TW201402331A - Method for manufacturing laminated sheet, and manufacturing device - Google Patents

Abstract

Disclosed is a device (30) for manufacturing the laminated sheet, comprising: an impreganation means (31), disposed inside a fibrous substrate (2), so as to have the organic material impreganated with predetermined intervals along the long-side of the fibrous substrate (2) in order to form a plurality of impreganation sections (21) extending toward the width direction of the fibrous substrate (2); a supply means, which supplies a resin layer upon the fibrous substrate (2) such that the impreganation sections (21) of the fibrous substrate (2) and the resin layer extend toward opposite directions; a chamber for conveying the fibrous substrate (2) and the resin layer; a conveying means, conveying the fibrous substrate (2) and the resin layer along the long-side of the fibrous substrate (2); a controlling means, making the intervals between the impreganation sections (21) of the fibrous substrate (2) and the resin layer be inside the chamber, and under the circumstance that the fibrous substrate (2) along the conveying direction, at the upper side and the lower side than the intervals between the impreganation sections (21), is exposed, stopping drving the conveying means; a decompression means, reducing the pressure of the chamber; and a heating means, heating the fibrous substrate and the resin layer inside the chamber so as to impreganate the resin layer inside the fibrous substrate (2).

Description

Manufacturing method of laminated sheet and manufacturing device of laminated sheet

The present invention relates to a method for producing a laminated sheet and a device for producing a laminated sheet.

In the past, a resin material was impregnated into a prepreg of a fiber base material, and it was used in a printed wiring board having a multilayer structure.

Such a prepreg system is manufactured by the following means (for example, refer to Patent Document 1).

A film coated with a resin varnish on the upper surface is laminated with a fiber base material from the upper side to press the fiber base material against the film. Thereby, the resin varnish is impregnated into the fibrous base material.

[prior technical literature] [Patent Document]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2010-47706

In the production of the prepreg, the inventors of the present invention have a concept in which a resin layer such as a resin varnish and a fibrous base material are pressure-bonded under reduced pressure. Presumably by In this manner, in addition to preventing bubbles from entering between the resin layer and the fibrous base material, the inside of the fibrous base material is also decompressed, and voids are formed inside the fibrous base material to obtain a desired prepreg.

However, since the fibrous base material has a long shape and it is difficult to place it all in the chamber for decompression, a part of the fibrous base material is located outside the chamber. As a result, the gas flows into the chamber through the fibrous substrate, making it difficult to depressurize the chamber, and it is difficult to obtain a desired prepreg.

The present invention has been made in view of the above problems.

That is, the present invention provides a method for producing a laminated sheet, comprising: preparing an elongated fibrous base material in which an organic material is interposed at a predetermined interval in a longitudinal direction of the fibrous base material; Impregnation, forming a plurality of impregnation portions extending in the width direction of the fiber substrate; supplying the resin layer to the surface or the back surface side of the fiber substrate, and the region between the impregnation portions of the fiber substrate and the resin a step of facing the fiber substrate and the resin layer along the longitudinal direction of the fiber substrate in the chamber; and a region between the impregnation portions of the fiber substrate and the resin The layer is located in the chamber, and the region between the region on the downstream side in the transport direction and the region on the upstream side in the region between the impregnation portions of the fibrous base material is located outside the chamber, and the transport of the fibrous substrate and the aforesaid are stopped. a step of resin layer; and decompressing the chamber, heating the fiber substrate and the resin layer in the chamber to impregnate the resin layer Step inside of the fiber base.

The fibrous substrate extends from inside the chamber to outside the chamber. As a result, the gas continues to flow from the outside of the chamber to the fiber substrate inside the chamber along the extending direction of the fiber substrate, so that it is difficult to decompress the chamber and the inside of the fiber substrate.

On the other hand, in the present invention, the impregnation portion is separated along the longitudinal direction of the fiber base material, and the fiber substrate is partitioned along the longitudinal direction by the impregnation portion. At least a portion of the path through which the gas flows into the chamber is partitioned by the impregnation portion, so that the chamber and the inside of the fibrous substrate are easily decompressed.

Further, the present invention can also provide a manufacturing apparatus used in the method of manufacturing the above laminated sheet.

That is, the present invention provides a manufacturing apparatus for a laminated sheet comprising: an impregnation portion forming means which is attached to the inside of the elongated fibrous base material so that the organic material is impregnated at a predetermined interval in the longitudinal direction of the fibrous base material a plurality of impregnation portions extending in a width direction of the fiber base material, and a supply means for supplying a resin layer to a surface or a back surface side of the fiber base material and a region between the impregnation portions of the fiber base material a conveying means for conveying the chamber of the fiber base material and the resin layer, and transporting the fiber base material and the resin layer along the longitudinal direction of the fiber base material toward the chamber; The control means is such that a region between the impregnation portions of the fiber base material and the resin layer are located in the chamber, and a region between the impregnation portion of the fiber base material and a downstream side in the conveyance direction and an upstream side a region in which the driving means is stopped in a state of being located outside the chamber; a decompression means for decompressing the chamber; and the chamber The fiber base material and the resin layer Heating means for impregnating the resin layer with the inside of the fiber substrate.

The present invention provides a method and apparatus for producing a laminated sheet which can obtain a desired laminated sheet.

1‧‧‧Prepreg

2‧‧‧Fiber substrate

3‧‧‧ resin layer, first resin layer

4‧‧‧ resin layer, second resin layer

5a, 5b‧‧‧Sheet

6‧‧‧Transportation means

7‧‧‧ chamber

8‧‧‧Decompression

9‧‧‧pressure means

12‧‧‧metal layer

20‧‧‧Center position of the thickness of the laminated sheet 40

21‧‧‧Immersion Department

30‧‧‧Laminated sheet manufacturing equipment

31‧‧‧Immersion formation means

32‧‧‧Supply means

40‧‧‧Layered film

61, 63‧‧‧ belt conveyor

62‧‧‧Transport roller

71‧‧‧Upside structure, first structure

72‧‧‧lower structure and second structure

73‧‧‧ Entrance

74‧‧‧Export

75, 76‧‧‧ Sealing members

77‧‧‧ Space

81‧‧‧ pump

82‧‧‧Connecting pipes and tubes

91‧‧‧Upper push member, first push member

92, 94‧‧‧ cylinder

93‧‧‧Bottom pressing member and second pressing member

95‧‧‧heating means, heater

96‧‧‧Detection means

97‧‧‧Discrimination means

98‧‧‧Control means

301‧‧‧1st impregnation

302, 402‧‧‧ Non-impregnated parts

311‧‧‧ Coating means

312‧‧‧ hardening means

321‧‧‧ Roll

322‧‧‧ Cutting means

401‧‧‧2nd Impregnation Department

711‧‧‧ top board

712, 712a, 712b, 722, 722a, 722b‧‧‧ side wall

721‧‧‧floor

921, 941‧‧‧ pole

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view showing a laminated sheet according to an embodiment of the present invention.

Figure 2 is a plan view of a laminated sheet.

Fig. 3 is a schematic view showing a means for forming an impregnation portion of the laminated sheet manufacturing apparatus of the present invention, taken along a longitudinal direction of the fiber base material.

Figure 4 is a schematic view of the supply means, taken along the longitudinal direction of the fibrous substrate.

Figure 5 is a cross-sectional view showing the chamber along a longitudinal direction of the fiber substrate.

Figure 6 is a cross-sectional view showing the chamber along a longitudinal direction of the fibrous substrate.

Figure 7 is a cross-sectional view showing the chamber along a longitudinal direction of the fibrous substrate.

Figure 8 is a cross-sectional view showing the chamber along a longitudinal direction of the fiber substrate.

Figure 9 is a cross-sectional view showing the chamber along a longitudinal direction of the fiber substrate.

Figure 10 is a cross-sectional view showing the chamber along the longitudinal direction of the fibrous substrate Cutaway view.

Figure 11 is a cross-sectional view showing the chamber, and a cross-sectional view taken along the line IX-IX of Figure 8.

Fig. 12 is a schematic view showing the results of the examples, comparative examples, and reference examples.

Hereinafter, embodiments of the present invention will be described based on the drawings. In the drawings, the same components are denoted by the same reference numerals, and the detailed description thereof will not be repeated.

First, the laminated sheet 40 manufactured by the manufacturing apparatus of this embodiment will be described.

<Laminated film>

First, the laminated sheet 40 will be described with reference to Fig. 1 . Further, the prepreg 1 is obtained by cutting at a predetermined size in the middle of the longitudinal direction of the laminated sheet 40. This prepreg 1 is used for a multilayer printed wiring board (circuit board), for example, as a core material. The metal layer 12 of the prepreg 1 is selectively removed to form a circuit layer, and further, other prepregs and circuit layers are alternately laminated on the front and back surfaces of the prepreg 1 to obtain a multilayer printed wiring board (circuit board). . Further, each of the resin layers 3 and 4 is in a B-stage state, and when used as a core material, the prepreg 1 is heat-cured to completely cure the resin layers 3 and 4 (C stage).

The laminated sheet 40 shown in Fig. 1 has a strip shape (long shape) as a whole, and has a thin plate-like (planar) fibrous base material (substrate) 2; one side of the fibrous base material 2 (upper surface) a side, a first resin layer (resin layer) 3 composed of a solid or semi-solid first resin composition; a second resin layer (resin layer) 4 composed of a solid or semi-solid second resin composition on the other surface (lower surface) side of the fiber base material 2; and a first resin layer 3 and a second resin layer The metal layer 12 on the resin layer 4. The laminated sheet 40 is cut into a predetermined size for use.

