Patent Description:
Resin films are used in an extremely wide range of applications such as decorative materials, packaging materials, adhesive films, and optical members because they have excellent mechanical properties such as moldability and corrosion resistance, are lightweight, easy to process, and they can easily be fused with other resin materials.

For example, when producing a thin plate-like laminate such as a semiconductor substrate, a film-like resin layer is laminated on the surface of a substrate. In such a thin plate-like laminate, a predetermined concave/convex shape is transferred and etched onto the resin layer on the thin plate-like substrate, whereby a concave/convex structure corresponding to the concave/convex shape of the resin layer is formed on the surface of the substrate (refer to, for example, <CIT>). In the transfer onto the resin layer of the thin plate-like laminate described above, as illustrated in, for example, <FIG>, a mold <NUM> having a mold surface <NUM> having a concave/convex surface shape is arranged on the resin layer <NUM> side with respect to a workpiece <NUM> having a substrate <NUM> on which a resin layer <NUM> is laminated and the workpiece is pressed via the mold <NUM>, whereby a concave/convex shape <NUM> is formed on the resin layer <NUM>. Note that in the drawing, reference sign <NUM> represents compression means such as a pressing device, and reference sign <NUM> represents a machine base of the compression means <NUM>.

Since such a concave/convex structure on the surface of the substrate exhibits a predetermined functionality, high precision is required. However, since the film-like resin layer of the thin plate-like laminate is extremely thin, it is difficult to stably form a concave/convex shape on the resin layer with high accuracy. In particular, when the projections and concavities on the surface of the substrate are fine, the quality of the processing accuracy has a significant influence on the functionality, and thus, it is necessary that processing accuracy be improved.

Paragraph [<NUM>] of <CIT> discloses a method as specified in the preamble of claim <NUM>. This method adopts an imprint apparatus comprising means for affixing sheets of a thermoplastic material to both sides of a glass sheet, first and second molds in the form of an endless belt, a heater for softening the sheets of the thermoplastic material, and two pairs of rollers. The structure in which the molds are arranged between the two pairs of rollers can be considered a "mold retention structure".

<CIT> and <CIT> disclose a method for the production of a component in which a conveyor introduces molds arranged on both surface sides of a workpiece between compression members.

The present invention is proposed in light of the above circumstances, and provides a method for the production of a thin plate-like laminate having a film-like resin layer in which a concave/convex shape can stably be formed with high accuracy on the film-like resin layer laminated on a thin plate-like substrate.

According to the present invention, the method for the production of a thin plate-like laminate having a film-like resin layer has the features specified in claim <NUM>.

The dependent claims <NUM> to <NUM> define further developments of the present invention.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the method wherein molds are arranged on both surface sides of a workpiece in which a film-like resin composition is laminated on at least one surface of a substrate and the molds are compressed from outer surfaces of the molds to integrally form the substrate and the film-like resin composition, since there are provided the steps of creating a mold retention structure in which the molds, which have been heated to a thermal deformation temperature of the film-like resin composition, are arranged on both surface sides of the workpiece, and introducing the mold retention structure in which the heated molds are arranged between two compression rollers and compressing the outer surfaces of the molds by rotating the compression rollers to integrally thermocompression-bond the film-like resin composition and the substrate to form a thin plate-like laminate having a film-like resin layer, pressure is applied uniformly to the molds to suppress the occurrence of pressure unevenness, whereby a concave/convex shape can be stably formed with high accuracy on the film-like resin layer laminated on the thin plate-like substrate.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claim <NUM>, the step of creating the mold retention structure comprises a setting step wherein a mold retention structure in which the molds are arranged on both surface sides of the workpiece is created, and a heating step wherein entireties of the molds, after creation of the mold retention structure, are heated to the thermal deformation temperature of the film-like resin composition, which is economically advantageous because excessive heating of the molds is not necessary.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claim <NUM>, since the step of creating the mold retention structure comprises a heating step wherein the molds are heated to the thermal deformation temperature of the film-like resin composition, and a setting step wherein a mold retention structure in which the molds, which were heated in the heating step, are arranged on both side surfaces of the workpiece, is created, it is possible to heat to a high temperature in a short time, whereby operation time can be shortened, and oxidation of the film-like resin composition of the workpiece due to heating is suppressed, which enables high-quality molding.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since there is provided a cooling step wherein the molds compressed by the compression rollers are cooled, the shape of the concave/convex surface of the thin plate-like laminate can be stabilized.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since the substrate is a thin plate-like material having a thickness of <NUM> or less and the thickness of the film-like resin composition is <NUM> or less, lightweight and precise products can be obtained.

According to the method for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since the film-like resin composition is laminated on each surface of the substrate, products with various functionalities can be easily produced.

According to the device for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since a plurality of the workpieces are arranged, and the molds are arranged on both surface sides of each of the workpieces, a plurality of thin plate-like laminates of the same type or different types can be molded at the same time, whereby work efficiency and production efficiency can be improved.

According to the device for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since the film-like resin composition is a decorative, adhesive, or conductive functional resin composition, products which can be used in a very wide range of applications can be provided.

According to the device for the production of a thin plate-like laminate having a film-like resin layer according to claim <NUM>, in the invention of claims <NUM> to <NUM>, since mold surfaces of the molds have fine concave/convex surface shapes, a fine concave/convex shape can stably be formed with high accuracy on the film-like resin layer.

The present invention relates to a method for the production of the thin plate-like laminate (<NUM>) having a film-like resin layer on which a predetermined concave/convex surface shape is formed on a surface thereof shown in <FIG>. The thin plate-like laminate <NUM> is a laminate in which a film-like resin layer <NUM> is laminated on at least one surface of a thin plate-like substrate <NUM>, and the film-like resin layer <NUM> has a predetermined concave/convex shape <NUM>. <FIG> shows a thin plate-like laminate 80A in which the film-like resin layer <NUM> is formed on one surface of the thin plate-like substrate <NUM>, and <FIG> shows a thin plate-like laminate 80B in which the film-like rein layer <NUM> is formed on both surface sides of the thin plate-like substrate <NUM>. In the thin plate-like laminate <NUM>, by forming the predetermined concave/convex shape <NUM> on the surface thereof, various products such as semiconductor substrates, optical members such as optical lenses and optical films, separators for fuel cells, wearable electrodes, sensors, electrostatic adsorbents, resistance heating elements, electromagnetic wave shield materials, connectors, solar cell members, and separators for water electrolysis devices can be produced.

The thin plate-like laminate <NUM>, as shown in <FIG>, can be obtained by forming the predetermined concave/convex shape <NUM> on a surface of a film-like resin composition <NUM> laminated on at least one surface of the thin plate-like substrate <NUM> of a workpiece <NUM> by a predetermined mold <NUM>. In the thin plate-like laminate <NUM>, though the shapes, thickness, etc., of the thin plate-like substrate <NUM> and film-like resin composition <NUM> are determined in accordance with the type of the desired products, for example, the thickness of the thin plate-like substrate <NUM> is <NUM> or less and the thickness of the film-like resin composition <NUM> is <NUM> or less, and more preferably, the thickness of the thin plate-like substrate <NUM> is <NUM> or less and the thickness of the film-like resin composition <NUM> is <NUM> to <NUM>. By setting the thicknesses of the thin plate-like substrate <NUM> and the film-like resin composition <NUM> as described above, lightweight and precise products can be obtained. In particular, when imparting a conductive function, which is described later, suitable conductivity can be provided.

