15 from lifting, by treating the sheet 15 as a beam. Figure 4 is an explanatory diagram illustrating a schematic model of the deformation of the sheet 15 shown in Figure 3. The sheet 15 is pressed against the main surface 11a of the base body 11 and the sheet contact surface 27 by the pressure difference between the first chamber CB1 and the second chamber CB2, and curves from point P1 to P2. At this time, the sheet 15 extends along the base body extension line L3, which extends the main surface 11a of the base body 11 toward the gap CR, at the outer edge P2 on the gap CR side of the main surface 11a of the base body 11. Also, at the inner edge P1 on the gap CR side of the sheet contact surface 27, it extends along the contact surface extension line L4, which extends the sheet contact surface 27 toward the gap CR. Therefore, if Q is the intersection point of the base body extension line L3 and the contact surface extension line L4, the displacement of the sheet 15 between the intersection point Q and point P1 can be considered equivalent to the displacement between the intersection point Q and point P2.

[0033] Figure 5 is a schematic diagram illustrating the displacement of the sheet 15 that has lifted. In Figure 5, the intersection point Q shown in Figure 4 is set as the origin of the x-axis (x=0), and the sheet contact surface 27 and the main surface 11a of the base body 11 are shown with the same inclination angle to show the symmetry of the displacement. The y-axis is the central axis in which the sheet contact surface 27 and the main surface 11a of the base body 11 are symmetrical with the same inclination angle, and the x-axis is an axis perpendicular to the y-axis. A uniformly distributed load due to differential pressure is applied to the sheet 15.

[0034] In this case, lift-up 41 occurs in the area from point P1 to point P3, which is further away from the gap CR, and in the area from point P2 to point P4, which is further away from the gap CR, on the sheet contact surface 27 against which the sheet 15 is pressed. Below, the angle φ at which the sheet contact surface 27 tilts to eliminate this lift-up 41 is determined based on beam theory with the sheet 15 as a beam. Here, the deformation within the range in which small deformation of the sheet 15 is possible in the area of ​​the sheet contact surface 27 including points P1 and P2 from the intersection point Q is the subject of analysis.

[0035] Fig. 6 is an explanatory diagram showing the displacement state of the sheet 15 along the forming die 13 on the right side from the intersection point Q in Fig. 5. Assuming that the uplifting 41 occurs from the above-mentioned point P1 to point P3. Here, the y-direction height of the sheet 15 along the x-direction is expressed as a function y = w(x). The x-coordinate of point P1 is l A and it becomes the reference height in the y-direction (y = 0). Hereinafter, point P1 is also referred to as point A. The x-coordinate of point P3 is l B and hereinafter, point P3 is also referred to as point B. A pressure P is applied to the sheet 15 in the normal direction of the sheet surface along the x-direction. At point P1, it is assumed that the sheet 15 is simply supported. The depth dimension of the sheet 15 is sufficiently long compared to the thickness of the film sheet 15, and it is considered as a plane strain state.

[0036] As the conditions of each part for the premise of the analysis, the definitions of each variable are shown below. E: Young's modulus of the sheet 15 [MPa] ν: Poisson's ratio of the sheet 15 h: Thickness of the sheet 15 [mm] P: Pressure [MPa] l A : Half value of the gap CR [mm] φ: Inclination angle [rad] of the sheet contact surface 27 of the forming die 13 from the horizontal direction (x-direction)

[0037] Also, the values derived from the above-mentioned variables are as follows. D: Flexural rigidity considering plane strain (D = Eh 3 / 12(1 - ν 2 )) [MPa·mm 3

[0038] Hypothetical values set at point A and point B R A : Resistance at point A [MPa·mm 2 R B : Resistance at point B [MPa·mm 2 L: Horizontal distance from point A to point B [mm]

[0039] ​​​Based on the above preconditions, we calculate the function y=w(x), which is the transformed curve on Sheet 15. First, we divide this function y=w(x) into multiple functions using points A and B as the boundary. In the interval Q to P1, the function y1 = w1(x) | 0 ≤ x ≤ l A |, In the interval P1 to P2, the function y² = w²(x)|l A ≤x ≤l B |, In the interval P2 to P3, the function y3 = w3(x)|l B Let ≤ x|.

[0040] At point A where functions w1(x) and w2(x) are connected, equations (1) and (2) hold.

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[0041] Point B, which is the edge of the lifted portion 41 of sheet 15, is the same as the point where there is no lifting portion. B Since this point is adjacent to the region ≤ x and is where the functions w2(x) and w3(x) are connected, equations (3) and (4) hold.

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[0042] Also, l B In the region ≤ x, there is no rotation or lifting of sheet 15, and no bending moment acts on it, so equation (5) holds true.

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[0043] Furthermore, since sheet 15 is a transformation with the y-axis as the axis of symmetry, equation (6) holds true.

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[0044] l BIn the region ≤ x, equation (7) holds trivially.

