Method for manufacturing a plate-shaped member, and apparatus for manufacturing a plate-shaped member

Abstract

To provide a method for producing a plate-like member and a device for producing a plate-like member which can suppress the occurrence of chipping in the plate-like member.SOLUTION: A method for producing a plate-like member includes a placement step for placing a to-be-processed plate P between a support member 15 and a pressing member 16, and a cutting step for cutting the to-be-processed plate P along a first scribe line L21. The support member 15 includes: a first support part 17; and a second support part 18 that is placed away from the first support part 17 and has a low height difference compared to the first support part 17. The to-be-processed plate P includes a first plate part P1 that is placed on the first support part 17 side of the support member 15 and a second plate part P2 that is placed on the second support part 18 side of the support member 15, based on the first scribe line L21. The length dimension A1 of the first plate part P1 is set to be smaller than the length dimension A2 of the second plate part P2. In the cutting step, the pressing member 16 applies external force to the to-be-processed plate P.SELECTED DRAWING: Figure 2

Description

Technical Field

[0004] , ,

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[0001] The present invention relates to a method for manufacturing a plate-like member and a manufacturing apparatus for the plate-like member.

Background Art

[0002] As described in Patent Documents 1 and 2, a method for manufacturing a plate-like member by cutting a workpiece plate is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] When manufacturing a plate-like member by cutting a workpiece plate as described above, there is still room for improvement from the viewpoint of suppressing the occurrence of chipping in the plate-like member. An object of the present invention is to provide a method for manufacturing a plate-like member and a manufacturing apparatus for the plate-like member that can suppress the occurrence of chipping in the plate-like member.

Means for Solving the Problems

[0005] Each aspect of the method for manufacturing a plate-like member and the manufacturing apparatus for the plate-like member that solve the above problems will be described. The method for manufacturing a plate-shaped member according to Embodiment 1 is a method for manufacturing a plate-shaped member by cutting a workpiece sheet having a first main surface and a second main surface opposite to the first main surface, wherein the first main surface of the workpiece sheet has a scribe line, and the method comprises an arrangement step of arranging the workpiece sheet between a support member and a pressing member such that the first main surface of the workpiece sheet faces the support member, and a cutting step of cutting the workpiece sheet along the scribe line, wherein the support member comprises a first support portion and a portion spaced apart from the first support portion and lower in height than the first support portion. The support member has a second support portion and a first support portion, and in the arrangement step, the workpiece is positioned so that the scribe line is along the first support portion and the second support portion, and the workpiece has a first plate portion positioned on the first support portion side of the support member relative to the scribe line and a second plate portion positioned on the second support portion side of the support member, the length dimension of the first plate portion is set to be smaller than the length dimension of the second plate portion, and in the cutting step, the support member and the pressing member are moved relative to each other so that an external force is applied to the workpiece by the pressing member. According to this method, it is thought that the recoil immediately after cutting of the workpiece is suppressed on the second main surface side of the workpiece. As a result, the impact applied to the plate-shaped member can be suppressed, and thus it is possible to suppress the occurrence of chipping in the plate-shaped member.

[0006] In the manufacturing method of the plate-shaped member of Embodiment 2, in Embodiment 1, at least one of the first support portion and the second support portion may be a support surface for supporting the plate material to be processed. According to this method, for example, the plate material to be processed can be stably supported. Therefore, the cutting process can be carried out stably.

[0007] The method for manufacturing a plate-shaped member according to Embodiment 3, in Embodiment 1 or Embodiment 2, the scribe line of the plate material to be processed includes a first scribe line and a second scribe line adjacent to the first scribe line, the arrangement step includes a first arrangement step of arranging the plate material to be processed such that the first scribe line lies between the first support portion and the second support portion, and a second arrangement step of arranging the plate material to be processed such that the second scribe line lies between the first support portion and the second support portion, the cutting step includes a first cutting step of cutting the plate material to be processed along the first scribe line and a second cutting step of cutting the plate material to be processed along the second scribe line, and after performing the first arrangement step and the first cutting step in order, in the second arrangement step, the end of the plate material to be processed formed by the first cutting step may be moved toward the first support portion. This method allows for a smoother second cutting process, thereby increasing the productivity of plate-shaped members.

[0008] The method for manufacturing a plate-shaped member according to Embodiment 4 is such that, in Embodiment 3, the first support portion is a first support surface that supports the plate material to be processed, and in the second arrangement step, the end portion of the plate material to be processed may be placed on the first support surface. This method makes it possible to stabilize the position of the plate material to be processed.

[0009] In the manufacturing method of the plate-shaped member of Embodiment 5, in any one embodiment of Embodiments 1 to 4, the pressing member may be moved toward the plate material to be processed during the cutting step. With this method, for example, the position of the plate material to be processed can be stabilized by supporting the plate material to be processed with the first support. By moving the pressing member toward the plate material to be processed in this position, the cutting step can be performed stably.

