Patent Description:
Patent Literature <NUM> describes a glass panel unit including pillars sandwiched between a pair of substrates. Patent Literature <NUM> describes a manufacturing method including a step of manufacturing pillars, a step of once storing the pillars thus manufactured, and a step of mounting the pillars stored on one of the pair of substrates. Therefore, this manufacturing method includes a large number of steps and is thus inefficient.

<CIT> describes a pillar mounting device for manufacturing a glass panel unit according to the preamble of claim <NUM> and a glass panel unit manufacturing method according to the preamble of claim <NUM>.

It is an object of the present invention to efficiently manufacture a glass panel unit including pillars sandwiched between a pair of substrates.

A sheet of the pillar mounting device and used in the manufacturing method, is a sheet for forming pillars for a glass panel unit and includes a base material having a sheet-like shape. The base material has a plurality of loop-shaped grooves. The base material has a plurality of portions serving as the pillars. Each of the plurality of portions is surrounded by a corresponding one of the plurality of loop-shaped grooves. Each of the plurality of loop-shaped grooves is a groove having a continuous or discontinuous loop shape.

A pillar mounting device according to the invention is defined in appended claim <NUM>.

A manufacturing method of another aspect of the present invention is a manufacturing method for a glass panel unit and includes a punching step, a pillar mounting step, and a bonding step as defined in appended claim <NUM>.

<FIG>, <FIG> each schematically illustrate a pillar mounting device of a first example. The pillar mounting device is a device configured to mount pillars <NUM> on one surface <NUM> of a substrate <NUM> to manufacture a pillar mounting substrate <NUM> (see <FIG>).

The pillar mounting substrate <NUM> forms a part of a glass panel unit <NUM> and has a structure including a plurality of pillars <NUM> mounted on the surface <NUM> of the substrate <NUM>.

Another substrate <NUM> is placed on the pillar mounting substrate <NUM> to face the surface <NUM> of the substrate <NUM>, and peripheral edges of the substrates <NUM> and <NUM> facing each other are bonded with a sealing member <NUM> having a frame shape, thereby obtaining the glass panel unit <NUM> (see <FIG>) having an inside space <NUM>.

The substrates <NUM> and <NUM> are both glass panes which are transparent but which may be semi-transparent or non-transparent. Moreover, the substrates <NUM> and <NUM> each include at least a glass pane and preferably include a coating such as a thermal ray reflecting film in addition to the glass pane.

In the following description, the substrate <NUM> and the substrate <NUM> are respectively referred to as a "first substrate <NUM>" and a "second substrate <NUM>" to be distinguished from each other.

As illustrated in <FIG>, <FIG>, the pillar mounting device includes a substrate supporting part <NUM>, a support table <NUM> installed above the substrate supporting part <NUM>, a sheet <NUM> supported in a horizontal position by the support table <NUM>, and a punch <NUM> installed above the sheet <NUM>. In the figure, an arrow D1 indicates the up direction, and a direction opposite to the direction indicated by the arrow D1 is the down direction.

The substrate supporting part <NUM> has a support surface <NUM> which supports the first substrate <NUM>. The substrate supporting part <NUM> supports the first substrate <NUM> in a position in which the surface <NUM> faces upward. As long as the substrate supporting part <NUM> has a structure that enables the first substrate <NUM> to be supported in the above-described position, the substrate supporting part <NUM> may have any appropriate structure.

The support table <NUM> is provided to be located above the surface <NUM> of the first substrate <NUM> supported by the substrate supporting part <NUM>.

The support table <NUM> has a through hole <NUM> penetrating therethrough in the up-down direction. The support table <NUM> has an upper surface on which the sheet <NUM> is put to cover the through hole <NUM>.

The sheet <NUM> includes a base material <NUM> in sheet form (film form). The base material <NUM> has a plurality of (a large number of) loop-shaped grooves <NUM>. The plurality of loop-shaped grooves <NUM> are disposed with a distance to one another in a matrix form (see <FIG>).

The base material <NUM> is preferably made of a resin, but other materials such as metal, glass, ceramic, or wood may be adopted as long as they are materials that can be punched with the punch <NUM>. As the base material <NUM>, a base material including a plurality of stacked resin layers may be adopted.

When the base material <NUM> is made of a resin, it is possible to form pillars <NUM> each having a low thermal conductivity. Moreover, when the resin of which the base material <NUM> is made is polyimide, excellent heat resistance is provided.

As illustrated in <FIG>, the plurality of (a large number of) loop-shaped grooves <NUM> are formed in the base material <NUM> of the sheet <NUM> in advance to surround respective portions <NUM> each having a round shape in plan view. Each of the loop-shaped grooves <NUM> includes so-called perforations discontinuously formed by laser processing with, for example, a laser machine. That is, each of the loop-shaped grooves <NUM> includes a plurality of (three) grooves <NUM> each having an arc shape. Each of the loop-shaped grooves <NUM> is located to surround a corresponding one of the portions <NUM>. Each of the portions <NUM> has a round shape in plan view. These grooves <NUM> each having an arc shape penetrate through the base material <NUM> in a thickness direction (the up-down direction) thereof. Between adjacent two of the grooves <NUM> each having an arc shape, a connection portion <NUM> is formed. A means for forming each groove <NUM> is not limited to the laser processing. It is also possible to form each groove <NUM> by another means such as etching process.

The connection portions <NUM> in the sheet <NUM> of the present embodiment are formed at a plurality of locations (three locations) at equal intervals in the circumferential direction along the outer shape of each portion <NUM>. The connection portions <NUM> are portions connecting the portion <NUM> of the base material <NUM> surrounded by the loop-shaped groove <NUM> to the remaining portion of the base material <NUM>.

As illustrated in <FIG>, the punch <NUM> includes a pin <NUM> protruding downward. The pin <NUM> has a columnar (cylindrical) shape. The pin <NUM> is configured such that a tip surface (lower surface) of the pin <NUM> downward punches the portion <NUM> from the base material <NUM> of the sheet <NUM>. The portion <NUM> is surrounded by the loop-shaped groove <NUM>. The sheet <NUM> is supported by the support table <NUM>. The through hole <NUM> in the support table <NUM> is located below the tip surface of the pin <NUM> with the sheet <NUM> placed between the tip surface and the support table <NUM>. The pin <NUM> has such a dimensional shape that allows the pin to penetrate through the through hole <NUM>.

Next, a description is given of a manufacturing method of the pillar mounting substrate <NUM> by using the pillar mounting device of the present example and further for manufacturing the glass panel unit <NUM> including the pillar mounting substrate <NUM>.

As illustrated in <FIG>, the manufacturing method according to the present embodiment includes a disposition step S1, a punching step S2, a pillar mounting step S3, a displacement step S4, a bonding step S5, and a process step S6. In the manufacturing method according to the present embodiment, the punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each including the punching step S2 and the pillar mounting step S3 which are repeated. Then, the bonding step S5 and the process step S6 are performed.

Each of the steps will be described below.