The thin plate-like substrate <NUM> is a thin plate member composed of a material having corrosion resistance and heat resistance such as titanium, aluminum, and stainless steel (SUS).

The film-like resin composition <NUM> is laminated on one or both sides of the thin plate-like substrate <NUM>, a predetermined concave/convex shape <NUM> is formed on the surface thereof, and is constituted as a film-like resin layer <NUM>. Though the shape, size, etc., of the concave/convex shape <NUM> of the film-like resin layer <NUM> are determined in accordance with the application of the thin plate-like laminate <NUM> or the like, fine protrusions and concavities may be formed thereon. Regarding the fine protrusions and concavities, for example, a groove depth (H) thereof is <NUM> to <NUM>, a groove upper surface width (W1) thereof is <NUM> to <NUM>, and a groove inner surface width (W2) thereof is <NUM> to <NUM>.

Examples of the material constituting the film-like resin composition <NUM> include ethylene homopolymers, propylene homopolymers (homopolypropylene), random copolymers of ethylene and one or two or more α-olefins such as propylene, <NUM>-butene, <NUM>-pentene, <NUM>-hexene, <NUM>-methyl-<NUM>-pentene, and block copolymers of the above components. Additionally, the examples of the material may include polyolefin resins such as the mixtures of the polymers described above, polyolefin elastomers, acid-modified polypropylene, acid-modified polyethylene, ethylene/vinyl alcohol copolymer resins, and hydrocarbon resins. Additional examples include fluororesins and fluororubbers. Furthermore, at least one type of conductive material such as a carbon material or a conductive ceramic may be added to these materials. Examples of the carbon material include carbon nanotubes, granular graphite, and carbon fibers.

The film-like resin composition <NUM> is constituted as a decorative, adhesive, or conductive functional resin composition depending on the desired product to be produced. Decorative functional resin compositions are resin layers in which fine protrusions and concavities are subjected to surface treatment such as wrinkling (wrinkle pattern), embossing (embossed pattern), or reflective processing (matte tone). Adhesive functional resin compositions are resin layers having high adhesive strength composed of a polyethylene resin. Conductive functional resin compositions are energizable resin layers in which a carbon material is added to the resin material. By providing these functional resin compositions, the thin plate-like laminate <NUM> can be used in an extremely wide range of applications.

The mold <NUM> is a member which is arranged on both surface sides of the substrate <NUM> of the workpiece <NUM> and which holds the workpiece <NUM>, and comprises a lower mold <NUM> on which the workpiece <NUM> is placed and an upper mold <NUM> which is arranged above the workpiece <NUM>. In the mold <NUM>, predetermined concave/convex surface shapes <NUM>, <NUM> are formed in the mold surfaces <NUM>, <NUM> of one or both of the lower mold <NUM> and the upper mold <NUM>. In the illustrated example, the concave/convex surface shapes <NUM>, <NUM> are formed on the mold surfaces <NUM>, <NUM>. By imparting the concave/convex surface shape <NUM> (<NUM>) of the mold surface <NUM> (<NUM>) with a particularly fine concave/convex surface shape, a fine concave/convex shape can be stably formed with high accuracy on the film-like resin layer. The concave/convex surface shapes <NUM>, <NUM> of the lower mold <NUM> and the upper mold <NUM> may be the same or may be different. Furthermore, as shown in <FIG>, interleaving paper (release paper) <NUM> for facilitating release of the molded workpiece (thin plate-like laminate <NUM>) may be interposed between the mold surfaces <NUM>, <NUM> of the mold <NUM> and the workpiece <NUM> as needed. Note that in <FIG>, interleaving paper has been omitted.

The method for the production of a thin plate-like laminate of the present invention comprises a mold retention structure creation step, a compression step, and an extraction step, and if necessary, a cooling step is performed. The method for the production of a thin plate-like laminate can be carried out using, for example, the device <NUM> for the production of a thin plate-like laminate shown in <FIG>. The device <NUM> for the production of a thin plate-like laminate comprises a setting part <NUM> having a setting device <NUM>, a heating part <NUM> having a heating device <NUM>, a pressurization part <NUM> having a compression roller device <NUM>, and an extraction part <NUM> having an extraction device <NUM>. The method for the production of a thin plate-like laminate of the present invention will be described below along with the device <NUM> for the production of a thin plate-like laminate.

The illustrated production device <NUM> comprises a machine base <NUM> which connects the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> by means of a rail part <NUM>. The rail part <NUM> has a rail body <NUM> composed of a pair of rod-shaped members located between the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM>, and connects the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> in series. The rail body <NUM> is installed so as to be capable of moving the mold <NUM> between the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> by means of the mold retention structure <NUM>. Reference sign <NUM> in the drawing indicates legs of the machine base <NUM> which support the rail part <NUM>.

The mold retention structure <NUM> is not particularly limited as long as it is capable of moving the mold <NUM> between the parts <NUM>, <NUM>, <NUM>, and <NUM> while holding the workpiece <NUM>. For example, an appropriate structure such as a structure having clip members or the like for holding the lower mold <NUM> and the upper mold <NUM> can be adopted.

The mold retention structure <NUM> shown in <FIG> is an example of a frame-like structure which retains the mold <NUM> in which the workpiece <NUM> is held, and moves between the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> along the rail body <NUM>. The mold retention structure <NUM> comprises a retention body <NUM> which has a lower opening <NUM>, which is placed on the rail body <NUM>, and which is capable of sliding, and a pair of mold retention parts <NUM>, <NUM> which retain the lower mold <NUM> of the mold <NUM>. Furthermore, in the mold <NUM> which is retained by the mold retention structure <NUM>, mating protrusions <NUM> are provided at a plurality of positions of the lower mold <NUM>, and a plurality of mating holes <NUM> corresponding to the mating protrusions <NUM> of the lower mold <NUM> are provided on the upper mold <NUM>, and by mating the mating protrusions <NUM> of the lower mold <NUM> with corresponding mating holes <NUM> of the upper mold <NUM>, the upper mold <NUM> is overlaid on the lower mold <NUM> at an appropriate position.

<FIG> is a schematic plan view showing variations of the mold retention structure <NUM> and the mold <NUM>. <FIG> is an example of a mold retention structure 100A in which a mold 110A for processing a single workpiece <NUM> is retained. The mold retention structure 100A comprises a frame-shaped retention body 101A composed of a pair of side edges <NUM>, <NUM> which are slidably placed on the rail body <NUM> and edge parts <NUM>, <NUM> that extend between both ends of the side edges <NUM>, <NUM>, and a pair of mold retention parts 105A, 105A extending between the edge parts <NUM>, <NUM>, and the mold 110A (lower mold <NUM>) is affixed between the mold retention parts 105A, 105A by means of fixation members (not illustrated) such as screw members.