[0010] The method for manufacturing a plate-shaped member according to Embodiment 6 is, in any one embodiment from Embodiments 1 to 5, the first support portion is a first support surface that supports the plate material to be processed, and the external dimensions of the plate-shaped member in plan view may be smaller than the external dimensions of the first support surface of the first support portion.

[0011] In the manufacturing method of the plate-shaped member according to Embodiment 7, in any one embodiment from Embodiments 1 to 6, if the thickness dimension of the plate-shaped member is T and the external dimensions of the plate-shaped member in a plan view are Wd, the ratio expressed as Wd / T may be 50 or less.

[0012] In the manufacturing method of the plate-shaped member according to Embodiment 8, in any one embodiment from Embodiments 1 to 7, a protective film may be attached to at least one of the first main surface and the second main surface of the plate material to be processed. This method makes it possible to protect at least one of the first main surface and the second main surface of the plate material to be processed, or to protect at least one of the two main surfaces of the plate-shaped member. Furthermore, it is possible to prevent the plate-shaped member from scattering into individual pieces or from colliding with each other and being damaged when the plate-shaped members are separated into individual pieces.

[0013] In the manufacturing method of the plate-shaped member according to Embodiment 9, in any one embodiment from Embodiments 1 to 8, if the distance between the first support portion and the second support portion is G and the height difference between the first support portion and the second support portion is ΔH, the ratio expressed as ΔH / G may be in the range of 0.01 or more and 1 or less.

[0014] In the manufacturing method of the plate-shaped member according to Embodiment 10, in any one embodiment from Embodiments 1 to 9, if the thickness of the plate material to be processed is T and the height difference between the first support portion and the second support portion is ΔH, the ratio expressed as ΔH / T may be in the range of 0.05 or more and 5 or less.

[0015] The manufacturing apparatus for the plate-shaped member of Mode 11 is a manufacturing apparatus for manufacturing a plate-shaped member by cutting a work target plate material, and has a support member and a pressing member, and an arrangement portion where the work target plate material is arranged between the support member and the pressing member, and a cutting operation mechanism that cuts the work target plate material by relatively moving the support member and the pressing member in a direction approaching each other. The support member has a first support portion and a second support portion arranged apart from the first support portion, and the first support portion and the second support portion have a height difference such that the second support portion is lower than the first support portion.

Effect of the Invention

[0016] The present invention exhibits an effect of being able to suppress the occurrence of chipping in the plate-shaped member.

Brief Description of the Drawings

[0017] [Figure 1] FIG. 1 is a plan view showing a work target plate material in an embodiment. [Figure 2] FIG. ② is a schematic cross-sectional view showing a manufacturing apparatus for a plate-shaped member. [Figure 3] FIG. 3 is a schematic cross-sectional view for explaining the operation of the manufacturing apparatus for a plate-shaped member. [Figure 4] FIG. 4 is a schematic cross-sectional view for explaining the operation of the manufacturing apparatus for a plate-shaped member.

Embodiments for Carrying Out the Invention

[0018] Hereinafter, an embodiment of a method for manufacturing a plate-shaped member and a manufacturing apparatus for a plate-shaped member will be described with reference to the drawings. In the drawings, for convenience of explanation, a part of the configuration may be shown exaggerated or simplified. Also, the dimensional ratios of each part may be different from the actual ones.

[0019] <Plate-shaped member> It should be noted that in the translation of "図2", it is translated as "FIG. ②" here as per your request. In a more standard translation, it should be "FIG. 2".As shown in FIG. 1, the plate-like member W is obtained by cutting the workpiece plate material P. The shape of the plate-like member W is, for example, rectangular in plan view. The plate-like member W is, for example, composed of a brittle material. Examples of the plate-like member W include a glass plate, a ceramic plate, a plate-like semiconductor element, a plate-like wavelength conversion member, and the like. As an example of the plate-like member W, the wavelength conversion member will be described.

[0020] The wavelength conversion member is a member having wavelength conversion properties. Examples of the member having wavelength conversion properties include those having an inorganic matrix and phosphor particles dispersed in the inorganic matrix, a phosphor single crystal composed only of a phosphor, and those in which the inorganic matrix itself has wavelength conversion properties. Here, the phosphor particles emit fluorescence upon incidence of excitation light. Therefore, when excitation light is incident on the wavelength conversion member, combined light of the excitation light and the fluorescence is emitted from the wavelength conversion member.

[0021] Examples of the phosphor particles include oxide phosphors, nitride phosphors, oxynitride phosphors, chloride phosphors, oxychloride phosphors, sulfide phosphors, oxysulfide phosphors, halide phosphors, chalcogenide phosphors, aluminate phosphors, halophosphate phosphors, garnet-based compound phosphors, and the like. One kind or two or more kinds of phosphor particles can be used. When blue light is used as the excitation light, for example, a phosphor that emits green light, yellow light, or red light as fluorescence can be used.