As shown in FIG. 2, the laminated sheet 40 is formed on one surface of the long-length fiber base material 2, and forms a sheet portion 5a (first sheet portion) composed of the first resin layer (resin layer) 3 and the metal layer 12. A plurality of structures are disposed apart from each other along the longitudinal direction of the fiber base material 2. 2 is a schematic view for easily understanding the case where a plurality of sheet portions 5a and 5b are separated from each other, and the length of the sheet portions 5a and 5b in the conveyance direction and the length of the conveyance direction of the impregnation portion 21 are not as shown in FIG. Consistent.

Further, on the other surface of the long-length fiber base material 2, the sheet portion 5b (second sheet portion) composed of the second resin layer (resin layer) 4 and the metal layer 12 is along the length of the fiber base material 2 A plurality of configurations are arranged in the side direction separation.

The first sheet portion 5a and the second sheet portion 5b are disposed at positions facing each other with the fiber base material 2 interposed therebetween. In the present embodiment, the length of the first sheet portion 5a and the second sheet portion 5b along the longitudinal direction of the fiber base material 2 is equal to the length of the gap between the impregnation portions 21. However, the length of the first sheet portion 5a and the second sheet portion 5b along the longitudinal direction of the fiber base material 2 may be shorter than the length of the gap between the impregnation portions 21.

Further, the first sheet portion 5a and the second sheet portion 5b may have a length along the longitudinal direction of the fiber base material 2, or may be longer than a length between the adjacent pair of impregnation portions 21, and a pair of adjacent impregnation portions. 21 lengths and a pair of impregnations 21 The total value along the length of the longitudinal direction of the fiber base material 2 is also short. In other words, the length of the first sheet portion 5a and the second sheet portion 5b along the longitudinal direction of the fiber base material 2 is longer than the length of the gap between the impregnation portions 21, and the end portion of the first sheet portion 5a and the second sheet portion 5b. The end portion may overlap with the impregnation portion 21.

The first sheet portions 5a and the second sheet portions 5b adjacent to each other in the longitudinal direction of the fiber base material 2 are separated from each other to expose the impregnation portion 21.

The prepreg 1 is obtained by cutting the fiber base material 2 between the fiber base material 2 and the second sheet portion 5b between the first sheet portions 5a. Further, each of the resin layers 3 and 4 is in a B-stage state.

The fibrous base material 2 has a function of enhancing the mechanical strength of the laminated sheet 40.

The fiber base material 2 is, for example, a glass fiber base material such as a glass woven fabric or a glass nonwoven fabric, and a poly arylene resin such as a polyamide resin fiber, an aromatic polyamide resin fiber, or a wholly aromatic polyamide resin fiber. Polyurethane resin fiber such as amine fiber, polyester resin fiber such as polyester resin fiber, aromatic polyester resin fiber or wholly aromatic polyester resin fiber, polyparaphenylene benzobisoxazole, poly a synthetic fiber substrate composed of a woven fabric or a non-woven fabric mainly composed of a quinone imine resin fiber or a fluororesin fiber, and a paper fiber substrate mainly composed of kraft paper, cotton velvet paper, cotton velvet and kraft pulp mixed paper. A fibrous base material such as an organic fiber base material.

Further, as the fiber base material, any of the above fibers may be used, or two or more kinds thereof may be used.

Among them, a fiber base material is preferably a fiber composed of any of glass, polyparaphenylene benzobisoxazole, and polyarylamine resin polyester.

Among these, the fiber base material 2 is preferably a glass fiber base material. By using the glass fiber base material, the mechanical strength of the prepreg 1 obtained by cutting the laminated sheet 40 can be improved. Further, there is also an effect of reducing the thermal expansion coefficient of the prepreg 1.

Examples of the glass constituting the glass fiber substrate include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, H glass, Q glass, quartz glass, etc., and any of them may be used. . Among these, glass is preferably S glass, T glass, quartz glass or Q glass. Thereby, the coefficient of thermal expansion of the glass fiber base material can be made small, so that the thermal expansion coefficient of the laminated sheet 40 can be made as small as possible.

Further, in the present invention, NE glass, S glass, and T glass are more preferable from the viewpoint of easily reducing the difference in the curvature of the impregnation portion 21, and E glass is more preferable from the viewpoint of economy.

The average thickness T of the fibrous base material 2 is not particularly limited, and is preferably 150 μm or less, more preferably 100 μm or less, and still more preferably about 10 to 50 μm. By using the fiber base material 2 having such a thickness, the mechanical strength of the prepreg 1 (the laminated sheet 40) can be ensured, and the thickness thereof can be reduced. Further, the workability and dimensional stability of the prepreg 1 can also be improved.

The first resin layer 3 is provided on one surface side of the fiber base material 2, and the second resin layer 4 is provided on the other surface side. Further, the first resin layer 3 is composed of a first resin composition, and the second resin layer 4 is composed of a second resin composition. The first resin composition and the second resin composition may be the same composition or a different one. In the present embodiment, the same composition is used.

In the present embodiment, above the first resin layer 3 and the second resin layer 4 Metal layers 12 are formed separately. The metal layer 12 is a wiring portion (conductor pattern) by performing, for example, etching or laser processing. Therefore, the first resin composition and the second resin composition are set to have a composition excellent in adhesion to metals.

As shown in Fig. 1, in the present embodiment, a part of the thickness of the fiber base material 2 in the thickness direction is impregnated with the first resin composition (first resin layer 3) (hereinafter referred to as "the first impregnation portion 301"), and the fiber base The remaining portion of the material 2 which is not impregnated with the first resin composition is impregnated with the second resin composition (second resin layer 4) (hereinafter referred to as "second impregnation portion 401"). Thereby, the first impregnation portion 301 which is a part of the first resin layer 3 and the second impregnation portion 401 which is a part of the second resin layer 4 are located in the fiber base material 2. In the fiber base material 2, the first impregnation portion 301 (the lower surface of the first resin layer 3) and the second impregnation portion 401 (the upper surface of the second resin layer 4) are in contact with each other. In other words, the first resin composition is impregnated into the fiber base material 2 from the upper surface side of the fiber base material 2, and the second resin composition is impregnated into the fiber base material 2 from the lower surface side of the fiber base material 2, by which The resin composition fills the voids in the fibrous base material 2.

Further, in the first resin layer 3, the region not impregnated into the fibrous base material 2 is the non-impregnated portion 302, and the region in the second resin layer 4 not impregnated with the fibrous base material 2 is the non-impregnated portion 402.

In the present embodiment, the thickness of the first impregnation portion 301 and the thickness of the second impregnation portion 401 are equal.

Further, the thickness of the first non-impregnated portion 302 of the first resin layer 3 and the thickness of the second non-impregnated portion 402 of the second resin layer 4 are equal. 1st The thickness of the non-impregnated portion 302 and the thickness of the second non-impregnated portion 402 are, for example, 2 to 20 μm. Further, the thickness of the first impregnation portion 301 and the thickness of the second impregnation portion 401 may be different, and the thickness of the first non-impregnation portion 302 and the thickness of the second non-impregnation portion 402 may be different. Further, reference numeral 20 of Fig. 1 denotes the center position of the thickness of the laminated sheet 40.

As shown in FIG. 5, the first resin layer 3 is supplied to the chamber 7 of the laminated sheet manufacturing apparatus 30 as a first sheet portion (sheet portion) 5a having a thin plate shape in a state in which the metal layer 12 is laminated. The second resin layer 4 is supplied to the chamber 7 of the laminated sheet manufacturing apparatus 30 as a second sheet portion (sheet portion) 5b having a thin plate shape in a state in which the metal layer 12 is laminated.

The metal layer 12 is processed in a portion of the wiring portion as described above, and is made of a conductive metal material. For example, a metal foil such as a copper foil or an aluminum foil is bonded to a corresponding resin layer, or copper or aluminum is plated. And formed on the surface of the corresponding resin layer. In the present embodiment, the first resin layer 3 or the second resin layer 4 has the characteristics as described above, and the metal layer 12 can be held with high adhesion, and the metal layer 12 can be formed in the wiring portion with high processing accuracy. .

The peeling strength of the metal layer 12 and the first resin layer 3 or the second resin layer 4 is preferably 0.3 kN/m or more, more preferably 0.6 kN/m or more. Thereby, the metal layer 12 is processed on the wiring portion, and for example, the reliability of electrical connection with the semiconductor device can be improved.

Next, the first resin composition and the second resin composition are preferably the following compositions.

The first resin composition contains, for example, a curable resin, and is contained as needed. It is composed of at least one of a curing aid (for example, a curing agent, curing promotion, and the like) and an inorganic filler.

Examples of the curable resin include urea (urea) resin, melamine resin, maleic imine compound, polyurethane resin, unsaturated polyester resin, resin having benzoxazine ring, and diene. Thermosetting resin such as bis-allylnadiimide compound, vinylbenzyl resin, vinyl benzyl ether resin, benzocyclobutene resin, cyanate resin, epoxy resin, etc. Resin, anaerobic resin, etc. Any one or more of these may be used. Among these, a combination of a curable resin and a glass transition temperature of 200 ° C or higher is preferred. For example, an epoxy resin having a spiro ring, a heterocyclic formula, a trimethylol type, a biphenyl type, a naphthalene type, an anthracene type, a novolac type, or a cyanate resin (containing a cyanate resin) is used. The prepolymer), the maleimide compound, the benzocyclobutene resin, and the benzoxazine ring are preferably preferred. Any one or more of these may be used.

Further, in the above-mentioned curable resin, after further forming a substrate to be described later by using a thermosetting resin, that is, by increasing the crosslinking density in the cured resin layers 3 and 4, the resin layer 3 after the hardening can be achieved. 4, the heat resistance of the obtained substrate.

By using the thermosetting resin and the filler in combination, the thermal expansion coefficient of the prepreg 1 (hereinafter sometimes referred to as "low thermal expansion") can be reduced. Further, it is also possible to improve the electrical characteristics (low dielectric constant, low dielectric tangent) of the prepreg 1 and the like.