<FIG> is an example of a mold retention structure 100B in which a mold 110B for processing of a plurality of workpieces <NUM> are retained by the same mold surface. In the mold retention structure 100B, the 110B, which is a rectangular mold in a plan view, is arranged between the edge parts <NUM>, <NUM> of the retention body 101A, and the edge parts <NUM>, <NUM> are affixed by affixation members (not illustrated) such as screw members as mold retention parts <NUM>, <NUM>.

<FIG> is an example of a mold retention structure 100C in which a mold 110C for processing a comparatively-large workpiece <NUM> is retained. In the mold retention structure 100C, the mold 110C corresponding to the size of the entirety of the lower opening <NUM> is arranged in the lower opening <NUM> of the retention body 101A, and the side edges <NUM>, <NUM> and the edge parts <NUM>, <NUM> of the retention body 101A are affixed by means of affixation members (not illustrated) such as screw members as mold retention parts <NUM>, <NUM>, <NUM>, <NUM>.

The frame-like structure of the mold retention structure is not limited to only the structures 100A to 100C described above, and an appropriate structure can be adopted in accordance with the number and size of workpieces <NUM>, the shape of the mold, etc. For example, a structure in which a recess which can mate with the mold is provided in the mold retention part of the mold retention structure so that the mold can be retained at a predetermined position, or a structure in which an appropriate mold positioning member is provided can be adopted. Furthermore, a movement device which is capable of moving on the rail body <NUM> may be separately prepared, and a mold retention structure may be installed on the movement device to enable movement.

The setting part <NUM> comprises a setting device <NUM> which creates the mold retention structure <NUM> in which the mold <NUM> is set. As the setting device <NUM>, a known transport means such as a robot arm by which the retention body <NUM>, the mold <NUM>, and the workpiece <NUM> can be appropriately installed can suitably be used. In the setting device <NUM> of the Examples, transportation of the retention body <NUM>, the mold <NUM>, and the workpiece <NUM> between a work table and the rail part <NUM> is performed, and creation of the mold retention structure <NUM> is performed.

The heating part <NUM> comprises a heating device <NUM> which heats the mold <NUM> to the thermal deformation temperature of the film-like resin composition <NUM>. The heating device <NUM> is not particularly limited as long as it is capable of efficiently heating the mold <NUM>. The heating device <NUM> of the Examples comprises hot plates <NUM>, <NUM> which are capable of being raised and lowered and which are arranged above and below the rail body <NUM>, and the heating device <NUM> is configured so as to hold and heat the mold <NUM> by means of the upper hot plate <NUM> and the lower hot plate <NUM>.

The thermal deformation temperature is a sufficient temperature at which the film-like resin composition <NUM> of the workpiece <NUM> held by the mold <NUM> can be thermally deformed and appropriately processed, and is appropriately set in accordance with the type of the film-like resin composition <NUM>. For example, the mold <NUM> is heated to a temperature higher than the melting point of the film-like resin composition <NUM> by <NUM> or more. Note that the upper limit thereof is not particularly limited, but since there is a risk that the film-like resin composition <NUM> of the workpiece <NUM> may react with oxygen in the atmosphere and oxidize and deteriorate due to excessive heating, the temperature may be set such that the film-like resin composition <NUM> is less likely to undergo oxidative deterioration due to heat.

The heating of the mold <NUM> by the heating device <NUM> may be performed on the mold <NUM> in a state in which the workpiece <NUM> is held thereby, or may be performed on the mold <NUM> in a state in which the workpiece <NUM> is not held thereby. When the mold <NUM>, which holds the workpiece <NUM>, is heated, excessive heating of the mold <NUM> is unnecessary, which is economically advantageous. Furthermore, when heating the mold <NUM>, which is not holding the workpiece <NUM>, since only the mold <NUM> is heated, it can be heated to a high temperature in a short time to shorten the operation time, and oxidation of the film-like resin composition <NUM> of the workpiece <NUM> due to the heating is suppressed, which enables high-quality molding.

The pressurization part <NUM>, as shown in <FIG> and <FIG>, comprises a compression roller device <NUM> which compresses the outer surfaces of the heated mold <NUM> to form the thin plate-like laminate <NUM>. The compression roller device <NUM> comprises a lower compression roller <NUM> which is arranged so as to be capable of rotating in a position in which it abuts the lower surface side of the mold <NUM>, an upper compression roller <NUM> which is arranged in a position directly above the lower compression roller <NUM> and so as to be capable of rotating on the upper side of the mold retention structure <NUM>, and a pressurization part lifting means <NUM> comprising a pressure cylinder or the like which raises and lowers the upper compression roller <NUM>. Furthermore, though not illustrated, the compression roller device <NUM> comprises a temperature adjusting means for adjusting the temperature of one or both of the lower compression roller <NUM> and the upper compression roller <NUM>. In the drawings, reference sign <NUM> represents a lower rotational drive device which rotationally-drives the lower compression roller <NUM>, reference sign <NUM> represents an upper rotational drive device which rotationally-drives the upper compression roller <NUM>, and reference sign <NUM> represents a rod part of the pressurization part lifting means <NUM>.

In the compression roller device <NUM>, as shown in <FIG>, the mold retention structure <NUM>, after heating of the mold <NUM>, is introduced between the two compression rollers, and the outer surfaces of the mold <NUM> are compressed by rotating the compression rollers to integrally thermocompression-bond the film-like resin composition <NUM> and the substrate <NUM> to form the thin plate-like laminate <NUM> having the film-like resin layer <NUM>. The compression roller device <NUM> of the Examples has a drive control device (not illustrated) which controls the rotation of the lower compression roller <NUM> and the upper compression roller <NUM>, and when the mold <NUM> is compressed, the rotation of the two compression rollers <NUM>, <NUM> and the shaking of the mold retention structure <NUM> are controlled so as to be synchronized.

The extraction part <NUM> comprises an extraction device <NUM> which extracts the mold <NUM> or workpiece <NUM> from the mold retention structure <NUM> after compression. As the extraction device <NUM>, a known transport means such as a robot arm is suitably used, and the extraction device <NUM> transports the mold retention structure <NUM>, the mold <NUM>, or the workpiece <NUM> between the work table on which the mold, etc., after processing are placed and the rail part <NUM>, and extracts the mold <NUM> or workpiece <NUM> from the mold retention structure <NUM>.

In the device <NUM> for the production of a thin plate-like laminate of the present invention, when the cooling step is performed in the production method of the present invention, a cooling part <NUM> may be arranged on the machine base <NUM>. The cooling part <NUM> comprises a cooling device <NUM> which cools the mold <NUM> compressed by the compression roller device <NUM>. The cooling device <NUM> is not particularly limited as long as it is capable of cooling the thin plate-like laminate <NUM> via the mold <NUM>. For example, the cooling device <NUM> shown in <FIG> comprises cooling plates <NUM>, <NUM> which are capable of being raised and lowered and which are arranged above and below the rail body <NUM>, and the cooling device <NUM> is configured so as to hold and cool the mold <NUM> retained in the mold retention structure <NUM> by means of the upper cooling plate <NUM> and the lower cooling plate <NUM>. By cooling the mold after compression in the cooling part <NUM>, the shape of the concave/convex surface of the thin plate-like laminate <NUM> can be stabilized.