[0022] The average particle diameter of the phosphor particles is preferably 1 μm to 50 μm, and more preferably 5 μm to 30 μm. By increasing the average particle diameter of the phosphor particles, it becomes possible to increase the emission intensity. On the other hand, by decreasing the average particle diameter of the phosphor particles, it becomes possible to improve the uniformity of the emission color.

[0023] The phosphor particle content in the wavelength conversion member is preferably 1 volume% or more, more preferably 1.5 volume% or more, and even more preferably 2 volume% or more. Increasing the phosphor particle content makes it possible to reduce the thickness dimension of the wavelength conversion member required to obtain the desired emission color. This suppresses internal scattering within the wavelength conversion member, thereby improving the light extraction efficiency.

[0024] The phosphor particle content in the wavelength conversion member is preferably 70% by volume or less, more preferably 50% by volume or less, and even more preferably 30% by volume or less. By reducing the phosphor particle content, it becomes possible to increase the thickness dimension of the wavelength conversion member in order to obtain the desired emission color. This makes it easier to ensure the mechanical strength of the wavelength conversion member.

[0025] Examples of inorganic matrices include glass. Examples of glass include borosilicate glass, phosphate glass, tin phosphate glass, and bismuthate glass. An example of borosilicate glass is a glass containing, by mass%, SiO2: 30-85%, Al2O3: 0-30%, B2O3: 0-50%, Li2O+Na2O+K2O: 0-10%, and MgO+CaO+SrO+BaO: 0-50%. An example of tin phosphate glass is a glass containing, by molar%, SnO: 30-90% and P2O5: 1-70%.

[0026] <Manufacturing equipment for plate-shaped components> As shown in Figure 2, the plate-shaped member manufacturing apparatus 11 includes a placement section 12 where the plate material P to be processed is placed, and a cutting operation mechanism 13 for cutting the plate material P to be processed. The plate-shaped member manufacturing apparatus 11 of this embodiment includes a moving mechanism 14 for moving the plate material P to be processed in a direction along the X-axis in Figure 2. The plate-shaped member manufacturing apparatus 11 manufactures a plate-shaped member W by cutting the plate material P to be processed.

[0027] The arrangement section 12 of the plate-shaped member manufacturing apparatus 11 includes a support member 15 and a pressing member 16. The support member 15 has a first support section 17 and a second support section 18 positioned spaced apart from the first support section 17. The second support section 18 is lower than the first support section 17, resulting in a height difference between the two sections.

[0028] When the distance between the first support portion 17 and the second support portion 18 is G, and the height difference between the first support portion 17 and the second support portion 18 is ΔH, the ratio expressed as ΔH / G is preferably in the range of 0.01 or more and 1 or less. By increasing the ratio expressed as ΔH / G, it is possible to suppress the sudden application of force to the plate material P to be processed. In addition, since the impact when the plate material P to be processed is cut can be reduced, the displacement of the posture of at least one of the plate material P and the plate-like member W after cutting can be suppressed. By decreasing the ratio expressed as ΔH / G, it is possible to cut the plate material P to be processed smoothly. From the viewpoint of further improving the shape quality of the plate-like member W, the ratio expressed as ΔH / G is more preferably 0.5 or less, even more preferably 0.4 or less, and particularly preferably 0.3 or less.

[0029] The distance G between the first support portion 17 and the second support portion 18 is not limited, as it can be changed according to the required plate-like member W. For example, the distance G between the first support portion 17 and the second support portion 18 can be 0.5 mm or more, 0.6 mm or more, or 0.8 mm or more. For example, the distance G between the first support portion 17 and the second support portion 18 can be 5 mm or less, 4 mm or less, 3 mm or less, or 2 mm or less.

[0030] The first support portion 17 is a first support surface that supports the sheet material P to be processed. The second support portion 18 is a second support surface that supports the sheet material P to be processed. The support member 15 is fixed to the base B.

[0031] The pressing member 16 has a blade at its tip. The blade of the pressing member 16 has a shape that extends linearly along the main surface of the plate material P to be processed. In a plan view, the blade of the pressing member 16 is located between the first support part 17 and the second support part 18, and is arranged to extend along the Y axis in Figure 2.

[0032] The splitting mechanism 13 of the plate-shaped member manufacturing apparatus 11 splits the plate material P to be processed by moving the support member 15 and the pressing member 16 relative to each other in a direction toward each other. In this embodiment, the splitting mechanism 13 moves the pressing member 16 toward the support member 15. The splitting mechanism 13 can be configured as a linear motion mechanism.

[0033] The moving mechanism 14 of the plate-shaped member manufacturing apparatus 11 moves the plate material P to be processed toward the first support portion 17 of the support member 15 in order to sequentially cut the plate material P to be processed. The moving mechanism 14 can be composed of, for example, a support portion that supports the plate material P to be processed and a linear motion mechanism.