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[0045] Next, for sheet 15, 0 ≤ x ≤ l A The region and l A ≤x ≤l B We determine the equilibrium of the bending moment M(x) from each free body diagram in the region. Figure 7 shows 0 ≤ x ≤ l A This is an explanatory diagram showing a free body in the case of l. A ≤x ≤l B This is an explanatory diagram showing a free body in the case of 0≦x≦l shown in Figure 7. A The equilibrium of bending moments in this case is given by equation (8), and is shown in Figure 8. A ≤x ≤l B The equilibrium of bending moments in this case is given by equation (9).

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[0046] Furthermore, due to the balance of forces, equation (10) always holds true.

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[0047] Here, the differential equation for the deflection curve w(x) considering Poisson's ratio can be expressed using the bending moment M(x) as follows:

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[0048] Equations (8) to (11) above, along with the constraints, result in two unknowns R. A ,R B By finding and calculating y=w(x), the unknown variable l B Calculate this l B ga l A When it becomes equal to (x=lB =l A ), no lifting occurs in sheet 15. From the differential equation (11), the deflection curve y=w(x) using the unknown k is given by 0≦x≦l A When equation (12) is given, l A ≤x ≤l B In this case, it can be expressed as in equation (13).

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[0049] Note, R A ,R B Based on equations (3), (4), and (10), l B and l A It can be calculated as follows using [the formula].

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[0050] From the above, the deflection curve y=w(x) has l unknowns. B It can be expressed as an equation that is only this. Next, the length of the lift of sheet 15 l B We calculate the following. Substituting the aforementioned equations into the constraint conditions of equation (2) and rearranging, we obtain equation (16).

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[0051] In general, a cubic equation in x expressed using real numbers a, b, c, and d is ax. 3 +bx 2 When the equation +cx+d=0 is completed in solid form, the cubic equation is simplified to equations (17) to (20).

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[0052] From equations (18), (19), and (20), equation (16) can be expressed as equation (21) by equation (17).

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[0053] Differentiating equation (21) with respect to X yields equation (22).

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[0054] f(x) is given by X = 2l A , in other words l B =l A It has an inflection point at this point. At this time, f(2l A If l is < 0, then the x-coordinate of point B is l B ga l B >l A It will exist in this state, causing it to float. At this time, l that causes floating B This can be expressed using Cardano's formula as equation (23).

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[0055] On the other hand,f(2l A If )=0 then l B =l A Therefore, no buoyancy occurs. f(2l A Rearranging the equation )=0, and assuming that the angle at which no lifting occurs is φ=α, we obtain the following equation (24). Therefore, lifting of sheet 15 is prevented when equation (24) is satisfied. Note that since α is small, it is acceptable to assume that sinα ≈ α.

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[0056] Figure 9 is an explanatory diagram showing the case where the load applied to sheet 15 is small. f(2l A )<0 and f(2l A The condition that ) = 0, i.e., f(2l A The condition that l > 0 occurs when the applied load is small, as shown in Figure 9.A ≤x ≤l B In this section, the sheet 15 deforms without following the sheet contact surface 27. In this case, 0≦x≦l B and l B We only need to consider two intervals: ≤x and x.

[0057] The following items can be listed as boundary conditions: The continuity at point B, which is the end point of the lift, satisfies equations (25) and (26).

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[0058] Also, l B For ≤ x, the sheet 15, which acts as a beam, does not rotate or lift, and no bending moment acts on it, so equation (27) is satisfied. Also, since the sheet 15 undergoes symmetric deformation with respect to the y-axis, equation (28) is satisfied.

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[0059] l B For ≤ x, the sheet 15 conforms to the shape of the sheet contact surface 27, so equation (29) holds.

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[0060] Similarly, let's consider the bending moment M(x). The region 0≦x≦l shown in Figure 8 B In this case, the equilibrium of the bending moments obtained is expressed by equation (30).

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[0061] Here, we have the differential equation and boundary conditions for the deflection curve, and the force equilibrium R. B =Pl B by lB This can be derived as shown in equation (31). B The deflection curve can be obtained using equation (32).

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[0062] From equation (32), l B ga l A When this is equal, it can be seen that sheet 15 does not lift up.

[0063] Here, in order to match the above model to the actual arrangement, the system is rotated so that the main surface 11a of the base 11 is horizontal. Figure 10 is an explanatory diagram showing the sheet 15 shown in Figure 5 rotated so that the main surface 11a of the base 11 is horizontal. The arrangement of each component shown in Figure 10 simulates the arrangement shown in Figure 4. In this case, the inclination angle φ of the sheet contact surface 27 is inclined by an angle ω (ω = 2α) with respect to the horizontal main surface 11a. Using equation (24) and the fact that α is a small angle, ω can be approximated by the following equation.