In the disposition step S1, the substrate supporting part <NUM>, the support table <NUM>, the sheet <NUM>, and the punch <NUM> are disposed (see <FIG>) such that the substrate supporting part <NUM> supports the first substrate <NUM>, the support table <NUM> is located above the first substrate <NUM>, the support table <NUM> supports the sheet <NUM>, and the punch <NUM> is located above the sheet <NUM>. The sheet <NUM> is disposed to cover the upper surface of the support table <NUM>. The pin <NUM> included in the punch <NUM> is located directly above the through hole <NUM> in the support table <NUM> with the sheet <NUM> placed between the pin <NUM> and the support table <NUM>.

In the punching step S2, the punch <NUM> including the pin <NUM> is driven downward. The punch <NUM> is driven downward, and thereby, the pin <NUM> having a columnar shape downward punches the portion <NUM> surrounded by the loop-shaped groove <NUM> from the base material <NUM> of the sheet <NUM> through the through hole <NUM> in the support table <NUM> (see the void arrow in <FIG>).

At this time, the connection portion <NUM> (see <FIG>) of the sheet <NUM> are broken by external force exerted by the pin <NUM>. As a result, the portion <NUM> surrounded by the loop-shaped groove <NUM> is punched to have a columnar shape with reduced formation of burrs.

In particular, when the base material <NUM> of the sheet <NUM> is made of a resin, burrs are likely to be formed due to punching, but the pillar mounting device of the present embodiment effectively reduces the burrs. Similarly, when the base material <NUM> includes a plurality of resin layers, burrs are likely to be formed due to punching, but the pillar mounting device of the present embodiment effectively reduces the formation of burrs.

In the pillar mounting step S3, the portion <NUM> which has been punched out downward by the pin <NUM> and which has a columnar shape is placed on the surface <NUM> of the first substrate <NUM> with the portion <NUM> being pressed onto the tip surface of the pin <NUM>. The portion <NUM> having a columnar shape and being placed on the surface <NUM> forms the pillar <NUM>.

That is, in the manufacturing method of the present example, the pin <NUM> functions as a movement mechanism <NUM> (see <FIG>). The pin <NUM> is configured to punch part of the base material <NUM> to form the pillar <NUM> in the punching step S2. The movement mechanism <NUM> is configured to move the pillar <NUM> immediately after being formed to the surface <NUM> of the first substrate <NUM>.

Liquid such as water is preferably applied to a location on the surface <NUM> of the first substrate <NUM> where the pillar <NUM> is to be placed. The presence of the liquid reduces dislocation of the pillar <NUM> on the surface <NUM>.

In the displacement step S4, the pin <NUM> is displaced upward as indicated by the void arrow in <FIG>, and then, the first substrate <NUM> and the sheet <NUM> are displaced in the horizontal direction relative to the support table <NUM> and the punch <NUM> respectively. In the present example, the travel direction of the first substrate <NUM> may be the same as or different from the travel direction of the sheet <NUM>.

<FIG> shows a case where the first substrate <NUM> and the sheet <NUM> are displaced, but the pillar mounting device may be configured such that the punch <NUM> and the support table <NUM> are displaced, or the pillar mounting device may be configured such that the first substrate <NUM> and the sheet <NUM> are displaced and the punch <NUM> and the support table <NUM> are displaced. Alternatively, the pillar mounting device may be configured such that the support table <NUM>, the sheet <NUM>, and the punch <NUM> are displaced relative to the first substrate <NUM> and the sheet <NUM> is displaced relative to the support table <NUM> and the punch <NUM>.

As illustrated in <FIG>, after the punching step S2, the pillar mounting step S3, and the displacement step S4 are performed in this order, a next punching step S2 and a next pillar mounting step S3 are performed.

In the next punching step S2, of a large number of portions <NUM> included in the sheet <NUM>, a portion <NUM> which has not been punched and remains is punched with the pin <NUM>. The portion <NUM> thus punched forms another pillar <NUM>. In the next pillar mounting step S3, the pillar <NUM> is mounted on the surface <NUM> of the first substrate <NUM> by the pin <NUM>.

In the manufacturing method according to the present example, the punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each including the punching step S2 and the pillar mounting step S3 which are repeated. While the relative position between the punch <NUM> and the first substrate <NUM> is changed, the punching step S2 and the pillar mounting step S3 are performed a plurality of times, and thereby, the plurality of pillars <NUM> are mounted with a distance to each other on the surface <NUM> of the first substrate <NUM>.

Thus, the pillar mounting substrate <NUM> (see <FIG>) including a plurality of pillars <NUM> is efficiently manufactured.

When a large number of pillars are manufactured in advance and are stored as described in the prior art technique, the pillars may be adsorbed on each other due to static electricity or the like. In contrast, according to the manufacturing method of the present example, it is possible to reduce pillars <NUM> adsorbed on each other. Thus, as a material for the pillars <NUM> (that is, as a material for the sheet <NUM>), it is possible to adopt a material such as a resin which is likely to generate static electricity, and thus, the degree of freedom of selection of the material for the pillars <NUM> increases.

Moreover, the manufacturing method of the present example reduces formation of burrs formed at the portion <NUM> punched from the base material <NUM>. This increases the strength (compressive strength) of the pillar <NUM> formed of the portion <NUM>.

As illustrated in <FIG>, in the bonding step S5, the sealing member <NUM> having a frame shape is disposed on a peripheral portion of the surface <NUM> of the first substrate <NUM>. The sealing member <NUM> is located on the surface <NUM> of the first substrate <NUM> to surround the plurality of pillars <NUM>.

Moreover, in the bonding step S5, the second substrate <NUM> is placed to sandwich the plurality of pillars <NUM> and the sealing member <NUM> between the second substrate <NUM> and the first substrate <NUM>, and the first substrate <NUM> and the second substrate <NUM> are bonded together with the sealing member <NUM>.

The inside space <NUM> is formed between the first substrate <NUM> the second substrate <NUM> thus bonded (see <FIG>). In the inside space <NUM>, the plurality of pillars <NUM> are located. Each pillar <NUM> is in contact with the first substrate <NUM> and the second substrate <NUM> and maintains the distance between the first substrate <NUM> and the second substrate <NUM>.

In the process step S6, through a ventilation hole <NUM> (see <FIG>) in the second substrate <NUM>, a pressure in the inside space <NUM> is reduced to a prescribed degree of vacuum (e.g., degree of vacuum lower than or equal to <NUM> Pa), or gas (dry air, argon, or the like) having thermal insulation properties is supplied to the inside space <NUM>, and then, the ventilation hole <NUM> is sealed.

The process step S6 forms the glass panel unit <NUM> as illustrated in <FIG>. In the glass panel unit <NUM> shown in <FIG>, a sealing site of the ventilation hole <NUM> is omitted.

The glass panel unit <NUM> has the inside space <NUM> between the first substrate <NUM> and the second substrate <NUM>. The inside space <NUM> is hermetically sealed with a reduced pressure therein or with gas supplied therein. The glass panel unit <NUM> has the inside space <NUM> and thus has a high thermal insulation property.

There may be a case where the pressure in the inside space <NUM> is not reduced and gas is not supplied to the inside space <NUM>. That is, a glass panel unit <NUM> may be formed by a manufacturing method without the process step S6. The glass panel unit <NUM> formed by this manufacturing method of the case also has thermal insulation properties to some extent.

Moreover, in this example, a large number of pillars <NUM> are disposed with the substantially same distance to one another in a matrix form between the first substrate <NUM> and the second substrate <NUM>. However, the number and locations of the pillars <NUM> are not particularly limited. One pillar <NUM> may be disposed on the surface <NUM> of the first substrate <NUM>.