The epoxy resin may, for example, be a phenol novolak type epoxy resin, a bisphenol type epoxy resin, a naphthalene type epoxy resin, a fluorene type epoxy resin, or an aryl extension. An alkyl type epoxy resin or the like. Any one or more of these may be used.

Among these, epoxy resin is preferably a naphthalene type or arylalkylene type epoxy resin. By using a naphthalene type or arylalkylene type epoxy resin, the cured first resin layer 3 (the obtained substrate) can improve moisture absorption solder heat resistance (solder heat resistance after moisture absorption) and flame retardancy. . Examples of the naphthalene type epoxy include HP-4700, HP-4770, HP-4032D, HP-5000 manufactured by DIC Co., Ltd., NC-7300L manufactured by Nippon Kayaku Co., Ltd., and Nippon Steel Chemical Co., Ltd. ESN-375, etc.; an arylalkylene type epoxy resin, NC-3000, NC-3000L, NC-3000-FH, and Nippon Chemical Co., Ltd. made by Nippon Kayaku Co., Ltd. 7300L, ESN-375, manufactured by Nippon Steel Chemical Co., Ltd. The arylalkylene type epoxy resin is an epoxy resin having a combination of one or more aromatic groups and an alkyl group such as a methyl group in a repeating unit, and is excellent in heat resistance, flame retardancy, and mechanical strength. Further, in order to correspond to a halogen-free wiring board, it is preferable to use an epoxy resin which does not substantially contain a halogen.

The cyanate resin can be obtained by, for example, reacting a halogenated cyanide compound with a phenol or a naphthol, and if necessary, prepolymerizing by heating or the like. Further, a commercially available product thus prepared can also be used.

Examples of the cyanate resin include a bisphenol type such as a phenolic type cyanate resin, a bisphenol A type cyanate resin, a bisphenol E type cyanate resin, and a tetramethyl bisphenol F type cyanate resin. A cyanate resin, a naphthol aralkyl type cyanate resin, or the like. Any one or more of these may be used.

Further, the cyanate resin preferably has two or more cyanate groups (-O-CN) in the molecule. For example, 2,2'-bis(4-cyanooxyphenyl)isopropylidene, 1,1'-bis(4-cyanooxyphenyl)ethane, bis(4-cyanooxy-3), 5- Dimethylphenyl)methane, 1,3-bis(4-cyanooxyphenyl-1-(1-methylethylidene))benzene, bis(4-cyanooxyphenyl) sulfide group, double ( 4-cyanooxyphenyl)ether, 1,1,1-tris(4-cyanooxyphenyl)ethane, tris(4-cyanooxyphenyl)phosphite, bis(4-cyanooxyphenyl)phosphonium , 2,2-bis(4-cyanooxyphenyl)propane, 1,3-, 1,4-, 1,6-, 1,8-, 2,6- or 2,7-dicyanooxynaphthalene , 1,3,6-tricyanooxynaphthalene, 4,4-dicyanooxybiphenyl and phenol novolac type, cresol novolac type, dicyclopentadiene type and other polyvalent phenols, by reacting with cyanogen halide The obtained cyanate resin, naphthol aralkyl type polyvalent naphthol, cyanate resin obtained by reacting with cyanogen halide, and the like. Among these, any one or more of these may be used. Among these, the phenol novolac type cyanate resin is excellent in flame retardancy and low thermal expansion property, and 2,2-bis(4-cyanooxyphenyl)isopropylidene and dicyclopentadiene type cyanate resins are used. It is excellent in joint density control and moisture resistance reliability. In particular, a phenol novolac type cyanate resin is preferred in terms of low thermal expansion property. Further, one or two or more other cyanate resins may be used in combination, and are not particularly limited.

The cyanate resin may be used singly or in combination with a cyanate resin having a different weight average molecular weight or a prepolymer of the cyanate resin.

By using these cyanate resins, heat resistance and flame retardancy can be exhibited with effect.

Further, the curable resin may be used in combination of two or more kinds. For example, when the epoxy resin is used as the curable resin, the cyanate resin may be used in combination in order to improve the flame retardancy, and the maleidene compound may be used in combination in order to improve the heat resistance. Further, using the foregoing When the cyanate resin is used as a curable resin, the above epoxy resin may be used in combination in order to further improve heat resistance, flame retardancy and the like.

The content of the curable resin is not particularly limited, and is preferably 5 to 70% by mass of the entire first resin composition, and more preferably 10 to 50% by mass. When the content of the curable resin is less than the above-described lower limit, the viscosity of the varnish of the first resin composition may be too low, and the prepreg 1 may be formed. On the other hand, when the content of the curable resin is more than the above upper limit, the amount of the other components is too small, and the mechanical strength of the prepreg 1 may be lowered depending on the type of the curable resin.

Further, the resin composition preferably contains an inorganic filler. Thereby, even if the prepreg is made thin (for example, the thickness is 35 μm or less), a substrate excellent in mechanical strength can be obtained. Further, the low thermal expansion of the substrate can also be improved.

Examples of the inorganic filler include talc, alumina, glass, cerium oxide such as molten cerium oxide, mica, aluminum hydroxide, magnesium hydroxide, and the like. Further, in view of the purpose of use of the inorganic filler, it is preferable to select a crushed or spherical shape. Among these, the inorganic filler is preferably cerium oxide, and the molten cerium oxide (especially spherical molten cerium oxide) is more preferable from the viewpoint of excellent low thermal expansion property.

Further, the resin composition may contain other components as needed in addition to the components described above as long as the effects of the present invention are not impaired. Other components include, for example, tackifiers such as Oruben and Benton, polyfluorene-based, fluorine-based, polymeric antifoaming agents or leveling agents, A coloring agent such as a binding agent such as a coupling agent, a flame retardant, a phthalocyanine blue, a phthalocyanine green, an iodine green, a disazo yellow, a carbon black, or a hydrazine.

<Laminar sheet manufacturing apparatus>

Next, a laminated sheet manufacturing apparatus 30 used for the production of the laminated sheet 40 will be described with reference to FIGS. 3 to 11 .

First, an outline of the laminated sheet manufacturing apparatus 30 will be described.

The laminated sheet manufacturing apparatus 30 includes an impregnation portion forming means 31 (see FIG. 3) which is attached to the inside of the elongated fibrous base material 2, and impregnates the organic material in the longitudinal direction of the fibrous base material 2 at predetermined intervals. An impregnation portion 21 extending in the width direction of the fiber base material 2 is formed; and a supply means 32 (see FIG. 4) is formed such that a region between the impregnation portions 21 of the fiber base material 2 faces the resin layers 3, 4 The resin layers 3 and 4 are supplied onto the fiber base material 2; the fiber substrate 2 and the chambers 7 of the resin layers 3 and 4 are transported (see FIG. 5); and the fiber base material 2 and the resin layers 3 and 4 are disposed. a conveying means 6 (see FIG. 5) for transporting the chamber 7 along the longitudinal direction of the fiber base material 2, and a control means 98 (see FIG. 5) for allowing the impregnation portion 21 of the fiber base material 2 The region and the resin layers 3 and 4 are located in the chamber 7, and the fiber substrate 2 on the downstream side in the conveyance direction and the upstream side of the fiber substrate 2 are exposed from the chamber 7 in a region between the impregnation portions 21, and the driving is stopped. Means 6; a decompression means 8 for decompressing the inside of the chamber 7 (refer to FIG. 5); and a fibrous substrate 2 and a tree in the chamber 7 The fat layers 3 and 4 are heated to impregnate the resin layers 3 and 4 with the heating means 95 inside the fiber base material 2 (see Fig. 5).

Next, the laminated sheet manufacturing apparatus 30 will be described in detail.

The laminated sheet manufacturing apparatus 30 includes the impregnation unit forming means 31, the conveying means 6, the supply means 32, the chamber 7, the decompression means 8, the heating means 95, and the control means 98, and further includes a pressurizing means 9 (see Fig. 5). ). Hereinafter, the configuration of each part will be described.

The impregnation portion forming means 31 will be described with reference to Fig. 3 . 3 is a cross-sectional view along the longitudinal direction of the fiber base material 2.

As shown in FIG. 3, the impregnation portion forming means 31 is such that the organic material is impregnated into the inside of the elongated fibrous base material 2 to form the impregnation portion 21. The fiber base material 2 is wound, for example, on a supply roller (not shown), and is supplied from the supply roller to the impregnation portion forming means 31.

The impregnation portion 21 is formed in plural in a longitudinal direction of the fiber base material 2 at a predetermined interval. Further, in the present embodiment, the impregnation portion 21 extends over the entire width direction of the fiber base material 2. However, the impregnation portion 21 may be extended in the width direction of the fiber base material 2. Further, the impregnation portion 21 may be such that the organic material enters the inside of the fiber base material 2, and may not completely fill the inside of the fiber base material 2.

The impregnation portion forming means 31 includes a coating means 311 for applying an organic material to the fibrous base material 2, and a hardening means 312 for curing the applied organic material.

The coating means 311 is applied over the entire width direction of the fiber base material 2, and the organic material is applied at a predetermined interval in the longitudinal direction of the fiber base material 2. Specifically, the coating means 311 is a die coater or the like, and the organic material is applied to the width direction of the fiber base material 2 by the coating means 311, and then conveyed by the transport means 6 (here, for example, the belt conveyor 61). The fibrous substrate 2 is until the coated organic material is positioned opposite the hardening means 312. The fibrous base material 2 is conveyed along the longitudinal direction thereof.

In addition, the organic material may be a resin material having a curable monomer or an oligomer and impregnated into the fiber base material 2 to form a resin, and may be a resin component in advance. However, in consideration of the ease of impregnation of the fibrous base material 2, the resin material is preferably a hardenable organic material which can be hardened after being impregnated into the fibrous base material 2.