Next, the method for the production of a thin plate-like laminate of the present invention using the device <NUM> for the production of a thin plate-like laminate described above will be specifically described.

The mold retention structure creation step is a step of creating a mold retention structure in which the molds <NUM> heated to the thermal deformation temperature of the film-like resin composition <NUM> are arranged on both sides of the workpiece <NUM>. This mold retention structure creation step is configured such that as shown in, for example, <FIG>, the heating step is performed in the heating part <NUM> after the setting step performed in the setting part <NUM>.

The setting step shown in <FIG> is a step in which, in the setting part <NUM>, using the setting device <NUM> (illustration omitted), the mold retention structure <NUM> in which the molds <NUM> are arranged on both surface sides of the workpiece <NUM> is created (setting step prior to heating). In the setting step, processes such as transporting the mold retention structure <NUM> onto the rail body <NUM> of the rail part <NUM> by the setting device <NUM>, such as a robot arm, transporting the lower mold <NUM> and the upper mold <NUM> of mold <NUM> to the mold retention structure <NUM> and retaining them therein, and transporting the workpiece <NUM> to the mold are performed. In the Examples, the lower mold <NUM> of the mold <NUM> is retained in advance in the retention body <NUM> of the mold retention structure <NUM>, and after the workpiece <NUM> is placed on the lower mold <NUM>, the mold retention structure <NUM> retaining the lower mold <NUM> is transported onto the rail body <NUM>, and thereafter setting processing in which the upper mold <NUM> is overlaid on the lower mold <NUM> is performed.

The heating step shown in <FIG> is a step in which, in the heating part <NUM>, using the heating device <NUM>, the entirety of the mold <NUM> after creation of the mold retention structure <NUM> is heated to the thermal deformation temperature of the film-like resin composition <NUM> (heating step after setting). In the heating step, a process in which the lower mold <NUM> and the upper mold <NUM> of the mold <NUM> are heated by the heating device <NUM>, and the workpiece <NUM> held in the mold <NUM> is heated to the thermal deformation temperature is performed on the mold retention structure <NUM>, which has moved from the setting part <NUM> to the heating part <NUM>. As a result, in the compression step, which is described later, suitable processing of the workpiece <NUM> is enabled. In the Examples, there is performed a process in which the upper and lower hot plates <NUM>, <NUM> of the heating device <NUM> are lowered and raised, respectively, and the mold <NUM> retained in the mold retention structure <NUM> on the rail body <NUM> is heated while being interposed by the hot plates <NUM>, <NUM>. Note that the heating temperature is determined in accordance with the material of the film-like resin composition of the workpiece.

As described above, in the mold retention structure creation step in which heating of the molds <NUM> is performed after the workpiece <NUM> is held in the molds <NUM> and the mold retention structure <NUM> is set, excessive heating of the mold <NUM> is unnecessary, which is economically advantageous.

Furthermore, the mold retention structure creation step may be configured such that the setting step is performed in the setting part <NUM> after the heating step performed in the heating part <NUM>, as shown in <FIG>, instead of performing the heating step after the setting step.

The heating step shown in <FIG> is a step (heating step prior to setting) in which, in the heating part <NUM>, using the heating device <NUM>, the mold is heated to the thermal deformation temperature of the film-like resin composition <NUM>. In this heating step, a process in which the lower mold <NUM> and the upper mold <NUM> of the mold <NUM> are heated by the heating device <NUM> is performed on the molds <NUM> which are retained in the retention body <NUM> and which do not hold the workpiece <NUM>. As a result, the mold <NUM> can be heated to a high temperature in a short time, and oxidation of the film-like resin composition <NUM> of the workpiece <NUM> by the heating is suppressed, which enables high-quality molding.

The setting step shown in <FIG> is a step (setting step after heating) in which, in the setting part <NUM> using the setting device <NUM> (illustration omitted), the workpiece <NUM> is held in the heated mold <NUM>, and the mold retention structure <NUM> is created. In this setting step, a setting process in which after the upper mold <NUM> of the mold <NUM> retained in the retention body <NUM> is temporarily removed by the setting device <NUM>, such as a robot arm, the workpiece <NUM> is placed on the lower mold <NUM>, and then the upper mold <NUM> is overlaid on the lower mold <NUM> is performed.

As described above, in the mold retention structure creation step in which the workpiece <NUM> is held in the mold <NUM> and the mold retention structure <NUM> is set after the mold <NUM> is heated, since only the mold <NUM> is heated, it can be heated to a high temperature in a short time, which reduced operation time, and oxidation of the film-like resin composition <NUM> of the workpiece <NUM> by the heating is suppressed, which enables high-quality molding.

The compression step is a step in which, in the pressurization part <NUM> as shown in <FIG>, <FIG>, <FIG>, and <FIG>, the mold retention structure <NUM>, in which the heated mold <NUM> is arranged, is introduced between the two compression rollers <NUM>, <NUM> of the compression roller device <NUM> and the outer surfaces of the mold <NUM> are compressed by rotating the compression rollers <NUM>, <NUM> to integrally thermocompression-bond the film-like resin composition and the substrate to form the thin plate-like laminate <NUM> having the film-like resin layer <NUM>. In the compression step, a process in which the entirety of the workpiece <NUM> held in the mold <NUM> is roll-pressed while shaking the mold retention structure <NUM> is performed on the heated mold <NUM> of the mold retention structure <NUM>, which has moved from setting part <NUM> or the heating part <NUM> to the pressurization part <NUM>.

In the Examples, regarding the mold <NUM> of the mold retention structure <NUM>, which has moved to the pressurization part <NUM>, as shown in <FIG>, since the upper end of the lower compression roller <NUM> is positioned at the same height as the lower surface of the mold <NUM>, the lower compression roller <NUM> and the lower surface of the mold <NUM> enter a contact state (contact position P1). Next, the upper compression roller <NUM> above the mold retention structure <NUM> is lowered by the pressurization part lifting means <NUM>, the upper compression roller <NUM> is pressed against the upper surface side of the heated mold <NUM> retained in the mold retention structure <NUM>, and the mold <NUM> is compressed by the two compression rollers <NUM>, <NUM> (refer to <FIG>). In the compression by the two compression rollers <NUM>, <NUM>, as shown in <FIG>, the upper compression roller <NUM> contacts (P2) and presses the mold <NUM> at a position directly above the contact position P1 between the lower compression roller <NUM> and the mold <NUM>. Thus, the mold <NUM> is subjected to the compression force from the two compression rollers <NUM>, <NUM> between the contact position P1 with the lower compression roller <NUM> and the contact position P2 with the upper compression roller <NUM>.