The loop-shaped groove <NUM> includes a plurality of grooves <NUM> penetrating the base material <NUM> of the sheet <NUM> in the thickness direction of the base material <NUM>. However, as illustrated in <FIG>, the loop-shaped groove <NUM> may include a non-through groove <NUM>. The non-through groove <NUM> is formed by laser processing on one surface of, for example, the sheet <NUM> to have a continuous loop shape. A means for forming the loop-shaped groove <NUM> having such a continuous shape is not limited to the laser processing, but another means such as an etching process enables the loop-shaped groove <NUM> to be formed.

When the pin <NUM> is driven into the portion <NUM> surrounded by the loop-shaped groove <NUM> (non-through groove <NUM>) in the base material <NUM>, a bottom part of the loop-shaped groove <NUM> is broken, and the portion <NUM> surrounded by the loop-shaped groove <NUM> is punched to have a columnar shape with reduced formation of burrs.

Note that not all the loop-shaped grooves <NUM> have to be non-through grooves. Some of the loop-shaped grooves <NUM> may be formed not to penetrate through the base material <NUM>, and the other of the loop-shaped grooves <NUM> may be formed to penetrate through the base material <NUM>. Alternatively, the loop-shaped groove <NUM> may have a discontinuous loop shape and may be formed not to penetrate through the base material <NUM>.

In the present embodiment, the loop-shaped groove <NUM> has an annular shape, but the shape of the loop-shaped groove <NUM> is not limited to this embodiment. The shape of the loop-shaped groove <NUM> may be, for example, a polygonal shape (quadrangular shape, hexagonal shape, or the like), or other shapes (ellipse shape, Reuleaux triangle-shape, star shape, or the like). In this case, the portion <NUM> surrounded by the loop-shaped groove <NUM> is punched from the base material <NUM>, thereby forming the pillar <NUM> having a shape corresponding to the shape of the loop-shaped groove <NUM>.

Moreover, in the present embodiment, the plurality of loop-shaped grooves <NUM> are disposed with a distance to each other in the base material <NUM> of the sheet <NUM>. However, no distance may be formed between adjacent loop-shaped grooves <NUM>. For example, when each loop-shaped groove <NUM> has a quadrangular shape, adjacent loop-shaped grooves <NUM> may share a part thereof (part on one side of the quadrangular shape). In this case, on the base material <NUM> of the sheet <NUM>, a plurality of (a large number of) portions <NUM> each having a quadrangular shape are arranged in rows and columns, that is, in a matrix form. The plurality of (a large number of) loop-shaped grooves <NUM> each having a quadrangular shape and surrounding the portions <NUM> are combined altogether to form a grid groove structure including a plurality of longitudinal grooves and a plurality of lateral grooves transverse to one another. The portions <NUM> surrounded by the respective loop-shaped grooves <NUM> are punched from the base material <NUM>, thereby forming quadrangular prism pillars <NUM>.

By using the pillar mounting device of this example, it is possible to manufacture a variation of the glass panel unit <NUM> as illustrated in <FIG> and <FIG> and it is possible to manufacture a glass window <NUM> as illustrated in <FIG>.

The variation of the glass panel unit <NUM> illustrated in <FIG> and <FIG> includes a third substrate <NUM> and a frame member <NUM> in addition to the components of the glass panel unit <NUM> shown in <FIG>. The third substrate <NUM> is located to face the second substrate <NUM>. The frame member <NUM> hermetically bonds entire peripheral portions of the second substrate <NUM> and the third substrate <NUM> together.

The third substrate <NUM> includes at least a glass pane similarly to the first substrate <NUM> and the second substrate <NUM> and may adopt an appropriate panel. The third substrate <NUM> is transparent generally but may be semi-transparent or non-transparent.

A space <NUM> which is sealed is formed between counter surfaces <NUM> and <NUM> respectively of the second substrate <NUM> and the third substrate <NUM>.

The third substrate <NUM> is located to face one of the first substrate <NUM> and the second substrate <NUM>. Although not shown in the figure, when the third substrate <NUM> is disposed to face the first substrate <NUM>, the frame member <NUM> is bonded to peripheral portions of the first substrate <NUM> and the third substrate <NUM>, and the space <NUM> is formed between the first substrate <NUM> and the third substrate <NUM>.

As illustrated in <FIG>, a spacer <NUM> is further disposed on an inner side of the frame member <NUM>. The spacer <NUM> has a frame shape having a hollow. The hollow of the spacer <NUM> is filled with desiccant <NUM>.

The spacer <NUM> is made of metal such as aluminum and has a through hole <NUM> on an inner circumferential side thereof. The hollow of the spacer <NUM> is in communication with the space <NUM> via the through hole <NUM>. The desiccant <NUM> may be a silica gel, for example. The frame member <NUM> is preferably made of, for example, a highly airtight resin such as a silicon resin and butyl rubber.

The space <NUM> is a space hermetically sealed with the second substrate <NUM> (or the first substrate <NUM>), the third substrate <NUM>, and the frame member <NUM>. The space <NUM> is filled with a dry gas. The dry gas is, for example, a dry rare gas such as argon gas or dry air. The dry air includes air dried after sealed in the space <NUM> due to the effect of the desiccant <NUM>.

In the variation of the above-described glass panel unit <NUM>, the inside space <NUM> and the space <NUM> are provided between the third substrate <NUM> and the first substrate <NUM> (or the second substrate <NUM>), thereby providing a high thermal insulation property. The third substrate <NUM> is located on one end in a thickness direction of the glass panel unit <NUM>, and the first substrate <NUM> (or the second substrate <NUM>) is located on the other end in the thickness direction. The inside space <NUM> has a pressure reduced to a prescribed degree of vacuum or is supplied with gas. The space <NUM> is filled with a drying gas.

As illustrated in <FIG>, the manufacturing method of the variation of the glass panel unit <NUM> includes a second bonding step S7 performed after the process step S6 in addition to the steps shown in <FIG>. The second bonding step S7 is a step of bonding the third substrate <NUM> to one of the first substrate <NUM> and the second substrate <NUM> with a frame member <NUM> disposed between the third substrate <NUM> and the one of the first substrate <NUM> and the second substrate <NUM>.

A glass window <NUM> shown in <FIG> has a structure in which a window frame <NUM> is fitted to the glass panel unit <NUM> shown in <FIG>, and the glass window <NUM> has a high thermal insulation property. In the glass window <NUM>, the sealing member <NUM> of the glass panel unit <NUM> is preferably hidden by the window frame <NUM> when viewed from the front side.

As illustrated in <FIG>, a manufacturing method of the glass window <NUM> includes a fitting step S8 of fitting the window frame <NUM> to the glass panel unit <NUM> in addition to the steps shown in <FIG>.

A target to which the window frame <NUM> is fitted is not limited to the glass panel unit <NUM> as shown in <FIG>. The window frame <NUM> may be fitted to a glass panel unit <NUM> as illustrated in, for example, <FIG> and <FIG>. In each case, a glass window <NUM> having a high thermal insulation property is obtained.