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[0064] As explained above, the intersection angle between the sheet contact surface 27 of the mold 13 and the main surface 11a of the base body 11, that is, the intersection angle between the sheet contact surface 27 and the bottom surface 25a of the recess 25 of the mold 13 (the bottom surface 25a is parallel to the main surface 11a), should be set to an angle ω that satisfies equation (33). In this case, the sheet 15 can be prevented from lifting up when pressed against the sheet by differential pressure. In practice, depending on the properties of the sheet 15, such as its elastic properties, the sheet 15 may not lift up even if the intersection angle is within a specific angle range other than angle ω = 0°. For example, such a specific angle range could be ±1°, ±1.5°, ±2°, or even ±5° from the angle ω obtained by equation (33), provided that it is greater than 0°. Furthermore, a specific angle range for the angle ω mentioned above can be exemplified as 0° < ω ≤ 10°.

[0065] <Curved substrate> The aforementioned base 11 was a flat plate with a flat main surface 11a and a constant thickness, but it is not limited to this, and may be a curved plate having at least a part of a concave or convex curved surface. Figure 11 is a cross-sectional view showing a sheet 15 pressed against a base body 11A, which is a curved plate placed in a recess 25 of a mold 13. The base body 11A is a curved plate with a constant thickness, and both main surfaces 11a and 11b are curved. In this case, the base 29A has a base support surface 29a that is curved along the main surface 11b of the base body 11A. The base body 11A may also be supported by the bottom surface 25a of the recess 25 without the base 29A. In that case, it is preferable that the bottom surface 25a is a curved shape that follows the curved surface of the base body 11A. The sheet contact surface 27 may be a flat surface or a curved surface.

[0066] Figure 12 is an enlarged explanatory diagram showing the arrangement of the sheet contact surface 27 between the base body 11A and the mold 13 as shown in Figure 11. Let L5 be the tangent line on the contact surface side along the sheet contact surface 27 at point P1, which is the inner edge on the gap CR side of the sheet contact surface 27, and let L6 be the base body contact line along the main surface 11a at point P2, which is the outer edge on the gap CR side of the main surface 11a of the base body 11A. Also, let L7 be the tangent line on the bottom surface side along the bottom surface 25a at the intersection P0 of the bottom surface 25a and the inner wall surface 25b of the recess 25 shown in Figure 11. If the bottom surface 25a is a flat surface, the bottom surface tangent line L7 is the same as the bottom surface extension line L1 which is an extension of the bottom surface 25a of the recess 25 as described above. Also, if the sheet contact surface 27 is a flat surface, the contact surface tangent line L5 is the same as the contact surface extension line L4 which is an extension of the sheet contact surface 27 as described above.

[0067] In this case, the tangent line L5 on the contact surface side and the tangent line L6 on the base side intersect each other, and the tangent line L5 on the contact surface side and the tangent line L7 on the bottom surface side also intersect each other. Furthermore, point P2 on the base 11 is positioned lower than point P1 on the mold 13. As a result, the sheet 15 is positioned in a curved shape so that the sheet contact surface 27 and the main surface 11a of the base 11A form a smooth curve between the gap CR. With this support configuration of the sheet 15, although not shown in the figures, the sheet 15 is positioned along the sheet contact surface 27 and the main surface 11a of the base 11A, and no lifting occurs. Moreover, when the sheet 15 is pressed against the base 11A via the adhesive layer, the adhesive layer absorbs any lifting of the sheet 15.

[0068] <Other configuration examples> (Configuration Example 1) Figure 13 is an explanatory diagram showing a mold 13A that curves the sheet 15 in the opposite direction to that shown in Figure 4 when the sheet 15 is brought into close contact with the base body 11. The mold 13A shown in Figure 13 has a slope where the sheet contact surface 27 becomes lower as it moves away from point P1. That is, the sheet contact surface 27 is an inclined surface that slopes downward toward the bottom surface 25a of the recess 25 as it moves away from the recess, and point P1 of the mold 13A is lower in the Y direction than point P2 of the base body 11. In this case, the contact surface extension line L8 along the sheet contact surface 27 intersects with the base body extension line L3 along the main surface 11a of the base body 11 at an angle ω.

[0069] In this configuration, when a uniformly distributed load is applied to the sheet 15, the sheet 15 curves in the region of the gap CR, making it difficult for the sheet 15 to sink into the gap CR. As a result, the sheet 15 is less likely to lift up. In this case, the deformation of the sheet 15 due to pressure from the second chamber CB2 shown in Figure 2B is preferably handled by adding a push-up method step, in which a mold (not shown) having an upwardly convex molding surface is pressed against the sheet 15 from the opposite side of the pressure direction (from bottom to top), causing the sheet 15 to conform to the final upwardly convex curved shape to some extent. After that, pressure is applied to press the sheet 15 against the molding die 13 so that it conforms to the shape. In this case, the elongation and stress generation of the sheet 15 are suppressed, and delamination of the functional layer is less likely to occur.