The organic material is, for example, a photocurable monomer or oligomer. The photocurable monomer is preferably an epoxy compound or an acrylic compound. Examples of the acrylic compound include monomers of acrylate or methacrylate, and specific examples thereof include ethylene glycol diacrylate, ethylene glycol dimethacrylate, and 1,6-hexanediol diacrylate. Ester, 1,6-hexanediol dimethacrylate, glyceryl diacrylate, glyceryl dimethacrylate, 1,10-decanediol diacrylate, 1,10-decanediol dimethacrylate Equivalent bifunctional acrylate, trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, pentaerythritol triacrylate, pentaerythritol trimethacrylate, dipentaerythritol hexaacrylate, dipentaerythritol hexamethacrylate A multifunctional acrylate such as an ester. Any one or more of these may be used.

Further, among these, acrylate is preferred, and an acrylate or alkyl methacrylate having a carbon number of 1 to 15 in the ester moiety is particularly preferred.

Further, the organic material may also contain a photopolymerization initiator.

Further, the organic material may contain an epoxy group-containing monomer or an epoxy group-containing oligomer as an epoxy compound. The monomer or oligomer having an epoxy group is polymerized by ring opening in the presence of an acid. Organic material contains light An acid generator, and hardening polymerization is started by an acid produced by the photoacid generator.

As the monomer having an epoxy group and the oligomer having an epoxy group, epoxy norbornene (EpNB manufactured by Promerus) can be used.

Further, 3,4-epoxycyclohexylmethyl-3',4'-epoxycyclohexylformate (Celloxide 2021P manufactured by DAICEL Chemical Co., Ltd.), 1,2-epoxy-4-vinylcyclohexane can be used. (Celloxide 2000 manufactured by DAICEL Chemical Co., Ltd.), 1,2:8,9 bisepoxide limonene (Celloxide 3000 manufactured by DAICEL Chemical Co., Ltd.). Any one or more of these may be used. Among them, it is preferred that the bending curvature after hardening is close to the fiber substrate 2. Although the details will be described later, in order to detect the position of the impregnation portion 21 to position the chamber 7, if the difference between the bending curvature of the impregnation portion 21 and the bending curvature of the fiber base material 2 is small, the difference between the impregnation portions can be easily performed. 21 and sheet portions 5a, 5b. The difference between the folding curvature of the hardened organic material and the bending curvature of the fibers constituting the fiber base material 2 is preferably, for example, 0 to 0.08. Further, the refractive index of the fiber base material 2 was 1.558 in E glass and 1.524 in T glass.

As the photoacid generator, as long as it absorbs light energy to form Brinellic acid or Lewis acid, for example, triphenylsulfonium hexafluorophosphate, triphenylsulfonium trifluoromethanesulfonate, or tris(3) a diazonium salt such as 4-t-butylphenyl)phosphonium trifluoromethanesulfonate or a diazonium salt such as p-nitrophenylhexafluorophosphate diazonium salt, an ammonium salt, a phosphonium salt or a diphenyliodine Diazomethane such as trifluoromethanesulfonate or (triisopropylphenyl)iodine ion tetrakis(pentafluorophenyl)borate; diazomethane such as quinonediazide or di(phenylindole)diazomethane a sulfonic acid such as 1-phenyl-1-(4-methylphenyl)sulfonyloxy-1-benzimidethane or N N-hydroxynaphthyl imine-trifluoromethanesulfonate Diesters such as esters, diphenyl difluorene, tris(2,4,6-trichloromethyl)-s-triazine, 2-(3.4-methylenedioxyphenyl)-4,6-double - A compound such as a triazine such as (trichloromethyl)-s-triazine. These photoacid generators may be used singly or in combination.

The organic material is in the form of a varnish, and after being applied to the surface of the fibrous base material 2, it is impregnated into the inside of the fibrous base material 2 by atmospheric pressure and capillary force.

In the present embodiment, the curing means 312 is formed by irradiating light to the applied organic material to form the impregnation portion 21. In the present embodiment, for example, a UV lamp or the like is used. However, the organic material may also be hardened by electron beam irradiation or heat treatment. Therefore, when curing the photocurable organic material, at least one of light irradiation, ultraviolet beam irradiation, and electron beam irradiation and heat treatment may be used. However, in order to sufficiently increase the crosslinking density of the organic material, it is preferred to use them in combination. Ultraviolet irradiation or electron beam irradiation and heat treatment.

Further, in the present embodiment, the organic material is set to be photocurable. The fibrous base material 2 is transparent, and since the inside easily passes light, the light can be surely irradiated with the organic material to form the impregnation portion 21.

Further, by using a photocurable organic material, the time required for hardening can be made shorter, and productivity can be improved.

The supply means 32 is disposed on the downstream side of the fiber substrate 2 in the conveyance direction of the impregnation portion forming means 31, and a resin layer is disposed on at least one of the front surface and the back surface of the fiber base material 2 (see FIG. 4). 4 is a schematic view showing the length of the sheet portions 5a and 5b in the conveyance direction and the length of the conveyance direction of the impregnation portion 21, which are not in accordance with FIG. 5.

By means of transport 6 (for example, the aforementioned belt conveyor 61 and handling The roller 62) sends the fiber base material 2 from the impregnation portion forming means 31 to the supply means 32. The fibrous base material 2 is conveyed along the longitudinal direction thereof.

In the present embodiment, the supply means 32 has a supply roller (not shown), a cutting means 322, and a pair of rollers 321. The outer peripheral surface of the pair of rolls 321 is a resin (made of rubber) pinch rolls.

A supply roll (not shown) is wound around the elongated first sheet. This sheet is cut as the sheet portion 5a. The sheet is supplied from the supply roller to between the pair of rollers 321. Then, the supply of the sheet from the supply roller is stopped, and the sheet is cut to a desired length by the cutting means 322. Thereby, the sheet portion 5a is formed.

At the same time, other supply rolls, not shown, are wound around other elongated second sheets. This sheet is cut as the sheet portion 5b. The sheet is supplied from the supply roller to between the pair of rollers 321. Then, the supply of the sheet from the supply roller is stopped, and the sheet is cut to a desired length by the cutting means 322. Thereby, the sheet portion 5b is formed.

Further, from the aforementioned supply roller, a sheet as the sheet portion 5a or a sheet as the sheet portion 5b is intermittently supplied at a predetermined timing. In the present embodiment, the timing of supplying the sheet from the supply roller is controlled so that the sheet portions 5a and 5b do not overlap the impregnation portion 21.

The sheet portions 5a and 5b are respectively disposed on the front and back surfaces of the fiber base material 2, and are supplied between the pair of rolls 321 together with the fiber base material 2. Specifically, the sheet portion 5 a is disposed on the surface side of the region between the impregnation portions 21 of the fiber base material 2 , and the region between the resin layer 3 and the impregnation portion 21 of the fiber base material 2 faces each other.

On the other hand, the sheet portion 5b is disposed in the impregnation portion of the fiber base material 2. On the back side of the region of 21, the region between the resin layer 4 of the sheet portion 5b and the impregnation portion 21 of the fiber substrate 2 faces each other. The sheet portions 5a and 5b are opposed to each other via the fiber base material 2.

The pair of rollers 321 abuts the sheet base portions 5a and 5b against the fiber base material 2. It is preferable that a pair of seals are disposed on the downstream side of the pair of rolls 321 in the conveyance direction of the fiber base material 2. The sealing strips which are opposed to each other by sandwiching the fiber base material 2 and the sheet portions 5a and 5b are brought close to each other, and one of the sealing strips is brought into contact with the sheet portion 5a, and the other sealing strip is brought into contact with the sheet portion 5b. Thereby, a part of the resin layers 3 and 4 is heated, and a part of the sheet portions 5a and 5b is melt-bonded to the fiber base material 2. For example, one end portion orthogonal to the conveyance direction of the sheet portions 5a and 5b is melt-bonded to the fiber base material 2.

In addition, the sheet portions 5a and 5b are disposed on the fiber base material 2, but the end surface (the end surface of the end portion in the TD direction) along the conveyance direction of the fiber base material 2 is not subjected to the first sheet portion 5a or the second sheet portion 5b. Covered, exposed. The width of the sheet portions 5a and 5b (the length in the direction orthogonal to the longitudinal direction of the fiber base material 2) is equal to or wider than the width of the fiber base material 2.

Among them, the first sheet portion 5a includes the first resin layer 3 and the metal layer 12 as a support for supporting the first resin layer 3. The second sheet portion 5b includes the second resin layer 4 and the metal layer 12 as a support for supporting the second resin layer 4. The first resin layer 3 and the second resin layer 4 are composed of a solid or semi-solid resin composition, and are in a B-stage state.

Further, the first resin layer 3 and the second resin layer 4 may be a liquid resin composition.

Further, the thickness of each of the resin layers 3 and 4 of the sheet portions 5a and 5b is, for example, 3 to 60 μm, preferably 5 to 30 μm. Further, the thickness of the metal layer 12 is, for example, 1 to 70 μm.

The chamber 7 shown in Fig. 5 is disposed on the downstream side of the supply means 32 in the sheet conveying direction. The fiber base material 2 and the sheet portions 5a and 5b are conveyed to the chamber 7 by the transport means 6 (here, for example, the belt conveyor 63).

The belt conveyor 63 is disposed on both sides of the chamber 7 via the chamber 7 . The belt conveyor 63 can convey the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b at a time from the left side to the right side (in the longitudinal direction), that is, in the horizontal direction. That is, the belt conveyor 63 supplies the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b into the chamber 7, and feeds the fiber base material 2 and the first sheet portion 5a from the chamber 7 and The second sheet portion 5b.

When the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are conveyed by the belt conveyor 63, the upper surface of the fiber base material 2 faces the first resin layer 3 of the first sheet portion 5a. The lower surface of the fiber base material 2 is in a state of being opposed to the second resin layer 4 of the second sheet portion 5b.