A pillar mounting device of a second example will be described with reference to <FIG>. Of components of the pillar mounting device of the present example, components similar to those of the first example are denoted by the same reference signs, and the detailed description thereof will be omitted. In the following description, of the components of the pillar mounting device, components different from those of the first example will be mainly described.

A support table <NUM> included in the pillar mounting device of the present example has a plurality of through holes <NUM> (see <FIG>). The plurality of through holes <NUM> have the same dimensional shape and are located with a distance to one another. The plurality of through holes <NUM> are located in a matrix form in plan view.

A punch <NUM> included in the pillar mounting device includes a plurality of pins <NUM>. The plurality of pins <NUM> have the same dimensional shape and are located with a distance to one another. The plurality of pins <NUM> are located in a matrix form in plan view.

The arrangement pattern of the plurality of pins <NUM> corresponds to the arrangement pattern of the plurality of through holes <NUM> in plan view. The plurality of pins <NUM> may be driven into the plurality of through holes <NUM> located below on a one-to-one basis. Note that the pillar mounting device is configured to drive the plurality of pins <NUM> altogether but may be configured to drive the plurality of pins <NUM> individually.

Next, a manufacturing method of the glass panel unit <NUM> by using the pillar mounting device will be described. Similarly to the manufacturing method of the first example, the manufacturing method of the present example includes a disposition step S1, a punching step S2, a pillar mounting step S3, a displacement step S4, a bonding step S5, and a process step S6. In the following description, detailed description of components in each step which are similar to those in the first example is partially omitted.

In the disposition step S1 of the present example, a substrate supporting part <NUM>, a first substrate <NUM>, a support table <NUM>, a sheet <NUM>, and a punch <NUM> are disposed in this order (see <FIG>).

The sheet <NUM> has a base material <NUM> in which a plurality of (a large number of) loop-shaped grooves <NUM> are formed in advance in a matrix form. The plurality of pins <NUM> are disposed to correspond to the plurality of loop-shaped grooves <NUM> on a one-to-one basis.

In the punching step S2, the plurality of pins <NUM> included in the punch <NUM> are driven into the sheet <NUM> (see the void arrow in <FIG>). Thus, through the plurality of through holes <NUM> in the support table <NUM>, portions <NUM> surrounded by the plurality of loop-shaped grooves <NUM> are punched downward from the base material <NUM>. That is, the plurality of portions <NUM> are punched from the base material <NUM> by one time of punching.

In the pillar mounting step S3, the plurality of portions <NUM> punched from the base material <NUM> with the plurality of pins <NUM> are, immediately after being punched, mounted as is on a surface <NUM> of the first substrate <NUM> by the plurality of pins <NUM>. The plurality of portions <NUM> mounted on the surface <NUM> form respective pillars <NUM>.

The plurality of pins <NUM> for forming the plurality of pillars <NUM> in the punching step S2 functions as a movement mechanism <NUM> (see <FIG>) configured to move the plurality of pillars <NUM> immediately after being formed to the surface <NUM> of the first substrate <NUM>.

Also in the present example, liquid such as water is preferably applied to locations on the surface <NUM> of the first substrate <NUM> where the plurality of pillars <NUM> are to be mounted. The presence of the liquid reduces dislocation of each pillar <NUM> on the surface <NUM>.

In the displacement step S4, similarly to the first example, the plurality of pins <NUM> are displaced upward, and then, the first substrate <NUM> and the sheet <NUM> are displaced in the horizontal direction relative to the support table <NUM> and the punch <NUM> respectively (see the void arrow in <FIG>). Also in the present example, the punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each including the punching step S2 and the pillar mounting step S3 which are repeated. Thus, a pillar mounting substrate <NUM> including a plurality of (a large number of) pillars <NUM> is manufactured.

Note that when the punching step S2 is performed once, the pillar mounting substrate <NUM> may be manufactured. In this case, the displacement step S4 is not required.

The bonding step S5 and the process step S6 are similar to those in the first example. Further performing both the steps S5 and S6 provides a glass panel unit <NUM> including the pillar mounting substrate <NUM> and having a high thermal insulation property.

Also in the manufacturing method of the present example, similarly to the variation described in the first example, further performing a second bonding step S7 enables a glass panel unit <NUM> including three layers to be manufactured. Moreover, further performing a fitting step S8 enables a glass window <NUM> having a high thermal insulation property to be manufactured.

A pillar mounting device of a first embodiment will be described with reference to <FIG>. Of components of the pillar mounting device of the present embodiment, components similar to those of the first example are denoted by the same reference signs, and the detailed description thereof will be omitted. In the following description, of the components of the pillar mounting device of the present embodiment, components different from those of the first example will be mainly described.

The pillar mounting device of the present embodiment includes a support table <NUM>, a sheet <NUM> held in a horizontal position by the support table <NUM>, and a punch <NUM> installed above the sheet <NUM>.

The support table <NUM> includes a lower member <NUM> and an upper member <NUM>. The lower member <NUM> has a groove <NUM> that is recessed downward. The upper member <NUM> has a through hole <NUM> penetrating therethrough in the up-down direction. An upper end of the groove <NUM> has an opening, and a lower end of the groove <NUM> has a bottom surface <NUM>. Between the lower member <NUM> and the upper member <NUM>, a small gap is provided, and the sheet <NUM> is disposed in the gap.

Similarly to the first example, the sheet <NUM> has a base material <NUM> in which a plurality of (a large number of) loop-shaped grooves <NUM> are formed in a matrix form (see <FIG>).

The punch <NUM> has a suction pin <NUM> which has a hollow and which protrudes downward. The suction pin <NUM> is configured such that a tip surface (lower surface) of the suction pin <NUM> downward punches a portion <NUM> from the base material <NUM> of the sheet <NUM>. The portion <NUM> is surrounded by the loop-shaped groove <NUM>. The sheet <NUM> is supported by the support table <NUM>. The groove <NUM> in the lower member <NUM> is located below the tip surface of the suction pin <NUM> with the sheet <NUM> placed between the tip surface and the lower member <NUM>.

The tip surface of the suction pin <NUM> has an inlet <NUM> formed therein. The inlet <NUM> is in communication with a space <NUM> formed in the punch <NUM> through a hollow section <NUM> of the suction pin <NUM>. Reducing a pressure in the space <NUM> with, for example, a vacuum pump enables the tip surface of the suction pin <NUM> to be in vacuum contact with the pillar <NUM>.

Next, a manufacturing method of a pillar mounting substrate <NUM> by using the pillar mounting device of the present embodiment will be described. In the following description, detailed description of components in each step which are similar to those in the first example is partially omitted.

In a disposition step S1, the support table <NUM>, the sheet <NUM>, and the punch <NUM> are disposed (see <FIG>) such that the support table <NUM> supports the sheet <NUM> and the suction pin <NUM> is located above the sheet <NUM>. The suction pin <NUM> is located directly above the groove <NUM> in the lower member <NUM> of the support table <NUM> with the sheet <NUM> placed between the suction pin <NUM> and the lower member <NUM>.

In the punching step S2, the suction pin <NUM> included in the punch <NUM> is driven downward through the through hole <NUM> in the upper member <NUM>. The suction pin <NUM> downward punches the portion <NUM> surrounded by a loop-shaped groove <NUM> from the base material <NUM> of the sheet <NUM> through the groove <NUM> of the lower member <NUM> downward (see the void arrow in <FIG>).