[0070] (Configuration example 2) Figure 14 is a schematic plan view of a mold 13B having multiple recesses 25 formed therein. By having multiple recesses 25, the mold 13B can accommodate a substrate in each recess 25, and a functional layer of a sheet (not shown) can be bonded to each substrate simultaneously. There are not limited to two recesses 25, but there may be three or more, and each recess 25 may be the same shape, or they may be different shapes. With this configuration, the functional layer can be bonded to multiple substrates at once, thus shortening the cycle time and enabling efficient molding of composite materials.

[0071] (Configuration Example 3) Figure 15 is a schematic plan view of a mold 13C in which a recess 25 for accommodating an irregularly shaped substrate is formed. The planar shape of the recess 25 of the mold 13C can be appropriately changed according to various substrate shapes. The recess 25 shown in Figure 15 exemplifies a shape in which a part of a rectangle has a notch. Around the recess 25, a sheet contact surface 27 of a predetermined width is formed in an annular shape along the outer edge (inner wall surface 25b) of the recess 25. With this configuration, even a substrate with a complex shape can be stably supported by accommodating the entire substrate in the recess. Furthermore, the substrate can be positioned with high precision, and the functional layer can be uniformly bonded to the entire surface of the substrate at once.

[0072] (Shape of the sheet contact surface) Figures 16A and 16B are partially enlarged plan views showing the shape of the sheet contact surface 27 at the corner of the recess 25 of the mold 13. In a plan view of the base body, if the corners of the base body are rounded and chamfered, the outer edge (inner wall surface 25b) of the recess 25 may be made into a curved shape along the corner of the base body, as shown in Figure 16A. In that case, the sheet contact surface 27 is a continuous surface of constant width along the inner wall surface 25b of the recess 25, and becomes a smooth inclined surface that slopes toward the recess 25. In other words, the inclination angle of the sheet contact surface 27 toward the recess 25 remains constant along the circumferential direction of the annular sheet contact surface 27, and no wrinkles are formed in the sheet 15.

[0073] Furthermore, as shown in Figure 16B, if the corners of the base body are formed in a straight line, the outer edge (inner wall surface 25b) of the recess 25 may be made curved along the corners of the base body. In that case, the width of the sheet contact surface 27 will not be constant, but the sheet can be prevented from lifting up by having the sheet contact surface 27 inclined at the angle ω described above.

[0074] <<Materials for composite materials>> The following describes some examples of materials that make up composite materials. <Base> Preferably, the substrate 11 is made of a material with a higher glass transition temperature Tg than the sheet 15 and a larger Young's modulus than the sheet 15. Because the glass transition temperature Tg of the substrate 11 is higher than that of the sheet 15, significant thermal deformation does not occur in the substrate 11 even when heat is transferred from the heated sheet 15 to the substrate 11. Furthermore, because the Young's modulus of the substrate 11 is greater than that of the sheet, mechanical deformation of the substrate 11 due to pressure from the sheet 15 can be suppressed. The substrate 11 may also be a single plate or a laminate composed of multiple layers of material, and can be configured in any way that suits the intended use.

[0075] The substrate 11 is, for example, a transparent glass member, and may be a glass substrate having at least one main surface. The glass substrate is formed from ordinary glass. Examples of glass used to form the glass substrate include alkali-free glass, soda-lime glass, soda-lime silicate glass, aluminosilicate glass, borosilicate glass, lithium aluminosilicate glass, and borosilicate glass. Among these, aluminosilicate glass or lithium aluminosilicate glass is preferred because, even with a thin thickness, it is easy to apply large stresses through strengthening treatment, resulting in high-strength glass.

[0076] The shape of the glass substrate may be a flat plate, or a curved plate having a concave or convex curved surface in at least part of it. It may also have one or more bent or curved sections. The main surface of the glass substrate may be entirely flat, or at least part of it may be curved. If at least part of the main surface is curved, the entire main surface may be curved, or the main surface may be composed of a curved portion and a flat portion. The glass substrate may be any of the following shapes: polygons including rectangles, flat plates such as circles and ellipses, shapes in which part or all of these shapes are curved, or three-dimensional shapes.

[0077] The entire region of the main surface where the functional layer is placed may be planar, or at least a part of the above region may be curved. The region where the functional layer is placed may be entirely composed of curved surfaces, or it may be composed of curved surfaces and planar surfaces. Functional layers placed on a curved surface may deform to conform to the shape of the curved surface.

[0078] <Functional Layer> The functional layer 30 may be, for example, a colored layer. The colored layer is a layer that is in contact with the main surface of the substrate 11 and may contain, for example, a coloring agent, a curing resin, and a non-curing resin. In display devices that use a substrate with a colored layer as a cover glass, the colored layer can shield components such as wiring circuits located around the periphery of the display from the observer's field of view, thereby improving the visibility and aesthetic appeal of the display. The colored layer may also be formed to improve the design of the display device and can function as a decorative layer with characters and patterns. An example of the components contained in the colored layer is described below.