In processing methods such as transfer molding of the prior art, as shown in <FIG>, since the entirety of the mold <NUM> is pressed by the pressurizing means <NUM> such as a pressing device, a pressing force acts on the mold <NUM> in a two-dimensional (planar) manner. When pressure is applied in a planar manner, the pressure is dispersed so as to act on the entirety of the mold <NUM>, and the pressing force does not always act uniformly on the entire mold <NUM>, which may cause pressure unevenness. Conversely, in compression by the two compression rollers <NUM>, <NUM> shown in <FIG>, a one-dimensional (linear) pressing force between the contact positions P1 and P2 acts on the mold <NUM> retained by the mold retention structure <NUM>. Thus, as compared with the conventional method in which the pressure acts two-dimensionally (planar), the pressure is concentrated and it becomes easier to apply a large pressing force, and moreover, since the pressurized part of the mold <NUM> is limited to the portion between the contact positions P1 and P2, the pressurization acts relatively uniformly and the occurrence of pressure unevenness is suppressed.

When compression by the two compression rollers <NUM>, <NUM> is performed, in a state in which the compression is retained, as shown in <FIG>, the mold retention structure <NUM> is shaken so that the pressurized portion (between the contact positions P1, P2) of the mold <NUM> acts at least on the entirety of the workpiece <NUM> (between positions <NUM>, <NUM> of the ends of the workpiece <NUM>), which is held in the mold <NUM> of the mold retention structure <NUM>. In the shaking of the mold retention structure <NUM>, in accordance with the movement of the mold retention structure <NUM> in one direction (for example, the rearward direction in <FIG>), the two compression rollers <NUM>, <NUM> rotate in the same direction (for example, in <FIG>, the lower compression roller <NUM> rotates in the counterclockwise direction and the upper compression roller <NUM> rotates in the clockwise direction) in a compressing state, and in accordance with the movement of the mold retention structure <NUM> in the other direction (for example, the frontward direction of <FIG>), the two compression rollers <NUM>, <NUM> rotate in the same direction (for example, in <FIG>, the lower compression roller <NUM> rotates in the clockwise direction and the upper compression roller <NUM> rotates in the counterclockwise direction) in a compressing state.

At this time, the shaking of the mold retention structure <NUM> and the rotational driving of the compression rollers <NUM>, <NUM> are controlled so as to be performed synchronously by the drive controller (not illustrated) of the pressurization part <NUM>. In other words, the movement timing (shaking timing) of the mold retention structure <NUM>, the rotational timing of the compression rollers <NUM>, <NUM>, the movement direction (shaking direction) of the mold retention structure <NUM>, the rotational directions of the compression rollers <NUM>, <NUM>, the movement distance (shaking range) of the mold retention structure <NUM>, and the rotation amounts of the compression rollers <NUM>, <NUM> are controlled so as to match. Thus, smooth movement of the mold retention structure <NUM> is enabled in a state in which the predetermined pressure applied on the mold <NUM> from the two compression rollers <NUM>, <NUM> is retained. By shaking the mold retention structure <NUM> in an interposed state in this manner, the compression position (between P1 and P2) by the two compression rollers <NUM>, <NUM> extends over the entire surface of the mold <NUM>, whereby the entire surface of the mold <NUM> can be substantially-uniformly pressurized. The shaking of the mold retention structure <NUM> is performed as many times as necessary, including once (one round trip), depending on the type of the resin layer, the fineness of the concave/convex shape, the target product, etc. Furthermore, the start position and end position of the compression by the two compression rollers <NUM>, <NUM> are appropriately determined in accordance with the size of the workpiece <NUM>, the type of the concave/convex shape, etc. When the shaking of the mold retention structure <NUM> is stopped, the pressurization is completed and the upper compression roller <NUM> is raised to release the interposed state of the mold <NUM>.

In this compression step, if necessary, the temperature of one or both of the lower compression roller <NUM> and the upper compression roller <NUM> may be adjusted by the temperature adjusting means (not illustrated) during the compression by the compression roller device <NUM>. The temperature adjustment by the temperature adjusting means may be any appropriate method such as heating, cooling, and heat retention. For example, in the case of continuously processing a large number of products, if there is a difference in temperature between the mold <NUM> and the compression rollers <NUM>, <NUM>, the temperature of the mold <NUM> may change during compression, whereby it may be difficult to perform appropriate processing. Thus, in this temperature adjustment, the temperature of the mold <NUM> at the time of compression is appropriately maintained by heating or maintaining the temperature when the temperature of the mold <NUM> is low, or by cooling when the temperature is excessively high.

The extraction step is a step in which, in the extraction part <NUM>, using the extraction device <NUM>, the mold <NUM> after compression is extracted from the mold retention structure <NUM>. In the extraction step, a process in which the mold retention structure <NUM> is transported from the rail body <NUM> of the rail part <NUM> by the extraction device <NUM>, such as a robot arm, the lower mold <NUM> and the upper mold <NUM> of the mold <NUM> are extracted from the mold retention structure <NUM>, and the workpiece <NUM> is extracted from the mold <NUM> is performed on the mold retention structure <NUM>, which has moved from the pressurization part <NUM> to the extraction part <NUM>. In the examples, there is performed a process in which the upper mold <NUM> of the mold <NUM> retained in the mold retention structure <NUM> is extracted from the lower mold <NUM>, the mold retention structure <NUM> in which the lower mold <NUM> is retained is transported from the rail body <NUM> to another placement position, such as a work table, and the thin plate-like laminate <NUM> (processed workpiece) placed on the lower mold <NUM> is extracted. By extracting the thin plate-like laminate <NUM> from the mold <NUM>, the production method is completed.

When the above extraction step is performed, the thin plate-like laminate <NUM> immediately after processing is in a state in which it can be easily deformed by the heating of the heating part <NUM>. Thus, before the extraction step is performed, the thin plate-like laminate <NUM> is cooled to a temperature at which inadvertent deformation does not occur. At that time, it is possible to perform slow-cooling, such as allowing the thin plate-like laminate <NUM> to stand for a predetermined time without extracting it from the mold <NUM>, but it is preferable that the device <NUM> for the production of a thin plate-like laminate be provided with a cooling part <NUM> to perform the cooling step.

The cooling step is a step in which, in the cooling part <NUM>, using the cooling device <NUM>, the entirety of the mold <NUM> after compression retained in the mold retention structure <NUM> is cooled. In the cooling step, a process in which the lower mold <NUM> and the upper mold <NUM> of the mold <NUM> are cooled by the cooling device <NUM>, and the processed thin plate-like laminate <NUM> held in the mold <NUM> is cooled to a temperature at which inadvertent deformation does not occur is performed on the mold retention structure <NUM>, which has moved from the pressurization part <NUM> to the cooling part <NUM>. As a result, the shape of the concave/convex surface of the thin plate-like laminate <NUM> is stabilized, and the molding of the thin plate-like laminate <NUM> in the mold <NUM> is complete. In the Examples, there is performed a process in which the upper and lower cooling plates <NUM>, <NUM> of the cooling device <NUM> are lowered and raised, respectively, and the mold <NUM> retained in the mold retention structure <NUM> on the rail body <NUM> is cooled while being interposed by the cooling plates <NUM>, <NUM>. After the cooling step has been performed, the mold retention structure <NUM> is moved from the cooling part <NUM> to the extraction part <NUM> and the extraction step described above is performed. Note that the cooling temperature is lower than the thermal deformation temperature of the film-like resin composition <NUM> by <NUM> or more.