At this time, connection portions <NUM> (see <FIG>) of the sheet <NUM> are broken by external force exerted by the suction pin <NUM>. As a result, the portion <NUM> surrounded by the loop-shaped groove <NUM> is punched to have a columnar shape with reduced formation of burrs.

The portion <NUM> which is punched out with the suction pin <NUM> and which has a columnar shape is pressed against the bottom surface <NUM> of the groove <NUM> with the portion <NUM> being pressed against the tip surface of the suction pin <NUM>. The portion <NUM> having a columnar shape and being pressed against the bottom surface <NUM> forms the pillar <NUM>.

In the pillar mounting step S3, the suction pin <NUM> is in vacuum contact with the pillar <NUM> pressed against the tip surface. The punch <NUM> is driven upward (see the void arrow in <FIG>) with the vacuum contact of the suction pin <NUM> with the pillar <NUM> being maintained to move the pillar <NUM> to a prescribed location on a surface <NUM> of a first substrate <NUM> (see, for example, <FIG>).

That is, in the manufacturing method of the present embodiment, the suction pin <NUM> functions as a movement mechanism <NUM>. The suction pin <NUM> is configured to punch part of the base material <NUM> to form the pillar <NUM> in the punching step S2. The movement mechanism <NUM> is configured to move the pillar <NUM> to the surface <NUM> of the first substrate <NUM>.

Although not shown, in the displacement step S4, after the punching step S2 and the pillar mounting step S3 are performed, the sheet <NUM> is displaced in the horizontal direction relative to the support table <NUM>. After the displacement step S4 is performed, a next punching step S2 and a next pillar mounting step S3 are performed.

In the next punching step S2, of a large number of portions <NUM> included in the sheet <NUM>, a portion <NUM> which is not punched and remains is punched with the suction pin <NUM>. The portion <NUM> thus punched forms another pillar <NUM>. In the next pillar mounting step S3, the pillar <NUM> is mounted on the surface <NUM> of the first substrate <NUM> by the suction pin <NUM>.

Similar to the first example, in the manufacturing method of the present embodiment, the punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each including the punching step S2 and the pillar mounting step S3 which are repeated. Thus, the pillar mounting substrate <NUM> (see <FIG>) including the plurality of pillars <NUM> is efficiently manufactured.

Steps of manufacturing a glass panel unit <NUM> and a glass window <NUM> each including the pillar mounting substrate <NUM> thus manufactured are similar to the steps described in the first example.

That is, also in the manufacturing method of the present embodiment, a bonding step S5 and a process step S6 similar to those of the first example are further performed to manufacture a glass panel unit <NUM> as illustrated in <FIG>. The bonding step S5, the process step S6, and a second bonding step S7 similar to those of the first example are further performed to manufacture a glass panel unit <NUM> having a three-layer structure as illustrated in <FIG> and <FIG>. The bonding step S5, the process step S6, and a fitting step S8 similar to those of the first example are further performed to manufacture a glass window <NUM> as illustrated in <FIG>.

In the pillar mounting device of the present embodiment, the punch <NUM> includes one suction pin <NUM>, but the punch <NUM> may include a plurality of suction pins <NUM>. In this case, similar to the plurality of pins <NUM> included in the pillar mounting device of the second example, the plurality of suction pins <NUM> included in the punch <NUM> punch a plurality of portions <NUM> from the base material <NUM> of the sheet <NUM>, thereby forming a plurality of pillars <NUM>. The plurality of suction pins <NUM> may be driven altogether or individually.

The plurality of pillars <NUM> thus formed are mounted on the surface <NUM> of the first substrate <NUM> with the plurality of pillars <NUM> being in vacuum contact with the plurality of suction pins <NUM>. In this case, the plurality of suction pins <NUM> function as movement mechanisms <NUM> configured to move the plurality of pillars <NUM> thus formed to the surface <NUM> of the first substrate <NUM>.

A timing at which the suction pin <NUM> starts sucking air through the inlet <NUM> may be a timing at which the suction pin <NUM> punches a portion <NUM> from the base material <NUM>, or before or after this timing.

A pillar mounting device of a second embodiment will be descried based on <FIG>. Of components of the pillar mounting device of the present embodiment, components similar to those of the first example are denoted by the same reference signs, and the detailed description thereof will be omitted. In the following description, of the components of the pillar mounting device of the present embodiment, components different from those of the first example will be mainly described.

The pillar mounting device of the present embodiment includes a table <NUM> having a surface <NUM> which is flat and which faces upward, a support table <NUM> installed above the table <NUM>, a sheet <NUM> supported in a horizontal position by the support table <NUM>, and a punch <NUM> installed above the sheet <NUM>. The configurations of the support table <NUM>, the sheet <NUM>, and the punch <NUM> are similar to those in the first example.

In the disposition step S1, the table <NUM>, the support table <NUM>, the sheet <NUM>, and the punch <NUM> are disposed (see <FIG>) such that the support table <NUM> is located above the table <NUM>, the support table <NUM> supports the sheet <NUM>, and the punch <NUM> is located above the sheet <NUM>.

In the punching step S2, a pin <NUM> included in the punch <NUM> is driven downward through a through hole <NUM> in the support table <NUM>. The pin <NUM> downward punches a portion <NUM> surrounded by a loop-shaped groove <NUM> from a base material <NUM> of the sheet <NUM> through the through hole <NUM> (see the void arrow in <FIG>).

The portion <NUM> punched by the pin <NUM> forms a pillar <NUM>. The pillar <NUM> is placed on the surface <NUM> of the table <NUM> with the pillar <NUM> being pressed against a tip surface of the pin <NUM>.

In the pillar mounting step S3, after the punch <NUM> is separated from the pillar <NUM>, a suction tool <NUM> (see <FIG>) different from the punch <NUM> comes into vacuum contact with the pillar <NUM> placed on the table <NUM>. The suction tool <NUM> has an end surface in which an inlet <NUM> is formed. The inlet <NUM> is in communication with a space <NUM> formed in the suction tool <NUM>. Reducing a pressure in the space <NUM> with, for example, a vacuum pump enables the inlet <NUM> of the suction tool <NUM> to be in vacuum contact with the pillar <NUM>.

The suction tool <NUM> moves the pillar <NUM> to a prescribed location on a surface <NUM> of a first substrate <NUM> (see, for example, <FIG>) with the vacuum contact of the inlet <NUM> with the pillar <NUM> being maintained. That is, in the manufacturing method of the present embodiment, the suction tool <NUM> functions as a movement mechanism <NUM> configured to move the pillar <NUM> to the surface <NUM> of the first substrate <NUM>.

Although not shown, in the displacement step S4, the sheet <NUM> and the table <NUM> are displaced in the horizontal direction relative to the support table <NUM>. After the displacement step S4 is performed, a next punching step S2 and a next pillar mounting step S3 are performed.

In the next punching step S2, of a large number of portions <NUM> included in the sheet <NUM>, a portion <NUM> which has not been punched and remains is punched with the pin <NUM>. The portion <NUM> thus punched forms another pillar <NUM>. In the next pillar mounting step S3, the pillar <NUM> is mounted on the surface <NUM> of the first substrate <NUM> by the suction tool <NUM>.

The punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each including the punching step S2 and the pillar mounting step S3 which are repeated. Thus, the pillar mounting substrate <NUM> (see <FIG>) including a plurality of pillars <NUM> is efficiently manufactured.

That is, also in the manufacturing method of the present embodiment, a bonding step S5 and a process step S6 similar to those of the first example are further performed to manufacture a glass panel unit <NUM> as illustrated in <FIG>. The bonding step S5, the process step S6, and a second bonding step S7 similar to those of the first example are further performed to manufacture a glass panel unit <NUM> having a three-layer structure as illustrated in <FIG> and <FIG>. The bonding step S5, the process step S6, and a fitting step S8 similar to those of the first embodiment are further performed to manufacture a glass window <NUM> as illustrated in <FIG>.

In the pillar mounting device of the present embodiment, the punch <NUM> includes one pin <NUM>, but the punch <NUM> may include a plurality of pins <NUM>. In this case, similar to the pillar mounting device of the second example, the plurality of pins <NUM> included in the punch <NUM> punch a plurality of portions <NUM> from the base material <NUM> of the sheet <NUM>, thereby forming a plurality of pillars <NUM>. The plurality of pins <NUM> may be driven altogether or individually.

The plurality of pillars <NUM> thus formed are mounted on the surface <NUM> of the first substrate <NUM> with the pillars <NUM> being in vacuum contact with the plurality of suction tools <NUM>. That is, the plurality of suction tools <NUM> function as movement mechanisms <NUM> configured to move the plurality of pillars <NUM> thus formed to the surface <NUM> of the first substrate <NUM>.

A pillar mounting device of a third embodiment will be descried based on <FIG>. Of components of the pillar mounting device of the present embodiment, components similar to those of the first example are denoted by the same reference signs, and the detailed description thereof will be omitted. In the following description, of the components of the pillar mounting device of the present embodiment, components different from those of the first example will be mainly described.

The pillar mounting device of the present embodiment includes a support table <NUM>, a sheet <NUM> held in a horizontal position by the support table <NUM>, a punch <NUM> installed below the sheet <NUM>, and a suction tool <NUM> installed above the sheet <NUM>.

The support table <NUM> includes a lower member <NUM> and an upper member <NUM>. The lower member <NUM> has a through hole <NUM> vertically penetrating therethrough. The upper member <NUM> has a through hole <NUM> vertically penetrating therethrough. Between the lower member <NUM> and the upper member <NUM>, a small gap is provided, and the sheet <NUM> is disposed in the gap.

The punch <NUM> has a pin <NUM> protruding upward. The pin <NUM> is configured such that a tip surface (upper surface) of the pin <NUM> punches a portion <NUM> upward from the base material <NUM> of the sheet <NUM>. The portion <NUM> is surrounded by the loop-shaped groove <NUM>. The sheet <NUM> is supported by the support table <NUM>. The suction tool <NUM> is located above the tip surface of the pin <NUM> with the sheet <NUM> placed between the tip surface and the suction tool <NUM>.

The suction tool <NUM> has an end surface (lower surface) in which an inlet <NUM> is formed. The inlet <NUM> is in communication with a space <NUM> formed in the suction tool <NUM>. Reducing a pressure in the space <NUM> with, for example, a vacuum pump enables the inlet <NUM> of the suction tool <NUM> to be in vacuum contact with the pillar <NUM>.

In the disposition step S1, the support table <NUM>, the sheet <NUM>, the punch <NUM>, and the suction tool <NUM> are disposed such that the support table <NUM> supports the sheet <NUM>, the punch <NUM> is located below the sheet <NUM>, and the suction tool <NUM> is located above the sheet <NUM> (see <FIG>). The pin <NUM> of the punch <NUM> and the inlet <NUM> of the suction tool <NUM> are located on respective sides of the sheet <NUM> (portion <NUM>).

In the punching step S2, the pin <NUM> included in the punch <NUM> is driven upward through the through hole <NUM> in the lower member <NUM>. The pin <NUM> upward punches a portion <NUM> surrounded by the loop-shaped groove <NUM> from the base material <NUM> of the sheet <NUM> through hole <NUM> of the upper member <NUM> (see the void arrow in <FIG>).

The portion <NUM> upward punched by the pin <NUM> and having a columnar shape forms the pillar <NUM>. The pillar <NUM> is pressed against the inlet <NUM> of the suction tool <NUM> with the pillar <NUM> being pressed against the tip surface of the pin <NUM>.

In the pillar mounting device of the present embodiment, the inlet <NUM> of the suction tool <NUM> abuts on the portion <NUM> of the sheet <NUM> before the pin <NUM> is driven upward. The pillar mounting device of the present embodiment is configured to pushes up both the portion <NUM> (pillar <NUM>) and the suction tool <NUM> when the pin <NUM> punches the portion <NUM> from the base material <NUM>.

Note that before the pin <NUM> is driven, the suction tool <NUM> may be out of contact with the sheet <NUM>. In this case, after the pin <NUM> punches the portion <NUM> from the base material <NUM>, the suction tool <NUM> abuts on and sucks up the portion <NUM> (pillar <NUM>).

As illustrated in <FIG>, in the pillar mounting step S3, while the suction tool <NUM> is in vacuum contact with the pillar <NUM> which abuts on the inlet <NUM>, the suction tool <NUM> moves the pillar <NUM> to a prescribed location on a surface <NUM> of a first substrate <NUM> (see, for example, <FIG>). That is, in the manufacturing method of the present embodiment, the suction tool <NUM> function as a movement mechanism <NUM> configured to move the pillar <NUM> thus formed to the surface <NUM> of the first substrate <NUM>.

A timing at which the suction tool <NUM> starts sucking air through the inlet <NUM> may be a timing at which the pin <NUM> punches the portion <NUM> from the base material <NUM>, or before or after this timing.

Although not shown, in the displacement step S4, after the punching step S2 and the pillar mounting step S3 are performed, the sheet <NUM> is displaced in the horizontal direction relative to the support table <NUM>, the punch <NUM>, and the suction tool <NUM>. After the displacement step S4 is performed, a next punching step S2 and a next pillar mounting step S3 are performed.

Similar to the first example, in the manufacturing method of the present embodiment, the punching step S2 and the pillar mounting step S3 following the punching step S2 are repeated a plurality of times with the displacement step S4 performed between sets each of which including the punching step S2 and the pillar mounting step S3 which are repeated. Thus, the pillar mounting substrate <NUM> (see <FIG>) including a plurality of pillars <NUM> is efficiently manufactured.

In the pillar mounting device of the present embodiment, the punch <NUM> includes one pin <NUM> and one suction tool <NUM> is provided, but the punch <NUM> may include a plurality of pins <NUM>, and a plurality of suction tools <NUM> may be provided. In this case, similar to the pillar mounting device of the second embodiment, the plurality of pins <NUM> included in the punch <NUM> punch a plurality of portions <NUM> from the base material <NUM> of the sheet <NUM>, thereby forming a plurality of pillars <NUM>. The plurality of pins <NUM> may be driven altogether or individually.

The plurality of pillars <NUM> thus formed are transported to the surface <NUM> of the first substrate <NUM> and mounted on the surface <NUM> with the pillars <NUM> being in vacuum contact with the plurality of suction tools <NUM>. In this case, the plurality of suction tools <NUM> function as movement mechanisms <NUM> configured to move the plurality of pillars <NUM> to the surface <NUM> of the first substrate <NUM>.