In the chamber 7, the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b conveyed by the transport means 6 are passed while being maintained in a relative state, and at this time, they are pressed.

The chamber 7 is composed of an upper structure (first structure) 71 and a lower structure (second structure) 72 that are close to/separated from each other in the vertical direction.

The upper side structure 71 has a top plate 711 and a rim surrounding the top plate 711 The side wall 712 formed throughout the circumference. The side wall 712 protrudes downward from the edge of the top plate 711. The lower structure 72 has a bottom plate 721 and a side wall 722 formed over the entire circumference of the edge of the bottom plate 721. The side wall 722 protrudes upward from the edge of the bottom plate 721.

When the upper side structure 71 and the lower side structure body 72 are separated by a predetermined distance or more (hereinafter referred to as "separated state"), the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b can be fed into the same. The inside of the structures 71 and 72 can also be sent to the outside of the structures 71 and 72. In the chamber 7, the portion on the left side in the drawing between the upper side structure 71 and the lower side structure body 72 is the inlet 73, and the portion on the right side is the outlet 74. More specifically, the side wall 712A and the side wall 722A are partitioned into the inlet, and the side wall 712A is disposed in the pair of side walls 712 of the upper side structure body 71 orthogonal to the conveyance direction of the fiber base material 2 or the like, and is disposed upstream of the conveyance side. On the side, the side wall 722A is disposed on the upstream side of the conveyance side among the pair of side walls 722 of the side structure body 72 that is orthogonal to the conveyance direction of the fiber base material 2 or the like. In addition, the side wall 712B and the side wall 722B are arranged in the downstream side of the pair of side walls 712 of the side structure 71 which is orthogonal to the conveyance direction of the fiber base material 2 and the side wall 722B. The side wall 722B is disposed on the downstream side in the conveyance direction among the pair of side walls 722 of the side structure 72 that is orthogonal to the conveyance direction of the fiber base material 2 or the like. The opposite end faces of the side walls 712A, 722A are inlets, and the opposite end faces of the side walls 712B, 722B are outlets.

The constituent materials of the upper side structure 71 and the lower side structure body 72 are not particularly limited, and examples thereof include various metals such as iron, stainless steel, and aluminum, or the like. Alloys.

The portion of the upper structure 71 that partitions the inlet 73 (that is, the end surface of the side wall 712A) and the portion that partitions the outlet 74 (that is, the end surface of the side wall 712B) are respectively provided with a sealing member 75 made of an elastic material. Further, a portion of the lower structure 72 that partitions the inlet 73 (that is, an end surface of the side wall 722A) and a portion that partitions the outlet 74 (that is, an end surface of the side wall 722B) are also respectively provided with a sealing member 76 made of an elastic material. . Each of the sealing members 75 and 76 has a circular cross-sectional shape to form a circular member. The sealing member 75 is fixed to the lower portion of the side walls 712A and 712B of the upper structure 71, and the sealing member 76 is fixed to the upper portion of the side walls 722A and 722B of the lower structure 72.

Further, as shown in FIG. 6 to FIG. 8 , the sealing member 75 and the sealing member 76 sandwich the impregnation of the fiber base material 2 in a state in which the upper side structure 71 and the lower side structure body 72 are close to each other (hereinafter referred to as "closed state"). Department 21. That is, the sealing member 75 is in close contact with the surface side of the impregnation portion 21, and the sealing member 76 is in close contact with the back surface side of the impregnation portion 21. More specifically, the portion of the upper structure 71 that partitions the inlet and the portion of the lower structure 72 that partitions the inlet are sandwiched by the sealing member 75 and the sealing member 76. Further, the portion of the upper structure 71 that partitions the outlet and the portion of the lower structure 72 that partitions the outlet are sandwiched by the sealing member 75 and the sealing member 76.

Thereby, the airtightness in the space 7 which is the space 77 which the upper side structure 71 and the lower side structure 72 are partitioned is maintained. At this time, the inside of the space 77 can be decompressed by the decompression means 8.

Further, although not shown here, among the four side walls of the upper structure 71, a sealing member is also disposed at the lower end portion of the side wall other than the side walls 712A and 712B. Similarly, among the four side walls of the lower structure 72, a sealing member is also disposed at the upper end portion of the side wall other than the side walls 722A and 722B. Thereby, the airtightness in the chamber 7 can be maintained.

The constituent materials of the sealing members 75 and 76 are not particularly limited, and examples thereof include natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, nitrile rubber, neoprene rubber, and butyl rubber. Various rubber materials such as acrylic rubber, ethylene-propylene rubber, polyepichlorohydrin rubber, urethane rubber, polyoxyethylene rubber, fluororubber (especially those treated with sulfur), or styrene or polyene Various thermoplastic elastomers such as polyvinyl chloride, polyurethane, polyester, polyamine, polybutadiene, trans-polyisoprene, fluororubber, and chlorinated polyethylene. One or two or more of these may be used.

The decompression means 8 is a system that decompresses the inside of the chamber 7 into a negative pressure, and has two sets of pumps 81 and a connecting pipe (tube) 82.

One of the (upper side in the drawing) connecting pipes 82 is connected to the top plate 711 of the upper side structure 71, and the top plate 711 has an opening. Thereby, the connecting pipe 82 is connected to the inside of the chamber 7. One of the pumps 81 and the upper side structure 71 are caused by the connecting pipe 82.

The other set (lower side in the drawing) of the connecting pipe 82 is connected to the bottom plate 721 of the lower side structure 72, and the bottom plate 721 has an opening. Thereby, the connecting pipe 82 is connected to the inside of the chamber 7. The other pump 81 is connected to the lower structure 72 by the connecting pipe 82.

Each pump 81 is disposed outside the chamber 7, for example, a vacuum pump. Each of the connecting pipes 82 is a rigid pipe made of a metal material such as stainless steel or the like.

Further, as shown in FIGS. 7 and 8, in the closed state of the chamber 7, the respective pumps 81 are activated, and the air G in the space 77 can be sucked through the respective connecting pipes 82, so that the space 77 can be surely provided. stress reliever.

In the chamber 7 in the closed state, the pressurizing means 9 presses the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b in the opposite direction at a time in the thickness direction (see Fig. 8). .

In the chamber 7 in the closed state, the pressurizing means 9 presses the fiber base material 2 and the first sheet portion 5a in the opposing state together in the thickness direction.

The pressurizing means 9 includes an upper pressing member (first pressing member) 91, a cylinder barrel 92 coupled to the upper pressing member 91, a lower pressing member (second pressing member) 93, and a lower side pressing force. The cylinder 94 of the member 93.

Further, the laminated sheet manufacturing apparatus 30 may have only one of the cylinders 92 and 94. In other words, the pressing members 91 and 93 can be driven and approached and separated by only one of the upper pressing member 91 and the lower pressing member 93.

The upper pressing member 91 is a member that is placed in the chamber 7 and that presses the first sheet portion 5a from the upper side thereof. The upper pressing member 91 is formed into a flat rectangular plate shape, and the entire length thereof (the length along the conveyance direction of the fiber base material 2 or the like) is the prepreg 1 (or the first sheet portion 5a) formed by cutting the laminated sheet 40. The total length is substantially the same or shorter than the total length. Further, the width of the upper pressing member 91 (the length in the direction toward the depth of the paper surface in Fig. 5) is larger than that of the prepreg 1 The width of the ply 40) is also wide.

The upper surface of the upper pressing member 91 is coupled to the cylinder 92. The cylinder barrel 92 is a driving means for bringing the upper pressing member 91 into contact with and separating the lower pressing member 93. The cylinder 92 has a rod 921 that is freely detachable, and the upper pressing member 91 can be moved in the vertical direction by the presence of the rod 921. Further, when the upper pressing member 91 is moved downward, the first sheet portion 5a can be pressed from the upper side. Further, the cylinder 92 is a rod 921 that penetrates the top plate 711 of the upper structure 71, and is mostly located outside the chamber 7.

The lower pressing member 93 is a member that is located in the chamber 7 and that presses the second sheet portion 5b from the lower side thereof. The lower pressing member 93 and the upper pressing member 91 are in the shape of a flat rectangular plate, and the total length thereof is substantially the same as the total length of the prepreg 1 (or the second sheet portion 5b) formed by the cut laminated sheet 40 or Shorter than this full length. Further, the width of the lower pressing member 93 is wider than the width of the prepreg 1.

The lower surface of the lower pressing member 93 is coupled to the cylinder 94. The cylinder tube 94 is a driving means for bringing the lower pressing member 93 closer to and separated from the lower pressing member 91. The cylinder tube 94 has a rod 941 that is freely detachable, and the lower side pressing member 93 can be moved in the vertical direction by the presence of the rod 941. Further, when the lower pressing member 93 is moved upward, the second sheet portion 5b can be pressed from the lower side. Further, the cylinder 94 tie rod 941 penetrates the bottom plate 721 of the lower side structure 72, and is mostly located outside the chamber 7.

The cylinder 92 is configured to adjust the amount of protrusion of the rod 921, that is, the magnitude of the pressure, and the cylinder 94 is also configured to adjust the amount of protrusion of the rod 941, that is, the magnitude of the pressure. Thereby, the first resin of the first sheet portion 5a can be used. The degree of impregnation of the layer 3 with respect to the fiber base material 2 (the average thickness of the first impregnation portion 301) and the degree of impregnation of the second resin layer 4 of the second sheet portion 5b with the fiber base material 2 (the average thickness of the second impregnation portion 401) ), adjust to the desired size.

The constituent materials of the upper pressing member 91 and the lower pressing member 93 are not particularly limited, and a metal material such as stainless steel or the like can be used. Further, a rubber, a glass plate, and particularly a member having a high surface smoothness can be attached to a surface facing the metal material. Thereby, the laminated sheet 40 excellent in smoothness can be obtained further.