An array combination of the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, the extraction part <NUM>, and the cooling part <NUM> of the device <NUM> for the production of a thin plate-like laminate will be described. <FIG> shows variations (10A to 10D) of the device for the production of a thin plate-like laminate in which after the workpiece is held by the molds in the setting part <NUM> and the mold retention structure is created, the molds holding the workpiece are heated in the heating part <NUM>. Furthermore, <FIG> shows variations (10E to <NUM>) of the device for the production of a thin plate-like laminate in which after the molds which are not holding the workpiece are heated in the heating part <NUM>, the workpiece is held in molds in the setting part <NUM> and the mold retention structure is created.

The device 10A for the production of a thin plate-like laminate shown in <FIG> is an example in which the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> are arranged in series on the rail part <NUM>. In the device 10A for the production of a thin plate-like laminate, the workpiece is transported from the downstream side of the rail part <NUM> (setting part <NUM> side) and processed, and the processed thin plate-like laminate is transported to the upstream side of the rail part <NUM> (extraction part <NUM> side). Thus, the device 10A can be incorporated into the line process of a production line of various products using the thin plate-like laminates, and the thin plate-like laminates extracted by the extraction part <NUM> can be continuously transferred to another processing process.

The device 10B for the production of a thin plate-like laminate shown in <FIG> is an example in which the cooling part <NUM> is provided between the pressurization part <NUM> and the extraction part <NUM>, and the setting part <NUM>, the heating part <NUM>, the pressurization part <NUM>, the cooling part <NUM>, and the extraction part <NUM> are arranged in series in this order on the rail part <NUM>. In the device 10B for the production of a thin plate-like laminate, the shape of the concave/convex surface of the thin plate-like laminate can be stabilized by the cooling part <NUM>, and the device 10B for the production of a thin plate-like laminate can be incorporated into the line process of a production line in the same manner as the production device 10A.

The device 10C for the production of a thin plate-like laminate shown in <FIG> is an example in which the setting part <NUM> and the extraction part <NUM> are shared, and the setting device <NUM> and the extraction device <NUM> are shared, and the setting part <NUM>, which also serves as the extraction part <NUM>, the heating part <NUM>, the pressurization part <NUM>, and the cooling part <NUM> are arranged in series on the rail part <NUM> in this order. In the device 10C for the production of a thin plate-like laminate, since the setting part <NUM> and the extraction part <NUM> are configured so as to be shared, the space for the production device 10C can be reduced, and equipment to be used can be omitted to reduce cost. Furthermore, since the workpiece transported from the setting part <NUM> is processed by the pressurization part <NUM> and then returned to the setting part <NUM> (which also serves as the extraction part <NUM>) and extracted, man-hours during batch work can be reduced and work efficiency can be improved.

The device 10D for the production of a thin plate-like laminate shown in <FIG> is an example in which the setting part <NUM> and the extraction part <NUM> are shared, and the setting device <NUM> and the extraction device <NUM> are shared, and the setting part <NUM>, which also serves as the extraction part <NUM>, the cooling part <NUM>, the heating part <NUM>, and the pressurization part <NUM> are arranged in series on the rail part <NUM> in this order. In the device 10D for the production of a thin plate-like laminate, since the pressurization part <NUM> is arranged on the outermost side of the production device 10D, maintenance operations such as preparation of the compression roller device of the pressurization part <NUM> becomes easy. Like the production device 10C, space can be reduced to reduce cost, and work efficiency can be improved during batch work.

The device 10E for the production of a thin plate-like laminate shown in <FIG> is an example in which the heating part <NUM>, the setting part <NUM>, the pressurization part <NUM>, and the extraction part <NUM> are arranged in series on the rail part <NUM> in this order. In other words, the device 10E for the production of a thin plate-like laminate is configured such that the setting part <NUM> and the heating part <NUM> are reversed as compared to the device 10A for the production of a thin plate-like laminate. Thus, the workpiece is processed while being transported from the downstream side (the heating part <NUM> side) of the rail part <NUM> to the upstream side (the extraction part <NUM> side). Therefore, the device 10E for the production of a thin plate-like laminate can be incorporated into the line process of a production line of various products in the same manner as the production device 10A, and the produced thin plate-like laminates can be continuously transferred to another processing process.

The device 10F for the production of a thin plate-like laminate shown in <FIG> is configured such that the setting part <NUM> and the heating part <NUM> are reversed as compared to the device 10B for the production of a thin plate-like laminate, and is an example in which the heating part <NUM>, the setting part <NUM>, the pressurization part <NUM>, the cooling part <NUM>, and the extraction part <NUM> are arranged in series on the rail part <NUM> in this order. In the device 10F for the production of a thin plate-like laminate, in the same manner as the device 10B for the production of a thin plate-like laminate, the shape of the concave/convex surface of the thin plate-like laminate can be stabilized by the cooling part <NUM>, and the device 10F for the production of a thin plate-like laminate can be incorporated into the line process of a production line.

The device <NUM> for the production of a thin plate-like laminate shown in <FIG> is configured such that the setting part <NUM> and the heating part <NUM> are reversed as compared to the device 10C for the production of a thin plate-like laminate, and is an example in which the heating part <NUM>, the setting part <NUM>, which serves as the extraction part <NUM>, the pressurization part <NUM>, and the cooling part <NUM>, are arranged in series on the rail part <NUM> in this order. In the device <NUM> for the production of a thin plate-like laminate, in the same manner as the device 10C for the production of a thin plate-like laminate, the space for the production device <NUM> can be reduced, equipment to be used can be omitted to reduce the cost, man-hours during batch work can be reduced, and work efficiency can be improved.

The device <NUM> for the production of a thin plate-like laminate shown in <FIG> is an example in which the heating part <NUM>, the setting part <NUM>, which serves as the extraction part <NUM>, the cooling part <NUM>, and the pressurization part <NUM> are arranged in series on the rail part <NUM> in this order. In the device <NUM> for the production of a thin plate-like laminate, maintenance operations such as preparation of the compression roller device of pressurization part <NUM> becomes easy. Furthermore, like the production device <NUM>, space can be reduced to reduce cost, and work efficiency can be improved during batch work.

Next, variations in the relationship between the laminate structure of the workpiece and the mold therefor will be described using <FIG>. <FIG> is an example of a mold structure 150A in which a mold 112A for single-side processing is arranged relative to a workpiece 85A in which a film-like resin composition 84A is laminated on one surface side (the upper surface side in the example of the drawing) of the substrate <NUM>. The mold 112A comprises a lower mold 120A having a mold surface 121A, which is a smooth surface, and an upper mold 125A having a mold surface 126A on which the concave/convex surface shape <NUM> is formed. In the mold structure 150A, the smooth lower mold 120A contacts the second side (the lower surface side) of the substrate <NUM> of the workpiece 85A, the upper mold 125A on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM>, whereby the concave/convex shape can be formed on only the resin composition 84A on the first surface side (upper surface side) of the substrate <NUM>.

<FIG> is an example of a mold structure 150B in which a mold 112A for single-side processing is arranged relative to a workpiece 85B in which film-like resin compositions 84A, 84B are laminated on both surfaces of the substrate <NUM>. In the mold structure 150B, the smooth lower mold 120A contacts the resin composition 84B on the second side (lower surface side) of the substrate <NUM> of the workpiece 85A, and the upper mold 125A on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM>. Thus, the resin composition 84B on the second side (lower surface side) of the substrate <NUM> is formed into a smooth resin layer by the lower mold 120A, and a concave/convex shape can be formed on only the resin composition 84A on the first side (upper surface side).