As can be seen from the three embodiments described above, a sheet <NUM> for forming pillars for a glass panel unit, includes a base material <NUM> having a sheet-like shape. The base material <NUM> has a plurality of loop-shaped grooves <NUM>. The base material <NUM> has a plurality of portions <NUM> serving as the pillars <NUM>, each of the plurality of portions <NUM> being surrounded by a corresponding one of the plurality of loop-shaped grooves <NUM>.

With an exemplary sheet <NUM> for forming the pillar for the glass panel unit, the plurality of portions <NUM> included in the base material <NUM> of the sheet <NUM> are punched while a glass panel unit <NUM> is manufactured, thereby obtaining the plurality of pillars <NUM>. Thus, the step of once storing a large number of pillars <NUM> is not required, and therefore, it is possible to reduce pillars <NUM> adsorbed on each other. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, formation of burrs at each portion <NUM> (pillar <NUM>) thus punched is reduced. Since formation of burrs reduces the compressive strength of the pillar <NUM>, the pillar <NUM> with reduced burrs provides a high compressive strength.

In the exemplary sheet <NUM> for forming pillars for a glass panel unit, the base material <NUM> is made of a resin.

With the sheet <NUM> for forming the pillar for the glass panel unit, the plurality of portions <NUM> included in the base material <NUM> are punched while a glass panel unit <NUM> is manufactured, thereby obtaining the plurality of pillars <NUM> made of a resin. The plurality of pillars <NUM> made of a resin generally has a property of being easily adsorbed on each other due to static electricity, but the step of once storing these pillars <NUM> is not required, and therefore, adsorption of the plurality of pillars <NUM> made of a resin on each other is reduced. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, formation of burrs at the portion <NUM> (pillar <NUM> made of a resin) is reduced.

In a sheet <NUM> for forming pillars for a glass panel unit, according to the appended claims, the base material <NUM> includes a plurality of resin layers.

With the sheet <NUM> for forming the pillar for the glass panel unit, the plurality of portions <NUM> included in the base material <NUM> are punched while a glass panel unit <NUM> is manufactured, thereby obtaining the plurality of pillars <NUM> made of a resin. The plurality of pillars <NUM> made of a resin generally has a property of being easily adsorbed on each other due to static electricity, but the step of once storing these pillars <NUM> is not required, and therefore, adsorption of the plurality of pillars <NUM> on each other is reduced. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, it is possible to reduce formation of burrs at each portion <NUM> (pillar <NUM> including a plurality of resin layers) punched out.

In a sheet <NUM> for forming pillars for a glass panel unit, at least one of the plurality of loop-shaped grooves <NUM> has a discontinuous loop shape. With the sheet <NUM> of the fourth aspect, for forming the pillar for the glass panel unit, it is possible to effectively reduce formation of burrs at the portion <NUM> (pillar <NUM>) punched from the base material <NUM>.

In a sheet <NUM> for forming pillars for a glass panel unit, at least one of the plurality of loop-shaped grooves <NUM> has a discontinuous loop shape and penetrates through the base material <NUM>. With the sheet <NUM> uf the for forming the pillar for the glass panel unit, it is possible to effectively reduce formation of burrs at the portion <NUM> (pillar <NUM>) punched from the base material <NUM>.

In a sheet <NUM> for forming pillars for a glass panel unit, at least one of the plurality of loop-shaped grooves <NUM> has a continuous loop shape, and at least a part of the continuous loop shape does not penetrate through the base material <NUM>. With the sheet <NUM> for forming the pillar for the glass panel unit, it is possible to effectively reduce formation of burrs at the portion <NUM> (pillar <NUM>) punched from the base material <NUM>.

In a sheet <NUM> for forming pillars for a glass panel unit, each of the plurality of loop-shaped grooves <NUM> is a laser-processed loop-shaped groove. With the sheet <NUM> for forming the pillar for the glass panel unit, it is possible to effectively reduce formation of burrs at the portion <NUM> (pillar <NUM>) punched from the base material <NUM>.

An example of a pillar mounting device for manufacturing a glass panel unit, includes the sheet <NUM> for forming the pillar for the glass panel unit, a punch <NUM> configured to punch at least one of the plurality of portions <NUM> from the base material <NUM> of the sheet <NUM> to form at least one pillar <NUM>, and a movement mechanism <NUM> configured to move the at least one pillar <NUM> to a surface <NUM> of a substrate <NUM> including a glass pane.

With the pillar mounting device of for manufacturing the glass panel unit, it is possible to punch, at a timing immediately before the pillar <NUM> is mounted, the portion <NUM> from the base material <NUM> of the sheet <NUM> to obtain the pillar <NUM>. Thus, a step of once storing and transporting a large number of pillars <NUM> is not required. Thus, it is possible to reduce pillars <NUM> adsorbed on each other. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, formation of burrs at each portion <NUM> (pillar <NUM>) thus punched is reduced. The pillar <NUM> with reduced burrs provides a high compressive strength.

In another example of a pillar mounting device for manufacturing a glass panel unit, the movement mechanism <NUM> includes at least one pin <NUM> included in the punch <NUM>. The at least one pin <NUM> is configured to punch the at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM>, and then move the at least one pillar <NUM> to the surface <NUM> of the substrate <NUM>.

The pillar mounting device for manufacturing the glass panel unit, enables both forming the pillar <NUM> and mounting the pillar <NUM> thus formed on the substrate <NUM> to be performed by the pin <NUM>.

In a pillar mounting device according to the invention as defined by the appended claims, for manufacturing a glass panel unit, the movement mechanism <NUM> includes at least one suction pin <NUM> included in the punch <NUM>. The at least one suction pin <NUM> is configured to punch the at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM>, and then move the at least one pillar <NUM> to the surface <NUM> of the substrate <NUM> with the at least one pillar <NUM> being sucked up by the at least one suction pin <NUM>.

The pillar mounting device according to the invention as defined by the appended claims, for manufacturing the glass panel unit, enables both forming the pillar <NUM> and mounting the pillar <NUM> thus formed on the substrate <NUM> to be performed by the suction pin <NUM>.

In a pillar mounting device according to the invention as defined by the appended claims, for manufacturing a glass panel unit, the movement mechanism <NUM> includes a suction tool <NUM> configured to suck up the at least one pillar <NUM>.

The pillar mounting device for manufacturing the glass panel unit, enables the pillar <NUM> formed by punching to be promptly mounted on the substrate <NUM> by using the suction tool <NUM>.

In a pillar mounting device according to the invention as defined by the appended claims, for manufacturing a glass panel unit, the punch <NUM> includes at least one pin <NUM>, and the movement mechanism <NUM> includes a suction tool <NUM> configured to suck up the at least one pillar <NUM>. The at least one pin <NUM> is configured to punch the at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM>, and then press the at least one pillar <NUM> against the suction tool <NUM>.

The pillar mounting device for manufacturing the glass panel unit, enables the pillar <NUM> thus formed by punching to be promptly mounted on the substrate <NUM> by using the suction tool <NUM>.