[0079] (Coloring agent) The coloring agent may be either a pigment or a dye. Furthermore, a coloring agent of an appropriate color can be used depending on the purpose of the colored layer. For example, when forming a colored layer to be used as a light-shielding film, a black coloring agent may be used, or multiple coloring agents of different colors may be mixed and used to form patterns such as wood grain. Pigments are preferred as coloring agents. For example, if the colored layer is black, a black pigment is preferred as the coloring agent. Examples of black pigments include carbon black, titanium black, titanium carbon, iron oxide, titanium oxide, and graphite, with graphite or carbon black being preferred, and carbon black being more preferred. A single coloring agent may be used, or two or more may be used in combination.

[0080] (cured resin) A cured resin refers to a cured product obtained by curing a curable resin. The cured resin may be a cured product of a curable resin and a curing agent, or it may be a cured product (polycondensate) obtained by reacting a curable resin with heat, light, acid, alkali, etc. A cured product of a curable resin and a curing agent is preferred as the cured resin.

[0081] (Non-curing resin) The non-curable resin is a resin component different from the colorant and curable resin contained in the colored layer. The weight-average molecular weight (Mw) of the non-curable resin is, for example, less than 20,000, preferably 400 to 15,000, and more preferably 500 to 10,000. The glass transition temperature (Tg) of the non-curable resin is preferably 30 to 200°C, more preferably 50 to 150°C, and even more preferably 60 to 130°C, in terms of sufficient leveling at the interface with the glass substrate 11 and excellent adhesion to the substrate 11. From the viewpoint of adhesion to the glass substrate 11, the non-curable resin preferably has a functional group selected from the group consisting of hydroxyl groups and carboxyl groups.

[0082] <Examples of other functional layers> (AG layer) The AG (Anti-Glare) layer is an anti-glare layer that imparts anti-glare properties to the composite material. The AG layer is a layer with an uneven surface that is formed on the main surface of the substrate 11. The uneven surface may be formed directly on the main surface of the substrate 11, or it may be formed from a layer made of a different material from the substrate 11. The AG layer may be a layer formed by an uneven surface created by applying an anti-glare treatment and an etching treatment to the main surface of the substrate 11. Alternatively, the AG layer may be formed on the main surface of the substrate 11 by forming a coating film in which particles with an arbitrary refractive index are dispersed, or by laminating a transparent resin film having an uneven surface.

[0083] (AR layer) The AR (Anti-Reflection) layer is an anti-reflective layer provided on the main surface of the substrate 11. The AR layer reduces the reflectivity of the composite material, thereby reducing glare caused by reflected light, and also improves the visibility of the display device using the composite material equipped with the AR layer. The configuration of the AR layer is not particularly limited as long as it can suppress light reflection, but for example, it may be a configuration in which a high refractive index layer with a refractive index of 1.9 or higher at a wavelength of 550 nm and a low refractive index layer with a refractive index of 1.6 or lower at a wavelength of 550 nm are alternately stacked. The AR layer may be placed in contact with the AG layer, or the AR layer may be placed directly on the main surface of the substrate 11.

[0084] (AFP layer) The AFP (Anti-Finger-Print) layer is an anti-fouling layer that suppresses the adhesion of various types of dirt, such as fingerprints, sweat, and dust, making dirt less noticeable. The AFP layer is provided on the main surface of the substrate 11. The AFP layer is located on the outermost surface of the substrate 11. This allows the anti-fouling layer to fully exhibit its properties in keeping the display surface clean. The AFP layer consists of a fluorine-containing compound that can impart, for example, antifouling, water-repellent, and oil-repellent properties. A fluorine-containing organic compound (a compound having a fluorine-containing organic group) is preferred as the fluorine-containing compound. Examples of fluorine-containing organic compounds include fluorine-containing organosilicon compounds.

[0085] The AG layer, AR layer, and AFP layer described above are examples, and the configuration of each layer may be modified as appropriate, as long as it fulfills the function of that layer.

[0086] <Sheet> The sheet 15 is appropriately selected depending on the method of forming the functional layer and transferring it to the substrate 11. As the material of the sheet 15, a resin substrate is preferred in terms of flexibility, heat resistance, surface cleanliness, and smoothness. Examples of resins that make up the sheet 15 include thermoplastic resins such as polyethylene terephthalate resin, polyethylene resin, polypropylene resin, and polycarbonate resin. When a functional layer is provided on the surface of the sheet 15, the surface of the sheet 15 may be subjected to surface treatments such as easy-adhesion treatment or corona treatment, depending on the purpose of facilitating peeling after transfer.

[0087] The thickness of the sheet 15 is, for example, 10 to 1000 μm, preferably 10 to 300 μm, more preferably 20 to 250 μm, and even more preferably 40 to 200 μm. By keeping the thickness within the above range, the flexibility of the sheet 15 is improved. Furthermore, when the sheet 15 is softened when transferring the functional layer 30 to the substrate 11, the glass transition temperature (Tg) of the resin constituting the sheet 15 is preferably 70 to 180°C, and more preferably 100 to 150°C. The sheet 15 may also have a single-layer structure or a laminated structure composed of multiple layers.