[0034] <Method for manufacturing plate-shaped members> The method for manufacturing the plate-shaped member W is to manufacture the plate-shaped member W by cutting a plate material P to be processed. The method for manufacturing the plate-shaped member W comprises an arrangement step and a cutting step.

[0035] As shown in Figures 1 and 2, the sheet material P to be processed has a first main surface PA and a second main surface PB opposite to the first main surface PA. The first main surface PA of the sheet material P has a first direction scribe line L1 extending along a first direction and a second direction scribe line L2 extending along a second direction intersecting the first direction. In this embodiment, both the first direction scribe line L1 and the second direction scribe line L2 are present on the first main surface PA of the sheet material P to be processed, but this is not limited to this. For example, the first direction scribe line L1 may be formed on the second main surface PB of the sheet material P to be processed, then the sheet material P may be inverted, and then the second direction scribe line L2 may be formed.

[0036] The first direction of the first direction scribe line L1 is along the X-axis in Figures 1 and 2. Multiple first direction scribe lines L1 are arranged adjacent to each other along the Y-axis, which is perpendicular to the X-axis. The second direction of the second direction scribe line L2 is along the Y-axis. Multiple second direction scribe lines L2 are arranged adjacent to each other along the X-axis. The direction perpendicular to the X-axis and Y-axis is the Z-axis direction. The first main surface PA and the second main surface PB of the workpiece P are planes perpendicular to the Z-axis.

[0037] The first directional scribe line L1 and the second directional scribe line L2 can be formed, for example, by a tool such as a wheel, or by laser light. The depth dimensions of the first direction scribe line L1 and the second direction scribe line L2 are preferably 0.1 or more, and more preferably 0.5 or more, when the thickness dimension of the plate material P to be processed is 100. The depth dimensions of the first direction scribe line L1 and the second direction scribe line L2 are preferably 10 or less, and more preferably 5 or less, when the thickness dimension of the plate material P to be processed is 100.

[0038] The width dimensions of the first direction scribe line L1 and the second direction scribe line L2 are preferably 0.001 mm or more, and more preferably 0.002 mm or more. The width dimensions of the first direction scribe line L1 and the second direction scribe line L2 are preferably 0.010 mm or less, and more preferably 0.005 mm or less.

[0039] As shown in Figure 2, a first protective film F1 and a second protective film F2 are attached to the first main surface PA and the second main surface PB of the sheet material P to be processed, respectively. The first protective film F1 is attached so as to cover part or all of the first main surface PA of the sheet material P to be processed. Preferably, the first protective film F1 is attached so as to cover the entire first main surface PA of the sheet material P to be processed.

[0040] The second protective film F2 is attached so as to cover part or all of the second main surface PB of the sheet material P to be processed. Preferably, the second protective film F2 is attached so as to cover part or all of the second main surface PB of the sheet material P to be processed.

[0041] The first protective film F1 and the second protective film F2 can be made of adhesive resin films. Examples of adhesive films include laminated films having a non-adhesive base layer and an adhesive layer laminated on the base layer, and self-adhesive films.

[0042] The thickness dimensions of the first protective film F1 and the second protective film F2 are preferably in the range of 0.01 to 1 mm, and more preferably in the range of 0.05 to 0.5 mm.

[0043] Next, the arrangement and cutting steps in the manufacturing method of the plate-shaped member W will be described. Here, we will describe the case in which a plate material P to be processed, which has been pre-cut along a first direction scribe line L1, is cut along multiple second direction scribe lines L2.

[0044] As shown in Figure 2, in the manufacturing method of the plate-shaped member W, the arrangement step involves arranging the plate material P to be processed between the support member 15 and the pressing member 16 such that the first main surface PA of the plate material P to be processed faces the support member 15. In the arrangement step, the plate material P to be processed is arranged so that the second direction scribe line L2 runs along the first support portion 17 and the second support portion 18. That is, in the arrangement step, the plate material P to be processed is arranged so that the second direction scribe line L2 extends along the Y axis.

[0045] The plate material P to be processed, arranged in this manner, has a first plate portion P1 and a second plate portion P2. The first plate portion P1 is the portion located on the first support portion 17 side of the support member 15 relative to the second direction scribe line L2. The second plate portion P2 is the portion located on the second support portion 18 side of the support member 15 relative to the second direction scribe line L2. In the arrangement process, the length dimension A1 of the first plate portion P1 of the plate material P to be processed is set to be smaller than the length dimension A2 of the second plate portion P2. Length dimensions A1 and A2 are dimensions along the X axis in Figure 2.