An exemplary glass panel unit manufacturing method includes a punching step S2, a pillar mounting step S3, and a bonding step S5. In the punching step S2, a sheet <NUM> and a punch <NUM> are adopted. The sheet <NUM> includes a base material <NUM> having a plurality of loop-shaped grooves <NUM>. The punch <NUM> punches at least one of a plurality of portions <NUM> from the base material <NUM> to form at least one pillar <NUM>. Each of the plurality of portions <NUM> is surrounded by a corresponding one of the plurality of loop-shaped grooves <NUM> of the base material <NUM>. In the pillar mounting step S3, the at least one pillar <NUM> is mounted on a surface <NUM> of a first substrate <NUM> including a glass pane. In the bonding step S5, the first substrate <NUM> and the second substrate <NUM> including a glass pane are bonded together with a sealing member <NUM> to form an inside space <NUM> between the first substrate <NUM> and the second substrate <NUM> so that the at least one pillar <NUM> is located in the inside space <NUM>.

According to the glass panel unit manufacturing method, it is possible to punch, at a timing immediately before the pillar <NUM> is mounted on a first substrate <NUM>, the portion <NUM> from the base material <NUM> of the sheet <NUM> to obtain the pillar <NUM>. Thus, a step of once storing and transporting a large number of pillars <NUM> is not required. It is possible to reduce pillars <NUM> adsorbed on each other. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, formation of burrs at each portion <NUM> (pillar <NUM>) thus punched is reduced. The pillar <NUM> with reduced burrs provides a high compressive strength.

In another exemplary glass panel unit manufacturing method the base material <NUM> is made of a resin.

According to the glass panel unit manufacturing method it is possible to punch, at a timing immediately before the pillar <NUM> is mounted on the first substrate <NUM>, the portion <NUM> from the base material <NUM> to obtain the plurality of pillar <NUM> made of a resin. The pillars <NUM> made of a resin are generally easily adsorbed on each other due to static electricity, but since the step of once storing a plurality of these pillars <NUM> is not required, adsorption of the pillars <NUM> on each other is reduced. In addition, since each portion <NUM> of the base material <NUM> is surrounded by the loop-shaped groove <NUM>, formation of burrs at the portion <NUM> (pillar <NUM> made of a resin) is reduced.

In another exemplary glass panel unit manufacturing method in the pillar mounting step S3, the punch <NUM> mounts the at least one pillar <NUM> on the surface <NUM> of the first substrate <NUM>.

The glass panel unit manufacturing method enables both forming the pillar <NUM> and mounting the pillar <NUM> thus formed on the substrate <NUM> to be performed by the punch <NUM>.

In another exemplary glass panel unit manufacturing method in the punching step S2 and the pillar mounting step S3, the sheet <NUM> is located between the punch <NUM> and the first substrate <NUM>.

According to the glass panel unit manufacturing method it is possible to mount the pillar <NUM> on the first substrate <NUM> by the punch <NUM> immediately after the pillar <NUM> is formed by punching.

In a glass panel unit manufacturing method according to the invention as defined by the appended claims, the punch <NUM> includes at least one suction pin <NUM>. In the punching step S2, the at least one suction pin <NUM> punches at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM>. In the pillar mounting step S3, the at least one suction pin <NUM> mounts the at least one pillar <NUM> on the surface <NUM> of the first substrate <NUM> while sucking up the at least one pillar <NUM>.

The glass panel unit manufacturing method according to the invention as defined by the appended claims, enables both forming the pillar <NUM> and mounting the pillar <NUM> thus formed on the substrate <NUM> to be performed by the suction pin <NUM>.

In a glass panel unit manufacturing method according to the invention as defined by the appended claims, the punch <NUM> includes at least one pin <NUM>. In the punching step S2, the at least one pin <NUM> punches at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM>. In the pillar mounting step S3, a suction tool <NUM> different from the punch <NUM> mounts the at least one pillar <NUM> on the surface <NUM> of the first substrate <NUM> while sucking up the at least one pillar <NUM>.

This glass panel unit manufacturing method enables the pillar <NUM> thus formed by punching to be promptly mounted on the first substrate <NUM> by the suction tool <NUM>.

In a glass panel unit manufacturing according to the invention as defined by the appended claims, the punch <NUM> includes at least one pin <NUM>. In the punching step S2, the at least one pin <NUM> punches at least one of the plurality of portions <NUM> from the base material <NUM> to form the at least one pillar <NUM> and the at least one pin <NUM> presses the at least one pillar <NUM> against a suction tool <NUM>. In the pillar mounting step S3, the suction tool <NUM> mounts the at least one pillar <NUM> on the surface <NUM> of the first substrate <NUM> while sucking up the at least one pillar <NUM>.

In a glass panel unit manufacturing method the punching step S2 and the pillar mounting step S3 are repeated a plurality of times, and then, the bonding step S5 is performed.

The glass panel unit manufacturing method enables efficient manufacturing of a glass panel unit <NUM> including a plurality of pillars <NUM> sandwiched between the first substrate <NUM> and the second substrate <NUM>.

A glass panel unit manufacturing method can further include a second bonding step S7 of bonding a third substrate <NUM> to one of the first substrate <NUM> and the second substrate <NUM> with a frame member <NUM> disposed between the third substrate <NUM> and the one of the first substrate <NUM> and the second substrate <NUM>. The third substrate <NUM> includes a glass pane.

The glass panel unit manufacturing method enables manufacturing of a glass panel unit <NUM> having a further improved thermal insulation properties.

A glass window manufacturing method not defined by the appended claims, includes a fitting step S8 of fitting a window frame <NUM> to the glass panel unit <NUM> manufactured by the glass panel manufacturing method of any one of the first to ninth aspects.

Claim 1:
A pillar mounting device for manufacturing a glass panel unit (<NUM>), the pillar mounting device comprising:
a sheet (<NUM>) for forming pillars (<NUM>) for a glass panel unit (<NUM>), the sheet (<NUM>) comprising a base material (<NUM>) having a sheet-like shape,
the base material (<NUM>) having a plurality of loop-shaped grooves (<NUM>),
the base material (<NUM>) having a plurality of portions (<NUM>) serving as the pillars (<NUM>), each of the plurality of portions (<NUM>) being surrounded by a corresponding one of the plurality of loop-shaped grooves (<NUM>), and
the base material (<NUM>) including a plurality of resin layers,
a punch (<NUM>) configured to punch at least one of the plurality of portions (<NUM>) from the base material (<NUM>) of the sheet (<NUM>) to form at least one pillar (<NUM>), and
a movement mechanism (<NUM>) configured to move the at least one pillar (<NUM>) to a surface (<NUM>) of a substrate (<NUM>) including a glass pane, and characterised in that
(a) the movement mechanism (<NUM>) includes at least one suction pin (<NUM>) included in the punch (<NUM>), the at least one suction pin (<NUM>) being configured to:
punch the at least one of the plurality of portions (<NUM>) from the base material (<NUM>) to form the at least one pillar (<NUM>), and
then move the at least one pillar (<NUM>) to the surface (<NUM>) of the substrate (<NUM>) with the at least one pillar (<NUM>) being sucked up by the at least one suction pin (<NUM>), or in that
(b) the movement mechanism (<NUM>) includes a suction tool (<NUM>) configured to suck up the at least one pillar (<NUM>).