The cylinders 92 and 94 are not particularly limited, and for example, a hydraulic cylinder or a cylinder can be used.

Further, the upper pressing member 91 and the lower pressing member 93 are each provided with a heater 95 (heating means) made of, for example, a heating wire. Thereby, the first support body 5a can be surely heated by the upper side pressing member 91, and the second sheet portion 5b can be surely heated via the lower side pressing member 93. Further, the resin layers 3 and 4 are impregnated into the fiber base material 2 by the upper pressing member 91 and the lower pressing member 93.

In the present embodiment, the heater 95 is provided in both the upper pressing member 91 and the lower pressing member 93. However, the present invention is not limited thereto. For example, the heater 95 may be provided only inside the upper pressing member 91 and the lower pressing member. One of the 93s.

Further, as shown in FIG. 5, the laminated sheet manufacturing apparatus 30 includes a detecting means 96, a determining means 97, and a control means 98.

The detecting means 96 detects the gap between the adjacent first sheet portions 5a (the gap between the adjacent second sheet portions 5b), that is, the position of the impregnation portion 21. Check The measuring means 96 is exemplified by a CCD camera or the like.

The discriminating means 97 determines whether or not a part of the fibrous base material 2 (the region between the impregnation portions 21) and the respective sheet portions 5a, 5b have been transported to a predetermined position in the chamber 7. Specifically, it is determined by the discriminating means 97 whether or not the position of the impregnation portion 21 detected by the detecting means 96 is a predetermined position. Here, the predetermined position is a portion of the impregnation portion 21 and the partition inlet of the upper structure 71 and a portion of the lower structure 72 that faces the inlet portion.

In other words, the impregnation portion 21 is located opposite to the sealing member 75 provided on the side wall 712A of the upper side structure body 71, and the impregnation portion 21 is located at a position facing the sealing member 76 provided on the side wall 722A of the lower side structure body 72.

When it is discriminated by the discriminating means 97 that a part of the fibrous base material 2 and the sheet portions 5a, 5b have been conveyed to a predetermined position in the chamber 7, that is, when the impregnation portion 21 is determined to be at the predetermined position, the control means 98 is determined. The belt conveyor 63 that drives the conveyance means 6 is stopped. On the other hand, when it is not discriminated by the discriminating means 97 that a part of the fibrous base material 2 and the sheet portions 5a, 5b have been conveyed to a predetermined position in the chamber 7, it is judged that the impregnation portion 21 is not located in the aforementioned predetermined state. At the position, the control means 98 controls the belt conveyor 63 of the transport means 6 so as not to stop driving.

Further, in the present embodiment, the position of the impregnation portion 21 on the inlet side of the chamber 7 is detected by the detecting means 96. However, the present invention is not limited thereto, and the position of the impregnation portion 21 on the outlet side of the chamber 7 may be detected. In this case, it is discriminated by the discriminating means 97 whether or not the impregnation portion 21 is located in the division with the upper side structure 71. The portion of the outlet and the portion of the lower side structure 72 that partition the portion of the outlet are relatively opposed. That is, it is detected whether or not the impregnation portion 21 is located opposite to the sealing member 75 provided on the side wall 712B of the upper side structure body 71, and whether the impregnation portion 21 is located opposite to the sealing member 76 provided on the side wall 722B of the lower side structure body 72. Towards the location.

Further, when it is discriminated by the discriminating means 97 that the impregnation portion 21 is at the predetermined position, the control means 98 stops the belt conveyor 63 that drives the transport means 6, and when the discriminating means 97 discriminates that the impregnation portion 21 is not located at the predetermined position At this time, the control means 98 does not stop the belt conveyor 63 which drives the conveyance means 6.

Further, both the position of the impregnation portion 21 on the inlet side of the chamber 7 and the position of the impregnation portion 21 on the outlet side of the chamber 7 may be detected by the detecting means 96.

Next, a state (process) in which the laminated sheet manufacturing apparatus 30 is operated, that is, a state in which the laminated sheet 40 is produced by the laminated sheet manufacturing apparatus 30 will be described with reference to FIGS. 3 to 11 .

First, an outline of a method of manufacturing the laminated sheet 40 will be described.

The manufacturing method of the laminated sheet 40 of this embodiment includes: a step of preparing an elongated fibrous substrate 2; The organic material is impregnated into the inside of the fiber base material 2, and the impregnation portion 21 extending in the width direction of the fiber base material 2 is formed at a predetermined interval in the longitudinal direction of the fiber base material 2; The resin layers 3, 4 are supplied onto the fibrous substrate 2 in such a manner that the region between the impregnation portions 21 of the fibrous base material 2 and the resin layers 3, 4 are opposed to each other. a step of transporting the fibrous base material 2 and the resin layers 3 and 4 into the chamber 7 along the longitudinal direction of the fibrous base material 2; and a region between the impregnated portion 21 of the fibrous base material 2 and the resin The layers 3 and 4 are located in the chamber 7, and the fiber substrate 2 on the downstream side and the upstream side in the conveyance direction is exposed from the chamber 7 in a region between the impregnation portion 21 of the fibrous base material 2, and is stopped. a step of transporting the fiber base material 2 and the resin layers 3 and 4; decompressing the inside of the chamber 7, heating the fiber base material 2 and the resin layers 3 and 4 in the chamber 7, and impregnating the resin layers 3 and 4 The step of the inside of the fiber substrate 2 described above.

Next, a method of manufacturing the laminated sheet 40 will be described in detail.

First, the elongated fibrous base material 2 is prepared, and as shown in FIG. 3, the impregnation portion 21 is formed by the impregnation portion forming means 31. The fiber base material 2 wound around a roll (not shown) is sent out from the roll, and the fiber base material 2 is conveyed by the belt conveyor 61. Moreover, the transportation is stopped at predetermined intervals. After the conveyance is stopped, the organic material is applied by the coating means 311 so as to extend over the entire width direction of the fiber base material 2. Further, the fibrous base material 2 is conveyed, and the fibrous base material 2 is stopped while the organic material impregnated inside the fibrous base material 2 faces the curing means 312. Then, the organic material is hardened by the hardening means 312 to form the impregnation portion 21. Further, during the hardening of the organic material by the curing means 312, the organic material is first applied by the coating means 311 in other regions of the fibrous base material 2.

This operation is repeated to be predetermined in the longitudinal direction of the fibrous base material 2 The intervals form a plurality of impregnations 21.

The fiber base material 2 on which the impregnation portion 21 is formed is conveyed from the impregnation portion forming means 31 to the supply means 32 by the belt conveyor 61 and the conveyance roller 62 (refer FIG. 4).

Further, while the fiber base material 2 is conveyed or the conveyance is temporarily stopped, as shown in FIG. 4, the sheet portion 5a is supplied to the surface of the region between the impregnation portions 21 of the fiber base material 2 by the supply means 32, and the sheet portion is made. The resin layer 3 of 5a is in contact with the region between the impregnation portions 21 of the fibrous base material 2. On the other hand, the sheet portion 5b is supplied onto the back surface of the region between the impregnation portions 21 of the fiber base material 2 by the supply means 32, and the back surface of the region between the impregnation portions 21 of the fiber base material 2 and the sheet portion 5b are provided. The resin layer 4 is in contact.

Specifically, as described above, the first sheet which is elongated as the sheet portion 5a is supplied from a supply roller (not shown), and is cut by the cutting means 322 by a predetermined length. Simultaneously, the second sheet which is elongated as the sheet portion 5b is supplied from a supply roller (not shown), and is cut by a cutting means 322 by a predetermined length.

The sheet portions 5a and 5b are supplied together with the fiber base material 2 between the pair of rolls 321 and disposed on the front and back surfaces of the fiber base material 2, respectively.

Further, at the time of conveyance, it is preferable that a part of each of the sheet portions 5a is fixed to the fiber base material 2 and the other portion is not fixed to the fiber base material 2, so that the sheet portion 5a does not occur on the fiber base material 2. Position offset. Specifically, for example, it is preferable that the end portion on the downstream side in the conveyance direction of each sheet portion 5 a is pressure-bonded to the fiber base material 2 .

Similarly, it is preferable to fix a part of the sheet portion 5b to the fiber. The base material 2 is made to be in a state in which the other portion is not fixed to the fibrous base material 2 so that the sheet portion 5b does not have a positional deviation with respect to the fibrous base material 2. Specifically, for example, it is preferable that the end portion on the downstream side in the conveyance direction of the sheet portion 5 b is pressure-bonded to the fiber base material 2 .

The sheet portions 5a and 5b are disposed in the region between the impregnation portions 21 by the supply means 32. On the upper surface side of the fiber base material 2, a plurality of first sheet portions 5a are disposed adjacent to each other along the longitudinal direction with the impregnation portion 21 interposed therebetween, and the impregnation portions 21 are also disposed adjacent to each other on the lower surface side. A plurality of second sheet portions 5b. The impregnation portion 21 is exposed between the adjacent first sheet portions 5a, and the impregnation portion 21 is exposed between the adjacent second sheet portions 5b.

In this manner, the fiber base material 2 on which the sheet portions 5a and 5b are disposed is conveyed into the chamber 7 by the belt conveyor 63.

In addition, the end surface (the end surface of the end portion in the TD direction) along the conveyance direction of the fiber base material 2 is not covered by the first sheet portion 5a or the second sheet portion 5b, and is exposed.

As shown in FIG. 5, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are conveyed into the chamber 7 by the belt conveyor 63. At this time, the chamber 7 is in an open state. The position of the impregnation portion 21 is detected by the detecting means 96. Then, the discriminating means 97 discriminates whether or not the impregnation portion 21 detected by the detecting means 96 is located at a predetermined position. When the discriminating means 97 determines that the impregnation portion 21 is at a predetermined position, that is, when it is determined that a part of the fibrous base material 2 and the sheet portions 5a, 5b have been transported to a predetermined position in the chamber 7, the driving of the belt conveyor is stopped. 63. This stopped state is maintained until the fiber base material 2 in the chamber 7 and the first sheet portion 5a and the second sheet portion 5b are joined.