[0046] As shown in Figure 3, in the cutting step of the manufacturing method for the plate-shaped member W, the support member 15 and the pressing member 16 are moved relative to each other so that an external force is applied to the plate material P to be processed by the pressing member 16. In this embodiment, the pressing member 16 is moved toward the plate material P to be processed as shown by the dashed line in Figure 3. As a result, the plate material P to be processed is deformed until it is supported by the second support part 18, as shown by the dashed line in Figure 3. By applying further external force to the plate material P to be processed supported by the second support part 18 in this way, the plate material P to be processed can be cut along the second direction scribe line L2. In this way, the first plate-shaped member W1 is obtained.

[0047] In this embodiment, a second protective film F2 is laminated onto the sheet material P to be processed. Therefore, in this embodiment, the pressing member 16 is pressed against the sheet material P to be processed via the second protective film F2. Also in this embodiment, a first protective film F1 is laminated onto the sheet material P to be processed. Therefore, the sheet material P to be processed is supported by the first support portion 17 and the second support portion 18 via the first protective film F1.

[0048] Here, as shown in Figure 2, the second directional scribe line L2 of the sheet material P to be processed includes the first scribe line L21 and the second scribe line L22 adjacent to the first scribe line L21. The arrangement step for arranging the sheet material P to be processed includes a first arrangement step and a second arrangement step. The cutting step for cutting the sheet material P to be processed includes a first cutting step and a second cutting step.

[0049] In the first positioning step, the sheet material P to be processed is positioned so that the first scribe line L21 lies between the first support part 17 and the second support part 18. As shown in Figure 3, in the first cutting step, the sheet material P to be processed is cut along the first scribe line L21. As shown in Figure 4, in the second positioning step, the sheet material P to be processed is positioned so that the second scribe line L22 lies between the first support part 17 and the second support part 18. In the second cutting step, the sheet material P to be processed is cut along the second scribe line L22.

[0050] As shown in Figures 2 and 3, the manufacturing method for the plate-shaped member W involves sequentially performing a first arrangement step and a first cutting step. This yields a first plate-shaped member W1, and the workpiece P has an end Pa formed along the first scribe line L21. After the first cutting step, in the second arrangement step, as shown in Figure 4, the end Pa of the workpiece P formed in the first cutting step is moved towards the first support part 17. In the second arrangement step of this embodiment, the end Pa of the workpiece P formed in the first cutting step is placed on the first support surface which serves as the first support part 17. After the second arrangement step, the second cutting step is performed to obtain a second plate-shaped member.

[0051] Furthermore, by repeating the arrangement process and the cutting process in accordance with the scribe lines formed on the plate material P to be processed, plate-shaped members W can be obtained sequentially. When the thickness of the sheet material P to be processed is T, and the height difference between the first support part 17 and the second support part 18 is ΔH, the ratio expressed as ΔH / T is preferably in the range of 0.05 or more and 5 or less. Increasing the ratio expressed as ΔH / T makes it possible to suppress the sudden application of force to the sheet material P to be processed. Decreasing the ratio expressed as ΔH / T makes it possible to cut the sheet material P to be processed smoothly. From the viewpoint of further improving the shape quality of the plate-like member W, the ratio expressed as ΔH / T is more preferably 3.5 or less, even more preferably 3 or less, and particularly preferably 2 or less.

[0052] The thickness of the sheet material P to be processed is not limited. For example, the thickness of the sheet material P can be 0.1 mm or more, 0.12 mm or more, or 0.14 mm or more. For example, the thickness of the sheet material P can be 0.5 mm or less, 0.4 mm or less, 0.3 mm or less, 0.28 mm or less, or 0.25 mm or less.

[0053] The height difference (ΔH) between the first support portion 17 and the second support portion 18 is preferably 0.05 mm or more, more preferably 0.08 mm or more. From the viewpoint of further improving the shape quality of the plate-shaped member W, the height difference (ΔH) between the first support portion 17 and the second support portion 18 is preferably 0.50 mm or less, more preferably 0.40 mm or less, and particularly preferably 0.30 mm or less.

[0054] As shown in Figure 4, the external dimension Wd of the plate-shaped member W in a plan view is smaller than the external dimension 17d of the first support surface as the first support portion 17. When the thickness dimension of the plate-shaped member W is T and the external dimension of the plate-shaped member W in a plan view is Wd, the ratio expressed as Wd / T is preferably 50 or less, more preferably 25 or less, even more preferably 10 or less, and most preferably 6 or less. The lower limit of the ratio expressed as Wd / T is, for example, 3 or more.

[0055] <Prototype Example> Next, we will describe a prototype example in which a plate-shaped member was fabricated from the workpiece to be processed. (Prototype examples 1-1 to 1-5) In prototype example 1-1, the plate material to be processed was cut along multiple first-direction cut lines by performing the above-described arrangement and cutting processes using the plate-shaped member manufacturing apparatus. Subsequently, the plate material to be processed was cut along multiple second-direction cut lines by performing the above-described arrangement and cutting processes using the plate-shaped member manufacturing apparatus. This resulted in the production of a square plate-shaped member with a side dimension of 0.7 mm and a thickness dimension of 0.15 mm. This plate-shaped member is a wavelength conversion member and contains an inorganic matrix (borosilicate glass, softening point: 850°C) and phosphor particles (YAG phosphor powder) dispersed in the inorganic matrix. The phosphor particle content in the wavelength conversion member is 8.3 volume%.