<FIG> is an example of a mold structure 150C in which a mold 112B for double-sided processing is arranged relative to a workpiece 85B in which film-like resin compositions 84A, 84B are laminated on both surfaces of the substrate <NUM>. The mold 112B comprises a lower mold 120B having a mold surface 121B on which the concave/convex surface shape <NUM> is formed, and an upper mold 125A having a mold surface 126A on which the concave/convex surface shape <NUM> is formed. In the mold structure 150C, the lower mold 120B on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84B on the second side (lower surface side) of the substrate <NUM>, and the upper mold 125A on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM>. Thus, concave/convex shapes can be formed on the resin compositions 84B, 84A on the surfaces of the substrate <NUM> by the lower mold 120B and the upper mold 125A.

According to the mold structure 150A shown in <FIG>, a single resin layer having a concave/convex shape can be appropriately formed on the substrate <NUM>. The mold structures 150B, 150C shown in <FIG> are examples of processing of a workpiece 85B in which the film-like resin compositions 84A, 84B are laminated on both surfaces of the substrate <NUM>. In the mold structure 150B, a resin layer having a concave/convex shape and having a predetermined functionality can be formed on one side of the substrate <NUM>, and a resin layer such as a smooth adhesive layer can be formed on the other side. Furthermore, in the mold structure 150C, resin layers having concave/convex shapes and predetermined functionalities can be formed on both surfaces of the substrate <NUM>. In particular, in the mold structure 150C, by providing the lower mold 120B and the upper mold 125A with different concave/convex shapes, concave/convex shapes having different patterns can be formed on the surfaces of the substrate <NUM>. By laminating the resin compositions 84A, 84B on the surfaces of the substrate <NUM> in this manner, products with various functionalities can easily be produced.

<FIG> and <FIG> are examples of mold structures 150D, 150E in which processing is performed simultaneously on a plurality (two in the examples of the drawings) of workpieces. In the mold structure 150D shown in <FIG>, a mold 112C which is capable of processing a plurality of workpieces is arranged relative to a workpiece 85C in which the film-like resin composition 84A is laminated on one surface side (the upper surface side in the example of the drawing) of the substrate <NUM> and another workpiece 85D in which film-like resin compositions 84A, 84B are laminated on both surfaces of the substrate <NUM>. The mold 112C comprises a lower mold 120B having a mold surface 121B on which the concave/convex surface shape <NUM> is formed, an upper mold 125A having a mold surface 126A on which the concave/convex surface shape <NUM> is formed, and a middle mold 130A having smooth mold surfaces 131A, 136A on both surfaces thereof.

In the mold structure 150D, the lower mold 120B on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84B on the second side (lower surface side) of the substrate <NUM> of the second workpiece 85D, the upper mold 125A on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM> of the first workpiece 85C, the middle mold 130A is interposed between the first workpiece 85C and the second workpiece 85D, the smooth upper mold surface 131A of the middle mold 130A contacts the second side (lower surface side) of the substrate <NUM> of the first workpiece 85C, and the smooth lower mold surface 136A of the middle mold 130A contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM> of the second workpiece 85D. Thus, the concave/convex shape is formed on only the resin composition 84A on the first side (upper surface side) of the one workpiece 85C by the upper mold 125A, and on the second workpiece 85D, the concave/convex shape is formed on only the resin composition 84B on the second side (lower surface side) of the substrate <NUM> by the lower mold 120A, and the resin composition 84A on the first side (upper surface side) can be formed as a smooth resin layer.

In the mold structure 150E shown in <FIG>, a mold 112D which is capable of processing a plurality of workpieces is arranged relative to a workpiece 85E in which the film-like resin compositions 84A, 84B are laminated on both surfaces of the substrate <NUM> and another workpiece 85F in which the film-like resin compositions 84A, 84B are likewise laminated on both surfaces of the substrate <NUM>. The mold 112D comprise a lower mold 120B having a mold surface 121B on which the concave/convex surface shape <NUM> is formed, an upper mold 125Ahaving a mold surface 126A on which the concave/convex surface shape <NUM> is formed, and a middle mold 130B having mold surfaces 131B, 136B on which the concave/convex surface shapes <NUM>, <NUM> are formed on both surfaces thereof.

In the mold structure 150E, the lower mold 120B on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84B on the second side (lower surface side) of the substrate <NUM> of the second workpiece 85F, the upper mold 125A on which the concave/convex surface shape <NUM> is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM> of the first workpiece 85E, and the middle mold 130B is interposed between the first workpiece 85E and the second workpiece 85F, the upper mold surface 131B on which the upper concave/convex surface shape <NUM> of the middle mold 130B is formed contacts the second side (lower surface side) of the substrate <NUM> of the first workpiece 85E, and the lower mold surface 136B on which the lower concave/convex surface shape <NUM> of the middle mold 130B is formed contacts the resin composition 84A on the first side (upper surface side) of the substrate <NUM> of the second workpiece 85F. Thus, on the one workpiece 85E, the concave/convex shape can be formed on the resin composition 84A on the first side (upper surface side) by the upper mold 125A, and the concave/convex shape can be formed on the resin composition 84B on the second side (lower surface side) by the upper mold surface 131B of the middle mold 130B, and on the second workpiece 85F, the concave/convex shape can be formed on the resin composition 84B on the other side (lower surface side) of the substrate <NUM> by the lower mold 120B and the concave/convex shape can be formed on the resin composition 84A on the first side (upper surface side) by the lower mold surface 136B of the middle mold 130B.

According to the mold structure 150D shown in <FIG>, by interposing the middle mold 130A between different workpieces, a plurality of thin plate-like laminates having different types can be molded. According to the mold structure 150E shown in <FIG>, by interposing the middle mold 130B between identical workpieces, a plurality of identical thin plate-like laminates can be molded. Thus, by arranging a plurality of workpieces and arranging upper mold, middle mold, and lower mold on both sides of each workpiece, a plurality of thin plate-like laminates of the same type or of different types can be simultaneously molded, whereby work efficiency and production efficiency can be improved. Note that though the middle molds 130A, 130B of the mold structures 150D, 150E are configured so as to have the same mold surface on both sides thereof, a plurality of different thin plate-like laminates can be molded by forming different mold surfaces, for example, one is a smooth mold surface and the other is a mold surface having a concave/convex shape. Furthermore, the number of workpieces to be simultaneously processed is not particularly limited, and is preferably approximately <NUM> to <NUM> from the viewpoint of processing accuracy, etc..

The thin plate-like laminates of Prototype Examples <NUM> to <NUM> were produced under the following conditions using workpieces in which carbon-coated stainless steel (SUS316L) was used as the substrate, and a mixture of a polypropylene-based resin, carbon nanotubes (CNT), and graphite was used as the film-like resin composition.