As shown in FIG. 5, the chamber 7 is in an open state, and the fiber base material 2 and the first sheet portion 5a and the second sheet portion 5b in the opposing state are inserted into the chamber 7 via the inlet 73. Further, a part of the fibrous base material 2 is located in the chamber 7, but another portion of the fibrous base material 2 is located on the downstream side and the upstream side of the transporting direction from the chamber 7, and is exposed from the chamber 7.

Further, the other sheet portions 5a and 5b located outside the sheet portions 5a and 5b of the chamber 7 are located outside the chamber 7.

At this time, the heaters 95 respectively provided in the upper pressing member 91 and the lower pressing member 93 are operated in advance. Thereby, the upper pressing member 91 and the lower pressing member 93 are each in a preheated state.

Next, as shown in FIG. 6, the upper side structure 71 and the lower side structure body 72 are brought close, and the chamber 7 is closed. At this time, the impregnation portion 21 is sandwiched by the sealing member 75 of the upper side structure 71 of the chamber 7 and the sealing member 76 of the lower side structure 72 as described above. Thereby, the airtightness of the chamber 7 is maintained.

The fiber base material 2 is formed with a hole that communicates with the longitudinal direction thereof and communicates with the front and back surfaces, and the fiber base material 2 is a porous base material. Therefore, when the fibrous base material 2 is disposed inside and outside the chamber 7, the inside and the outside of the chamber 7 are communicated via the holes inside the fibrous base material 2.

On the other hand, in the present embodiment, since the impregnation portion 21 extending in the width direction of the fiber base material 2 is formed on the fiber base material 2, it is difficult to communicate with the inside of the fiber base material 2 located in the chamber 7 outside the chamber 7. The inside of the fibrous substrate 2. On the other hand, at least a part of the path of the gas flowing into the chamber 7 can be blocked by the impregnation portion 21, and the gas inside the chamber 7 can be prevented from leaking to the outside of the chamber 7 through the fiber base material 2. Therefore, the interior of the chamber 7 can be easily It is depressurized and can form a high vacuum.

In particular, in the present embodiment, the portion of the upper side structure 71 of the chamber 7 that partitions the entrance and the portion where the lower structure of the lower structure 72 are partitioned are sandwiched by the sealing member 75 and the sealing member 76. Further, in the portion of the partitioning outlet of the upper structure 71 and the portion of the partitioning outlet of the lower structure 72, the other impregnation portion 21 is sandwiched by the sealing member 75 and the sealing member 76. Thereby, the sealed space can be formed by the impregnation portion 21, the upper side structure body 71, the lower side structure body 72, and the sealing members 75 and 76, and the gas inside the chamber 7 can be surely prevented from leaking into the chamber 7 through the fiber base material 2. external.

Since the inside of the chamber 7 is easily decompressed in this manner, the inside of the chamber 7 can be quickly decompressed, and the productivity of the prepreg can be improved.

Further, since the inside of the chamber 7 can be increased in height, when the resin layer is impregnated into the inside of the fiber base material 2, the gas remaining in the fiber base material 2 can be prevented from becoming bubbles. Thereby, a prepreg having a reduced number of voids can be produced.

Next, as shown in FIG. 7, the decompression means 8 is actuated, and the pressure reduction of the chamber 7 is started. In the decompression, the upper pressing member 91 is moved downward by the operation of the cylinder 92, and the lower pressing member 93 is moved upward by the operation of the cylinder 94, and the fibrous base material 2 and the first one are made at a time. Before the sheet portion 5a and the second sheet portion 5b are pressurized, the pressure is reduced first.

Thereby, the space 77 is in a reduced pressure state, and the pressure-bonding of the auxiliary fiber base material 2 and the first resin layer 3 and the fiber base material 2 and the second resin layer 4 are performed by the pressure reduction (negative pressure) generated in the space 77. Crimp. In the present embodiment, as described above, a part of the sheet portion 5a is fixed to the fiber base material 2, and The other portion is not fixed to the state of the fibrous base material 2. In the same manner, a part of the sheet portion 5b is fixed to the fiber base material 2, and the other portion is not fixed to the fiber base material 2.

By depressurizing the inside of the chamber 7, the regions of the sheet portions 5a, 5b which are not fixed to the fibrous base material 2 are surely brought into contact with the fibrous base material 2.

Further, by actuating the decompression means 8, the gas (air) inside the fiber base material 2 is sucked, and the inside of the fiber base material 2 is also depressurized. As shown in FIG. 11, the end surface of the fiber base material 2 in the conveyance direction in the chamber is not covered by the sheet portions 5a and 5b, and is exposed from the fiber substrate 2 by the pressure reducing means. The end face attracts the gas inside the fiber substrate 2.

Further, the gas in the fiber base material 2 is also sucked from the gap between the fiber base material 2 and the sheet portion 5a and the gap between the fiber base material 2 and the sheet portion 5b by the pressure reducing means 8.

In addition, as described above, the resin layers 3 and 4 are impregnated in the region on the downstream side and the upstream side in the conveyance direction of the fiber base material 2 in the chamber 7, and the resin layers 3 and 4 are sealed, so that the substrate can be reliably attracted. The gas inside the fiber base material 2 in the chamber 7 decompresses the inside of the fiber base material 2.

Further, the end portion along the conveyance direction of the fiber base material 2 is located inside the chamber 7, and is not exposed from the chamber 7.

Next, as shown in FIG. 8, the pressure reduction state by the operation of the pressure reducing means 8 is maintained, and after the lower side pressing member 93 is moved upward, the upper side pressing member 91 is moved downward. Thereby, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are pressurized at one time.

Further, as described above, each of the upper pressing member 91 and the lower pressing member 93 is brought into a warm-up state. Thereby, the first sheet portion 5a transmits the entire first resin layer 3 through the metal layer 12. By heating, the first resin layer 3 is melted, pressure-bonded (fused) to the fiber base material 2, and further, the resin layer 3 is impregnated into the fiber base material 2. Moreover, the second sheet portion 5b also heats the entire second resin layer 4 through the metal layer 12. The second resin layer 4 is melted by this heating, and is pressed against the fiber base material 2, and further, the resin layer 4 is impregnated into the inside of the fiber base material 2.

Further, in the present embodiment, the resin layers 3 and 4 are impregnated into the fibrous base material 2 in a state where the inside of the chamber 7 is decompressed by a pressure reducing means. Thereby, as shown in FIG. 11, when the impregnation is performed, the gas which forms the inside of the fiber base material 2 is attracted by the pressure reduction means 8. Therefore, it is possible to suppress the gas remaining in the fiber base material 2 from becoming a bubble. Thereby, a prepreg which reduces voids can be manufactured. Further, Fig. 11 is a cross-sectional view taken along the line XI-XI of Fig. 8.

Further, the resin layers 3 and 4 are impregnated into the fibrous base material 2 in a state where the inside of the chamber 7 is depressurized by the decompression means 8. In other words, since the resin layer is impregnated in a state where the gas inside the fiber base material 2 is sucked by the decompression means 8, the impregnation property of the resin layer to the fiber base material 2 can be improved.

Further, the operating conditions of the pressurizing means 9 and the heating means 95, that is, the pressurizing time, the heating time, and the heating temperature are respectively based on the respective constituent materials and thicknesses of the fiber base material 2, the first resin layer 3, and the second resin layer 4. The difference is the same, but the pressurization time is preferably 5 to 180 seconds, and 10 to 120 seconds is better. Further, the heating time is preferably 5 to 180 seconds, more preferably 10 to 120 seconds. Further, the heating temperature is preferably 60 to 150 degrees, more preferably 80 to 130 degrees.

Further, the pressing force is preferably 0.1 to 3.0 MPa, preferably 0.5 to 1.5 MPa.

Next, as shown in FIG. 9, after the operation of the pressure reducing means 8 is stopped and the atmosphere is opened, the upper side pressing member 91 is moved upward, and the lower side pressing member 93 is moved downward. The upper side structure 71 and the lower side structure body 72 are separated, and the chamber 7 is opened.

Next, as shown in FIG. 10, the conveyance means 6 is actuated, and the laminated sheet 40 is sent out from the exit 74 of the chamber 7. In conjunction with this, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are inserted into the chamber 7, and the above operation is performed again to impregnate the inside of the fiber base material 2 with the resin layer.

Here, the layered body of the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b is sequentially sent out from the outlet 74 of the chamber 7 under atmospheric pressure. At this time, the impregnation portion 21 can be bent, and the laminated sheet 40 can be folded and recovered. Further, in the laminated sheet 40 of the present embodiment, the inside of the fibrous base material 2 is completely filled with the resin layers 3 and 4. However, the inside of the fiber base material 2 may not be completely filled with the resin layers 3 and 4, and a void may be formed inside the fiber base material 2.

Further, the laminated sheet 40 fed from the outlet 74 of the chamber 7 is cut by the impregnation portion 21 of the fibrous base material 2 by a step (not shown). Thereby, the prepreg 1 was obtained. In this way, the impregnation portion 21 when the prepreg 1 is produced from the laminated sheet 40 can be used as the cut region.

Further, the layered sheet 40 fed from the outlet 74 of the chamber 7 may not be folded, and the impregnation portion 21 may be immediately cut.

Further, the laminated sheet manufacturing apparatus 30 is configured to stop the driving and transporting means when the position of the impregnation portion 21 is detected and the impregnation portion 21 is at a predetermined position. 6.