[0056] In prototype example 1, a support member is used in which the second support is lower than the first support. The height difference (ΔH) between the first and second support is 0.02 mm. The distance (G) between the first and second support is 1 mm.

[0057] Table 1 shows the main conditions. In the “Arrangement of Support Members” column in Table 1, “A” indicates the case where the second support member is lower than the first support member. In prototype examples 1-2 to 1-5, plate-shaped members were fabricated in the same manner as in prototype example 1-1, except that the height difference (ΔH) was changed, as shown in Table 1.

[0058] (Prototype examples 2-1 to 2-4) In prototype example 2-1, a plate-shaped member was fabricated in the same manner as in prototype example 1-1, except that the first and second support parts had no height difference. The main conditions are shown in Table 2. In the “Arrangement of Support Members” column in Table 2, “B” indicates the case where there is no height difference between the first and second support parts of the support member, or where the first support part is lower than the second support part.

[0059] In prototype example 2-2, a plate-shaped member was fabricated in the same manner as in prototype example 1-1, except that a support member with a height difference such that the first support part is lower than the second support part was used. The height difference (ΔH) between the first support part and the second support part is 0.02 mm.

[0060] In prototype examples 2-3 and 2-4, plate-like members were fabricated in the same manner as in prototype example 2-2, except that the height difference (ΔH) was changed, as shown in Table 2. (Checking for chipping) In each prototype, 50,000 plate-shaped members were fabricated, and the presence or absence of chipping on the plate-shaped members was observed from the underside (the side connected to the second main surface PB of the plate material P to be processed) using a microscope or camera. This observation was performed by irradiating the plate-shaped members with illumination light using coaxial incident illumination. In this observation, chipping of 20 μm or more extending from the end face to the center of the plate-shaped member was determined to be a chipping defect. The chipping defect rates for each prototype are shown in Tables 1 and 2. In addition, for each prototype, the good product rate, which is the percentage of the total number of prototypes excluding the chipping defect rate, is shown in Tables 1 and 2.

[0061] (Confirming the shape) In each prototype example, the good prototypes that were not judged to have chipping defects out of the 50,000 plate-shaped member prototypes were further checked for shape defects. In the shape check, similar to the chipping check above, the outer edge surface of the plate-shaped member was observed from the lower surface (the surface connected to the second main surface PB of the plate material P to be processed) using a microscope or camera. In this observation, illumination light using coaxial incident illumination was shone onto the plate-shaped member. In this observation, products in which a portion of the outer edge of the lower surface of the plate-shaped member protruded with a protrusion length of 20 μm or more relative to the outer edge of the upper surface (the surface connected to the first main surface PA of the plate material P to be processed) were judged to be of shape grade B. The percentage of shape grade B products in each prototype example is shown in Tables 1 and 2. In addition, in each prototype example, the percentage of grade S products, which is the percentage obtained by excluding the chipping defect rate and the percentage of shape grade B products, with the total number of prototypes set at 100%, is shown in Tables 1 and 2.

[0062] [Table 1]

[0063] [Table 2] It can be seen that the yield rate for prototypes 1-1 to 1-5 is higher than that for prototypes 2-1 to 2-4.

[0064] Furthermore, the S-grade quality rate for prototype examples 1-1 to 1-4 is higher than that of prototype example 1-5. From these results, it can be seen that when ΔH, ΔH / G, and ΔH / T are within a certain range, it is possible to suppress the occurrence of chipping in plate-like members and improve the shape quality of the plate-like members.

[0065] <Operation and Effects of This Embodiment> Next, the operation and effects of this embodiment will be described. (1) The method for manufacturing the plate-shaped member W comprises an arrangement step and a cutting step. The support member 15 used in the arrangement step has a first support portion 17 and a second support portion 18 which is spaced apart from the first support portion 17 and has a lower height difference than the first support portion 17. In the arrangement step, the plate material P to be processed is arranged so that the scribe line runs between the first support portion 17 and the second support portion 18. The plate material P to be processed has a first plate portion P1 which is positioned on the side of the support member 15 towards the first support portion 17 and the second plate portion P2 which is positioned on the side of the support member 15 towards the second support portion 18. The length dimension A1 of the first plate portion P1 is set to be smaller than the length dimension A2 of the second plate portion P2. In the cutting step, the support member 15 and the pressing member 16 are moved relative to each other so that an external force is applied to the plate material P to be processed by the pressing member 16.

[0066] This method is expected to suppress the recoil immediately after cutting the sheet material P on the second main surface PB side of the sheet material P to be processed. As a result, the impact applied to the sheet-like member W can be reduced, and thus the occurrence of chipping in the sheet-like member W can be suppressed.