[0088] The present invention is not limited to the embodiments described above. It is also intended and within the scope of protection to be provided for the combination of each configuration of the embodiments, as well as for modifications and applications by those skilled in the art based on the description in the specification and well-known art.

[0089] As described above, the following matters are disclosed in this specification: (1) A manufacturing apparatus for composite materials that presses a sheet against a substrate via an adhesive layer to bond them together, A mold having a recess for supporting the substrate, and a sheet contact surface formed from the inner wall surface of the recess toward the outside of the recess, A sheet fixing portion is provided, which fixes the end of the sheet, which is positioned to cover the recess of the mold, to the mold, thereby forming a first chamber that is an airtight space on the mold side of the sheet, An opposing mold is provided on the opposite side of the mold from the sheet fixed to the mold, forming a second chamber that becomes an airtight space, A seat drive unit that causes the seat to flex by creating a pressure difference between the first chamber and the second chamber, Equipped with, A gap is provided between the end face of the base body housed in the recess and the inner wall surface of the recess facing the end face. In a cross-sectional view of the substrate of the mold in the thickness direction, the bottom-side tangent line along the bottom surface at the intersection of the bottom surface of the recess and the inner wall surface, and the contact-side tangent line along the sheet contact surface at the intersection of the sheet contact surface and the inner wall surface, intersect each other. Manufacturing equipment for composite materials. According to this composite material manufacturing apparatus, the bottom surface of the mold recess and the sheet contact surface are not flush but intersect with each other, which prevents lifting between the sheet and the substrate when the sheet is pressed against the substrate. This results in good adhesion between the sheet and the substrate, allowing the sheet to be uniformly bonded to the substrate.

[0090] (2) The intersection angle between the bottom surface tangent and the contact surface tangent is, The composite material manufacturing apparatus according to (1), wherein the sheet, which is pressed against the base-facing surface and the sheet-contact surface of the base body facing the sheet by the pressure difference, is positioned such that at the outer edge of the base-facing surface on the gap side, it extends along a base extension line extending the base-facing surface toward the gap, and at the inner edge of the sheet-contact surface on the gap side, it extends along a contact surface extension line extending the sheet-contact surface toward the gap, and the angle at which the base extension line and the contact surface extension line intersect each other. According to this composite material manufacturing apparatus, by setting the intersection angle between the bottom-side tangent and the contact-side tangent so that the base extension line and the contact surface extension line intersect each other, it is possible to prevent lifting between the sheet and the base when the sheet is pressed against the base.

[0091] (3) The apparatus for manufacturing a composite material according to (1) or (2), wherein the acute-angle intersection ω of the bottom-side tangent and the contact-side tangent is 0° < ω ≤ 10°. According to this composite material manufacturing apparatus, the occurrence of lifting can be prevented by curving the sheet with an intersection angle within the above range.

[0092] (4) The acute-angle intersection ω between the bottom-side tangent and the contact-side tangent is the bending stiffness D [MPamm] considering the plane strain state of the sheet. 3 A composite material manufacturing apparatus according to any one of (1) to (3), wherein the pressure P [MPa] applied to the sheet and the width L [mm] of the gap are within a range of ±5° centered on the value represented by the following formula D, and the angle is greater than 0°.

number

[0093] (5) The sheet contact surface is an inclined surface that protrudes in the opposite direction to the bottom surface of the recess as it moves away from the recess, The composite material manufacturing apparatus according to any one of (1) to (4), wherein the recess has a depth such that the outer edge on the gap side of the substrate-facing surface of the substrate housed in the recess that faces the sheet is positioned on the bottom surface side of the recess than the inner edge on the gap side of the sheet contact surface. According to this composite material manufacturing apparatus, the sheet is arranged in a smoothly curved manner from the sheet contact surface to the main surface on the bonding side of the substrate.

[0094] (6) The sheet contact surface is an inclined surface that slopes downward in the depth direction of the recess as it moves away from the recess, The composite material manufacturing apparatus according to any one of (1) to (5), wherein the recess has a depth such that the outer edge on the gap side of the substrate-facing surface of the substrate housed in the recess, which faces the sheet, protrudes on the opposite side of the bottom surface of the recess from the inner edge on the gap side of the sheet contact surface. According to this composite material manufacturing apparatus, the sheet is arranged in a smoothly curved manner from the sheet contact surface to the main surface on the bonding side of the substrate.

[0095] (7) The apparatus for manufacturing a composite material according to any one of (1) to (6), wherein the recess has a shape that accommodates the entire substrate, and the sheet contact surface is formed to surround the recess. According to this composite material manufacturing apparatus, the entire substrate is surrounded by recesses, allowing for stable support of the substrate. Furthermore, the substrate can be positioned with high precision, and the sheet can be uniformly bonded to the entire surface of the substrate in one go.

[0096] (8) The composite material manufacturing apparatus according to (7), wherein the sheet contact surface is a smooth continuous surface along the inner wall surface of the recess. According to this composite material manufacturing equipment, no wrinkles will form in the sheet.