In the setting part of the device for the production of a thin plate-like laminate, the above workpiece was held in a mold and a mold retention structure was created (operation time: approximately <NUM> seconds), and after heating was performed in the heating part at a heating temperature of <NUM> for a heating time of <NUM> seconds, and thermocompression-bonding was performed in the pressurization part with compression rollers at a pressure of <NUM> kN, a pressurization time of <NUM> seconds, and a pressurization temperature of <NUM>, the workpiece was slowly cooled to obtain the thin plate-like laminate of Prototype Example <NUM>.

In the heating part of the device for the production of a thin plate-like laminate, heating was performed on the mold at a heating temperature of <NUM> for a heating time of <NUM> seconds, in the setting part, the above workpiece was held in the heated mold and the mold retention structure was created (operation time: approximately <NUM> seconds), and after thermocompression-bonding was performed in the pressurization part with compression rollers at a pressure of <NUM> kN, a pressurization time of <NUM> seconds, and a pressurization temperature of <NUM>, the workpiece was slowly cooled to obtain the thin plate-like laminate of Prototype Example <NUM>.

Regarding the thin plate-like laminates of Prototype Examples <NUM> to <NUM>, the quality of the molding state was visually evaluated. The evaluation criteria were "Good" when the molded part (film-like resin layer) was acceptable as a product, and "Excellent" when it was in a superior condition. The results are shown in Table <NUM>.

In Prototype Example <NUM>, the mold in which the workpiece was held was processed by gently heating it. In Prototype Example <NUM>, the mold in which the workpiece was held was heated at a higher temperature and in a shorter time than in Prototype Example <NUM> to perform processing. In Prototype Example <NUM>, the mold, which did not hold the workpiece, was heated at a higher temperature and in a shorter time than in Prototype Example <NUM>, and immediately thereafter, the unheated workpiece was held by the heated mold and processing was performed. As a result, as shown in Table <NUM>, the thin plate-like laminate of Prototype Example <NUM> was able to be molded with a quality that does not cause any problems as a product. Conversely, in the thin plate-like laminates of Prototype Examples <NUM> and <NUM>, the molded product was in an extremely suitable state as compared with Prototype Example <NUM>.

As can be understood from the comparison of Prototype Example <NUM> and Prototype Example <NUM>, it was found that when the mold in which the workpiece is held is heated, a higher-quality product can be obtained at a relatively low temperature and with gentle heating than with high-temperature and short time heating. This is because in Prototype Example <NUM>, the workpiece is heated to a higher temperature, together with the mold, as compared with Prototype Example <NUM>, and thus, the film-like resin composition of the workpiece is more easily oxidized than in Prototype Example <NUM>, whereby it is considered that quality is less likely to be improved.

Conversely, in Prototype Example <NUM>, by heating the mold, which did not hold the workpiece, and then holding the workpiece therein, a high-quality product was obtained, as in Prototype Example <NUM>. It is considered that this is because the workpiece was not exposed to a high temperature at the time of heating the mold in Prototype Example <NUM>, and thus, the oxidation of the film-like resin composition of the workpiece was suppressed as compared with Prototype Example <NUM>, which enabled high-quality molding. Furthermore, since in Prototype Example <NUM>, the mold could be heated in a shorter time than in Prototype Example <NUM>, operation time can be shortened as compared with Prototype Example <NUM>.

As exemplified and described above, since the method for the production of a thin plate-like laminate having a film-like resin layer of the present invention comprises the steps of creating a mold retention structure in which molds, which have been heated to a thermal deformation temperature of the thin film-like resin composition, are arranged on both surface sides of a workpiece, and introducing the mold retention structure in which the heated molds are arranged between two compression rollers and compressing the outer surfaces of the molds by rotating the compression rollers to integrally thermocompression-bond the film-like resin composition and the substrate to form a thin plate-like laminate having a film-like resin layer, pressure is applied uniformly to the molds to suppress the occurrence of pressure unevenness, and the concave/convex shape can be formed on the film-like resin layer laminated on the thin plate-like substrate with high accuracy and stability. In particular, a fine concave/convex shape can be accurately and stably formed one the film-like resin layer laminated on the thin plate-like substrate.

Note that the method for the production of a thin plate-like laminate having a film-like resin layer of the present invention is not limited to only the Examples described above, and a portion of the structure can be appropriately modified without departing from the spirit of the invention. In the Examples described above, regarding the step of creating the mold retention structure in the setting part and the heating part, though a step in which the mold is heated to the thermal deformation temperature of the film-like resin composition after the creation of the mold retention structure in which the mold in which the workpiece is held is arranged or a step in which the mold in which the workpiece is not held is heated to the thermal deformation temperature of the film-like resin composition, the workpiece is then held in the heated mold and the mold retention structure is created was adopted in the Examples described above, this step is not limited thereto. For example, a step in which the mold retention structure is created after the mold, which is not retained in the retention body and in which the workpiece is held, is heated, a step in which the mold, which is not retained in the retention body and which does not hold the workpiece, is heated, and the workpiece is then held in the mold to create the mold creation structure, etc., can be performed by an appropriate procedure as long as it is a step in which the mold retention structure in which the heated mold in which the workpiece is held is arranged is ultimately created in the setting part and the heating part.

Furthermore, the array combination of the setting part, the heating part, the pressurization part, and the extraction part of the device for the production of a thin plate-like laminate is not limited to only the Examples described above, but it can be appropriately configured in accordance with the application, the installation location, etc..

Furthermore, though the setting part, the heating part, the pressurization part, and the extraction part are connected in series by the rail part provided on the machine base of the device for the production of a thin plate-like laminate, and the mold retention structure is configured so as to be capable of moving on the rail part in the Examples described above, a rail part may not be provided and the mold retention structure may be moved by means of a known transfer device or the like.

Claim 1:
A method for the production of a thin plate-like laminate (<NUM>) having a film-like resin layer (<NUM>), wherein molds (<NUM>, <NUM>) are arranged on both surface sides of a workpiece (<NUM>) in which a film-like resin composition (<NUM>) is laminated on at least one surface of a substrate (<NUM>) and the molds (<NUM>, <NUM>) are compressed from outer surfaces of the molds (<NUM>, <NUM>) to integrally form the substrate (<NUM>) and the film-like resin composition (<NUM>), the method comprising the steps of:
creating a mold retention structure (<NUM>) in which the molds (<NUM>, <NUM>), which have been heated to a thermal deformation temperature of the film-like resin composition (<NUM>), are arranged on both surface sides of the workpiece (<NUM>), and
introducing the mold retention structure (<NUM>) between two compression rollers (<NUM>, <NUM>) and compressing the outer surfaces of the molds (<NUM>, <NUM>) by rotating the compression rollers (<NUM>, <NUM>) to integrally thermocompression-bond the film-like resin composition (<NUM>) and the substrate (<NUM>) to form a thin plate-like laminate (<NUM>) having a film-like resin layer (<NUM>),
characterized in that
the mold retention structure (<NUM>) has members for holding the molds (<NUM>, <NUM>), and
the mold retention structure (<NUM>), in which the heated molds (<NUM>, <NUM>) are arranged by being held by the members for holding the molds (<NUM>, <NUM>), is introduced between the compression rollers (<NUM>, <NUM>).