[0067] (2) In the method for manufacturing the plate-shaped member W, in the cutting step, the pressing member 16 is moved toward the plate material P to be processed. In this case, for example, the position of the plate material P to be processed can be stabilized by supporting the plate material P to be processed with the first support part 17. By moving the pressing member 16 toward the plate material P to be processed which is positioned in this manner, the cutting step can be performed stably.

[0068] (3) In the method for manufacturing the plate-shaped member W, the arrangement step includes a first arrangement step and a second arrangement step. The cutting step includes a first cutting step and a second cutting step. After the first arrangement step and the first cutting step are performed in order, in the second arrangement step, the end Pa of the plate material P to be processed, formed in the first cutting step, is moved toward the first support part 17. In this case, the second cutting step can be performed smoothly, and the productivity of the plate-shaped member W can be increased.

[0069] (4) In the method for manufacturing the plate-shaped member W, the first support portion 17 is a first support surface that supports the plate material P to be processed. In the second placement step, the end portion Pa of the plate material P to be processed is placed on the first support surface. In this case, it is possible to stabilize the position of the plate material P to be processed. Therefore, it is possible to perform the cutting step stably.

[0070] (5) In the method for manufacturing the plate-shaped member W, the first support portion 17 and the second support portion 18 are the first and second support surfaces that support the plate material P to be processed. In this case, for example, the plate material P to be processed can be stably supported. Therefore, the cutting process can be carried out stably.

[0071] (6) When manufacturing a plate-shaped member W with a relatively small ratio of its external dimensions in plan view to its thickness (Wd / T) using conventional cutting methods, the incidence of chipping tends to increase. The manufacturing method of the plate-shaped member W according to this embodiment is particularly advantageous in terms of improving the yield when manufacturing plate-shaped members with a Wd / T ratio of 6 or less.

[0072] (7) The first main surface PA and the second main surface PB of the plate material P to be processed are fitted with a first protective film F1 and a second protective film F2, respectively. In this case, the first main surface PA and the second main surface PB of the plate material P to be processed can be protected, and both main surfaces of the plate-shaped member W can be protected. In addition, when the plate-shaped member W is cut into individual pieces, it is possible to prevent them from scattering or from colliding with each other and being damaged.

[0073] <Example of changes> The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0074] • The sheet material P to be processed has a first protective film F1 and a second protective film F2 attached to it, but at least one of the first protective film F1 and the second protective film F2 can be omitted.

[0075] In the above embodiment, the first support portion 17 of the support member 15 is composed of a first support surface that supports the plate material P to be processed, but it can also be composed of an axial portion or a projection that supports the plate material P to be processed. That is, the first support portion 17 may be configured to be able to make surface contact with the plate material P to be processed, or it may be configured to make line contact or point contact. The second support portion 18 of the support member 15 may also be configured to be able to make surface contact with the plate material P to be processed, or it may be configured to make line contact or point contact.

[0076] The external dimensions 17d of the first support surface, which serves as the first support portion 17 as shown in Figure 4, can be changed as appropriate. The distance from the end Pa of the plate material P to be processed to the second scribe line L22, i.e., the external dimensions of the plate-shaped member W, can also be changed as appropriate. In such an example of modification, in the second placement step, the end Pa of the plate material P to be processed may not be placed on the first support surface, which serves as the first support portion 17, but rather in a position protruding from the first support surface.

[0077] The number of scribe lines on the sheet material P to be processed may be multiple or one. The sheet material P to be processed may be configured such that the scribe lines divide the sheet material P into two, and a sheet-like member W is obtained by dividing the sheet material P into two through the arrangement step and the cutting step. In other words, the second arrangement step and the second cutting step can be omitted.

[0078] The above arrangement and cutting steps may be applied only to the cutting along the first direction scribe line L1, among the cutting along the first direction scribe line L1 and the cutting along the second direction scribe line L2. However, it is preferable to apply the above arrangement and cutting steps to the cutting of any of the four sides of the plate-shaped member W.

[0079] The scribe lines of the sheet material P to be processed can be appropriately changed according to the outer shape of the sheet-like member W. The scribe lines of the sheet material P to be processed may include, for example, multiple scribe lines that intersect each other at angles other than right angles.

[0080] The support member 15 may be composed of two or more members, or it may be composed of one member. For example, as in the above embodiment, the support member 15 can be composed of multiple support members, including a first support member having a first support portion 17 and a second support member having a second support portion 18. Alternatively, for example, the support member may be composed of a single support member having a first support portion 17, a second support portion 18, and a groove between the first support portion 17 and the second support portion 18.

[0081] In the above cutting process, the pressing member 16 is moved toward the sheet metal P to be processed, but the support member 15 may also be moved toward the sheet metal P to be processed. Alternatively, both the pressing member 16 and the support member 15 may be moved toward the sheet metal P to be processed.