[0097] (9) The apparatus for manufacturing a composite material according to any one of (1) to (8), wherein the mold has a plurality of recesses, and the substrate is housed in each of the plurality of recesses. This composite material manufacturing apparatus allows for the bonding of sheets to multiple substrates simultaneously, thus shortening the cycle time and enabling efficient molding of composite materials.

[0098] (10) A functional layer is provided on the outer surface of the sheet, A composite material manufacturing apparatus according to any one of (1) to (9), wherein the adhesive layer is provided on at least one of the functional layer of the sheet and the surface of the substrate facing the sheet. According to this composite material manufacturing apparatus, by pressing a sheet against a substrate, a functional layer can be selectively applied to areas where an adhesive layer is provided.

[0099] (11) The opposing mold is equipped with a heating section for heating the sheet that has been adsorbed onto the opposing mold, The apparatus for manufacturing a composite material according to any one of (1) to (10), wherein the substrate is formed from a material having a higher glass transition temperature Tg than the sheet and a larger Young's modulus than the sheet. According to this composite material manufacturing apparatus, the substrate's glass transition temperature (Tg) is higher than that of the sheet, so even when heat is transferred from the heated sheet to the substrate, significant thermal deformation does not occur in the substrate. Furthermore, because the substrate's Young's modulus is greater than that of the sheet, mechanical deformation of the substrate due to pressure from the sheet can be suppressed.

[0100] (12) The apparatus for manufacturing a composite material according to any one of (1) to (11), wherein the substrate is a flat plate or a curved plate having at least a part of a concave or convex curved surface. This composite material manufacturing apparatus allows for the bonding of sheets to either a flat plate or a curved plate as the base material.

[0101] (13) The apparatus for manufacturing a composite material according to any one of (1) to (12), wherein the substrate is a single layer of plate material or a laminate of multiple layers of material. This composite material manufacturing apparatus allows the use of substrates with any configuration suitable for the intended use.

[0102] (14) A composite material manufacturing apparatus according to any one of (1) to (13), wherein the thickness of the sheet is 10 to 1000 μm. According to this composite material manufacturing apparatus, the flexibility of the sheet is improved by keeping the thickness within the range described above.

[0103] (15) The apparatus for manufacturing a composite material according to any one of (1) to (14), wherein the sheet has a single-layer structure or a laminated structure composed of multiple layers. This composite material manufacturing equipment allows for the use of single-layer sheets or laminated sheets depending on the purpose.

[0104] (16) The mold used in the apparatus for manufacturing composite materials described in any one of (1) to (15), A molding die having surfaces where the bottom surface of the recess and the sheet contact surface intersect with each other. This molding method prevents lifting between the sheet and the substrate when the sheet is pressed against the substrate. This results in good adhesion between the sheet and the substrate, allowing the sheet to be uniformly bonded to the substrate.

[0105] (17) A method for manufacturing a composite material in which the sheet is bonded to the substrate, using a composite material manufacturing apparatus described in any one of (1) to (15), The base body is placed in the recess of the mold, The sheet is fixed to the sheet fixing part, The air pressure in the first chamber is made higher than the air pressure in the second chamber, causing the sheet to bend toward the mold, and the sheet is pressed against the substrate and bonded to the substrate. A method for manufacturing composite materials. According to this composite material manufacturing method, by pressing the sheet against the substrate using differential pressure, the adhesion between the sheet and the substrate is improved, and the sheet can be uniformly bonded to the substrate.

[0106] (18) A functional layer is provided on the outer surface of the sheet. A method for manufacturing a composite material according to (17), comprising: laminating the functional layer of the sheet to the substrate; lowering the air pressure in the first chamber to a lower pressure in the second chamber to separate the sheet from the mold; and transferring the functional layer to the substrate. According to this composite material manufacturing method, the functional layer can be selectively applied to the substrate by pressing the functional layer against the substrate and then pulling the sheet away from the substrate. [Explanation of symbols]

[0107] 11,11A Base 11a,11b Main surface 13,13A,13B,13C mold 15 sheets 15a end 17. Seat fixing part 19 Opposite type 21 Seat drive unit 23 Control Unit 25 recesses 25a Bottom 25b Inner wall surface 27 Sheet contact surface 29 Pedestal 29a Base support surface 30 Functional Layers 31 Heater 33 pumps 35 Pressure adjustment section 37 Pressure pipeline 41 Float 100 Manufacturing apparatus for substrates with functional layers CR gap CB1 First Chamber CB2 Second Chamber

Claims

1. A composite material manufacturing apparatus that presses a sheet against a substrate via an adhesive layer to bond them together, A mold having a recess for supporting the substrate, and a sheet contact surface formed from the inner wall surface of the recess toward the outside of the recess, A sheet fixing portion is provided, which fixes the end of the sheet, which is positioned to cover the recess of the mold, to the mold, thereby forming a first chamber that is an airtight space on the mold side of the sheet, An opposing mold is provided on the opposite side of the mold from the sheet fixed to the mold, forming a second chamber that becomes an airtight space, A sheet drive unit that causes the sheet to flex by creating a pressure difference between the first chamber and the second chamber, Equipped with, A gap is provided between the end face of the base body housed in the recess and the inner wall surface of the recess facing the end face. In a cross-sectional view of the substrate of the mold in the thickness direction, the bottom-side tangent line along the bottom surface at the intersection of the bottom surface of the recess and the inner wall surface, and the contact-side tangent line along the sheet contact surface at the intersection of the sheet contact surface and the inner wall surface, intersect each other. Manufacturing equipment for composite materials.

2. The intersection angle between the bottom surface tangent and the contact surface tangent is, When the sheet, which is pressed against the base-facing surface and the sheet-contacting surface of the base body facing the sheet by the aforementioned pressure difference, is positioned such that the base-facing surface extends along a base extension line extending toward the gap at the outer edge of the base-facing surface on the gap side, and the sheet-contacting surface extends along a contact surface extension line extending toward the gap at the inner edge of the sheet-contacting surface on the gap side, the base extension line and the contact surface extension line intersect each other, the angle is such that the base extension line and the contact surface extension line intersect each other. The apparatus for manufacturing a composite material according to claim 1.

3. The acute-angle intersection ω between the bottom surface tangent and the contact surface tangent is 0° < ω ≤ 10°. The apparatus for manufacturing a composite material according to claim 1.

4. The acute-angle intersection ω between the bottom-side tangent and the contact-side tangent is determined by the bending stiffness D [MPamm] of the sheet, taking into account the plane strain state. ３ ] and, depending on the pressure P [MPa] applied to the sheet and the width L [mm] of the gap, the angle is greater than 0°, within a range of ±5° centered on the value expressed by the following formula. The apparatus for manufacturing a composite material according to claim 1. [Math 1]

5. The sheet contact surface is an inclined surface that protrudes in the opposite direction to the bottom surface of the recess as it moves away from the recess. The recess has a depth such that the outer edge on the gap side of the base-facing surface of the base-facing surface that is housed in the recess and facing the sheet is positioned closer to the bottom surface of the recess than the inner edge on the gap side of the sheet-contact surface. The apparatus for manufacturing a composite material according to claim 1.

6. The sheet contact surface is an inclined surface that slopes downward in the depth direction of the recess as it moves away from the recess, The recess has a depth such that the outer edge on the gap side of the base-facing surface of the base-facing surface that is housed in the recess and facing the sheet protrudes on the opposite side of the bottom surface of the recess from the inner edge on the gap side of the sheet-contact surface. The apparatus for manufacturing a composite material according to claim 1.

7. The recess has a shape that accommodates the entire base body, and the sheet contact surface is formed to surround the recess. The apparatus for manufacturing a composite material according to claim 1.

8. The sheet contact surface is a smooth, continuous surface along the inner wall surface of the recess. The apparatus for manufacturing a composite material according to claim 7.

9. The mold has a plurality of recesses, and the base body is housed in each of the plurality of recesses. The apparatus for manufacturing a composite material according to claim 1.

10. A functional layer is provided on the outer surface of the aforementioned sheet. The adhesive layer is provided on at least one of the functional layer of the sheet and the surface of the substrate facing the sheet. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

11. The opposing mold is equipped with a heating section for heating the sheet that has been adsorbed onto the opposing mold, The substrate is formed from a material having a higher glass transition temperature Tg than the sheet and a larger Young's modulus than the sheet. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

12. The substrate is a flat plate, or a curved plate having at least a part of a concave or convex curved surface. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

13. The substrate is a single-layer plate material or a laminate made of multiple layers of material. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

14. The thickness of the aforementioned sheet is 10 to 1000 μm. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

15. The aforementioned sheet has a single-layer structure or a laminated structure composed of multiple layers. A manufacturing apparatus for composite materials according to any one of claims 1 to 9.

16. The mold used in the apparatus for manufacturing a composite material according to any one of claims 1 to 9, A molding die having surfaces where the bottom surface of the recess and the sheet contact surface intersect with each other.

17. A method for manufacturing a composite material, wherein the sheet is bonded to the substrate, using a composite material manufacturing apparatus according to any one of claims 1 to 9, The base body is placed in the recess of the mold, The sheet is fixed to the sheet fixing part, The air pressure in the first chamber is made higher than the air pressure in the second chamber, causing the sheet to bend toward the mold, and the sheet is pressed against the substrate and bonded to the substrate. A method for manufacturing composite materials.

18. A functional layer is provided on the outer surface of the aforementioned sheet. After bonding the functional layer of the sheet to the substrate, the air pressure in the first chamber is lowered to be lower than the air pressure in the second chamber to separate the sheet from the mold and transfer the functional layer to the substrate. A method for manufacturing a composite material according to claim 17.

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