[0082] The manufacturing method for the plate-shaped member W can also be carried out using a manufacturing apparatus other than the plate-shaped member manufacturing apparatus 11 described above. For example, the pressing member 16 may be operated manually in the cutting process. [Explanation of Symbols]

[0083] 11…Manufacturing apparatus for plate-shaped members 12…Arrangement section 13…Cutting operation mechanism 15…Support member 16…Pressing member 17...First support part 17d, Wd… External dimensions 18…Second support part A1, A2... Length dimensions F1...First protective film F2...Second protective film G...interval L2…Second Direction Scribe Line L21...First scribe line L22...Second scribe line P...Sheet material to be processed PA...First main surface PB...Second main surface P1...First panel P2...Second Panel Section Pa...end W...plate-shaped member

Claims

1. A method for manufacturing a plate-shaped member, which involves cutting a workpiece plate having a first main surface and a second main surface opposite to the first main surface, The first main surface of the plate material to be processed has scribe lines, A positioning step of arranging the plate material to be processed between the support member and the pressing member such that the first main surface of the plate material to be processed faces the support member, The process includes a cutting step of cutting the plate material to be processed along the scribe line, The support member comprises a first support portion and a second support portion that is spaced apart from the first support portion and has a lower height difference than the first support portion. In the arrangement step, the plate material to be processed is positioned so that the scribe line runs between the first support and the second support. The plate material to be processed has a first plate portion positioned on the first support portion side of the support member relative to the scribe line, and a second plate portion positioned on the second support portion side of the support member, wherein the length dimension of the first plate portion is set to be smaller than the length dimension of the second plate portion. A method for manufacturing a plate-shaped member, wherein in the cutting step, the support member and the pressing member are moved relative to each other so that an external force is applied to the plate material to be processed by the pressing member.

2. The method for manufacturing a plate-shaped member according to claim 1, wherein at least one of the first support portion and the second support portion is a support surface for supporting the plate material to be processed.

3. The scribe line of the plate material to be processed includes a first scribe line and a second scribe line adjacent to the first scribe line. The arrangement step includes a first arrangement step of arranging the plate material to be processed such that the first scribe line lies between the first support portion and the second support portion, The process includes a second positioning step of positioning the plate material to be processed between the first support portion and the second support portion such that the second scribe line lies along it. The cutting process includes a first cutting step of cutting the sheet material to be processed along the first scribe line, The process includes a second cutting step of cutting the plate material to be processed along the second scribe line, After performing the first arrangement step and the first cutting step in order, The method for manufacturing a plate-shaped member according to claim 1 or 2, wherein in the second arrangement step, the end of the plate material to be processed formed by the first cutting step is moved toward the first support portion.

4. The method for manufacturing a plate-shaped member according to claim 3, wherein the first support portion is a first support surface that supports the plate material to be processed, and in the second arrangement step, the end portion of the plate material to be processed is placed on the first support surface.

5. The method for manufacturing a plate-shaped member according to claim 1 or claim 2, wherein in the cutting step, the pressing member is moved toward the plate material to be processed.

6. The first support portion is a first support surface that supports the plate material to be processed, The method for manufacturing a plate-like member according to claim 1 or claim 2, wherein the external dimensions of the plate-like member in a plan view are smaller than the external dimensions of the first support surface of the first support portion.

7. A method for manufacturing a plate-like member according to claim 1 or claim 2, wherein, when the thickness dimension of the plate-like member is T and the external dimensions of the plate-like member in a plan view are Wd, the ratio expressed as Wd / T is 50 or less.

8. A method for manufacturing a plate-shaped member according to claim 1 or claim 2, wherein a protective film is attached to at least one of the first main surface and the second main surface of the plate material to be processed.

9. A method for manufacturing a plate-shaped member according to claim 1 or claim 2, wherein, when the distance between the first support portion and the second support portion is G, and the height difference between the first support portion and the second support portion is ΔH, the ratio expressed as ΔH / G is in the range of 0.01 or more and 1 or less.

10. The method for manufacturing a plate-shaped member according to claim 1 or 2, wherein, when the thickness of the plate material to be processed is T, and the height difference between the first support portion and the second support portion is ΔH, the ratio expressed as ΔH / T is in the range of 0.05 or more and 5 or less.

11. A manufacturing apparatus for plate-shaped members, which manufactures plate-shaped members by cutting a plate material to be processed, An arrangement section having a support member and a pressing member, wherein the plate material to be processed is placed between the support member and the pressing member, The system includes a cutting mechanism that cuts the plate material to be processed by moving the support member and the pressing member relative to each other in a direction that brings them closer together, The support member has a first support portion and a second support portion that is spaced apart from the first support portion. A manufacturing apparatus for plate-shaped members, wherein the first support portion and the second support portion are at different heights, with the second support portion being lower than the first support portion.

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