The impregnation portion 21 can be used for positioning the fiber substrate 2, the first sheet portion 5a, and the second sheet portion 5b with respect to the chamber 7. Thereby, the fiber base material 2, the first sheet portion 5a, and the second support body 5b constituting one prepreg 1 can be surely positioned in the chamber 7, and can be reliably obtained by performing subsequent pressure bonding. Prepreg 1.

Further, in the present embodiment, the long-sized fibrous base material 2 is fed into the chamber 7. By forming the fiber base material 2 into a long shape as described above, it is possible to suppress generation of cutting chips and the like on the fiber base material 2.

Further, in the present embodiment, the impregnation portion 21 impregnated with the organic material is formed, and the impregnation portion 21 is cut to obtain the prepreg 1. By cutting the impregnation portion 21, it is possible to suppress the generation of cutting chips and the like on the fiber base material 2.

Further, the present invention is not limited to the above-described embodiments, and modifications, improvements, etc. within a scope that can achieve the object of the present invention are included in the present invention.

For example, in the above-described embodiment, the organic material constituting the impregnation portion 21 is a photocurable organic material containing a photocurable monomer and undergoing a crosslinking reaction by irradiation with light, but is not limited thereto. For example, the organic material may contain a thermosetting resin, and the impregnation portion 21 may be formed by heat-crosslinking reaction and heat curing. In this case, the hardening means is a heating means for thermally hardening.

Also, an organic material can be used as the bonding agent. The binder is impregnated into the fibrous base material 2 and dried to form an impregnation portion 21. As the bonding agent, a type in which a cyanoacrylate or the like is used to carry out a polymerization hardening reaction with moisture in the air can be used.

Further, in the above embodiment, the impregnation portion 21 is sandwiched by the sealing member 75 and the sealing member 76, but the invention is not limited thereto. For example, the inside of the chamber 7 may be depressurized in a state where the impregnation portion 21 is located inside the chamber 7. In this case as well, the impregnation portions 21 are separated from each other along the longitudinal direction of the fiber base material 2, and the fiber base material 2 is partitioned at predetermined intervals along the longitudinal direction. At least a part of the path through which the gas flows into the chamber 7 is blocked by the impregnation portion 21, so that the inside of the chamber 7 is easily decompressed.

Further, in the above embodiment, the resin layers 3 and 4 are disposed on the front and back surfaces of the fiber base material 2, and the resin layers 3 and 4 are impregnated into the fiber base material 2, but may be disposed only on the side of the fiber base material 2 side. The resin layer is impregnated into the fibrous base material 2 by the resin layer.

Further, in the above-described embodiment, the sheet portions 5a and 5b have the metal layer 12, but are not limited to the metal layer, and may be, for example, a resin-supporting substrate that supports the resin layers 3 and 4. In this case, a laminated sheet which is used as a building material for a printed wiring board can be obtained.

[Examples]

Next, examples and comparative examples of the present invention will be specifically described. However, the invention is not limited to the following examples.

(Example 1)

The laminated sheet 40 is produced by the same method as the above embodiment.

1. Varnish preparation of the first resin layer and the second resin layer

Epoxy resin (brominated bisphenol A epoxy resin (manufactured by Mitsubishi Chemical Corporation, trade name: jER5046) having an epoxy equivalent of 530) 100 parts by weight of dicyandiamide (manufactured by Japan Carbide Co., Ltd.) as a curing agent Weight, do 0.5 parts by weight of 2-ethyl-4-methylimidazole (manufactured by Shikoku Chemicals Co., Ltd.) as a hardening accelerator, spherical cerium oxide as an inorganic filler (SO-25H, manufactured by Admatech Co., Ltd., average particle diameter 0.5 μm) 200 parts by weight of methyl ethyl ketone as a solvent, and the mixture was stirred at room temperature for 2 hours to prepare an epoxy resin-based varnish (as a resin layer) having a solid content of 65% by weight.

2. Manufacturing of sheets

Using a copper foil (width 530 mm), the varnish was applied by a comma wheel coating apparatus, and dried in a drying apparatus at 170 ° C for 3 minutes to form a resin layer having a thickness of 29 μm and a width of 530 mm. The sheet thus obtained was used as the first sheet and the second sheet. The first sheet is cut into the sheet portion 5a. At the same time, the second sheet is cut into the sheet portion 5b.

3. Manufacturing of prepreg

Using the manufacturing apparatus 30 of the above-described embodiment, a prepreg is produced in the same manner as in the above embodiment.

As the fiber base material, a glass woven fabric (cross type #2116, width 530 mm, thickness 90 μm, base amount 104 g/m ² ) was used.

First, in the same manner as the above embodiment, a plurality of impregnation portions 21 are formed on the fiber base material 2. The width of the impregnation portion 21 in the longitudinal direction of the fiber substrate was 25 mm. Further, the impregnation portion 21 extends over the entire width direction of the fiber base material 2. Further, the interval between the impregnation portions 21 is 700 mm (distance 1 = 700 mm in Fig. 3).

The material of the impregnation portion 21 is 100 parts by weight of Celloxide 2021P (manufactured by DAICEL Chemical Co., Ltd., epoxy equivalent 176) and 1 part by weight of a phosphoric acid photoacid generator (photopolymerization initiator) SP-150 (manufactured by Adeka). UV curing is performed by irradiating UV light of 240 mW/cm ² for several seconds (for example, 6.25 seconds).

Then, the first sheet and the second sheet are cut in the same manner as in the above embodiment, and the first sheet portion 5a and the second sheet portion 5b are opposed to each other in the region between the impregnation portions 21 of the fiber base material 2, and are disposed. The first sheet portion 5a and the second sheet portion 5b. Here, the first sheet portion 5a and the second sheet portion 5b are substantially equal in length in the longitudinal direction of the fiber base material 2 and the length between the pair of impregnation portions 21, and the first sheet portion 5a and the second sheet portion 5b are paired with each other. The impregnation portion 21 does not substantially overlap, and the impregnation portion 21 is exposed. Moreover, the end surface of the fiber base material 2 along the conveyance direction is exposed, and is not covered by the first sheet portion 5a and the second sheet portion 5b.

Next, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are placed in the chamber 7. At this time, the cavity 7 of the fiber base material 2 is located in the downstream side and the upstream side in the conveyance direction, and is exposed from the chamber 7 to the outside in the same manner as the above embodiment.

Next, the chamber 7 is closed, and the portion where the inlet of the upper side structure 71 of the chamber 7 is partitioned and the portion where the inlet of the lower side structure 72 is partitioned are sandwiched by the sealing member 75 and the sealing member 76. Further, the portion of the partitioning outlet of the upper side structure 71 and the portion of the partitioning outlet of the lower side structure body 72 are sandwiched by the sealing member 75 and the sealing member 76 to sandwich the other impregnation portion 21. Further, the outer dimension of the fiber substrate conveyance direction along the chamber 7 is 750 mm, and the inner dimension along the fiber substrate conveyance direction of the chamber 7 (the length between the side walls 712A, 712B, the side walls 722A, 722) The length between B) is 700mm.

Then, the inside of the chamber 7 is decompressed. At this time, as shown in FIG. 12, the pressure in the chamber 7 reached 80 Pa from the start of pressure reduction for 30 seconds, and an equilibrium state was formed.

In addition, the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are not disposed in the chamber 7, and in the state where the chamber 7 is empty, the chamber is decompressed, and the pressure is also reduced. After 30 seconds from the start, the pressure in the chamber 7 reached 80 Pa, and an equilibrium state was formed. Therefore, it was confirmed that the chamber 7 was decompressed in the same state as the chamber 7 was empty.

Then, the upper base pressing member 91 and the lower pressing member 93 heated to 90° C. heat and pressurize the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b in the chamber 7. The heating and pressing time was 30 seconds, and the pressing force was 1.0 MPa. The resin layers 3 and 4 are impregnated inside the fibrous base material 2.

Then, the upper pressing member 91 and the lower pressing member 93 are separated from each other, and the heating and pressing are completed, and the laminated sheet 40 is sent out from the chamber 7.

When the cross section of the laminated sheet 40 was observed, it was confirmed that there was substantially no void.

(Reference example 1)

Here, the fiber base material 2 was previously cut to 700 mm, and the first sheet portion 5a was placed on the surface side of the cut fiber base material 2. Moreover, the second sheet portion 5b is placed on the back side of the cut fiber base material 2.

Then, the cut fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b are placed in the chamber 7. The fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b do not protrude from the chamber 7.

Next, the inside of the chamber 7 is decompressed. At this time, as shown in FIG. 12, the pressure in the chamber 7 reached 80 Pa from the start of pressure reduction for 30 seconds, and an equilibrium state was formed.

Then, the upper base pressing member 91 and the lower pressing member 93 heated to 90° C. heat and pressurize the fiber base material 2, the first sheet portion 5a, and the second sheet portion 5b in the chamber 7. The heating and pressing time was 30 seconds, and the pressing force was 1.0 MPa.

Then, the upper pressing member 91 and the lower pressing member 93 are separated from each other, and the heating and pressing are completed, and the cut fibrous base material 2, the first sheet portion 5a, and the second sheet portion 5b are fed from the chamber 7. Layered film.

When the cross section of the laminated sheet was observed, it was confirmed that there was substantially no void.

In the case where the laminated sheet was produced in a single piece as in Example 1, the pressure was reduced to the same extent in the chamber 7, and it was found that in the first embodiment, the same effect as in the case of manufacturing the laminated sheet in a single piece was obtained. .

(Comparative Example 1)

Here, the impregnation portion 21 is not formed. Other points are the same as in the first embodiment.

In this case, when the chamber 7 was decompressed, the pressure in the chamber 7 reached 533 Pa from the start of the pressure reduction for 30 seconds to form an equilibrium state.

When the cross section of the laminated sheet 40 thus produced was observed, the voids were small, but more than that of the first embodiment.

Priority is claimed on the basis of Japanese Patent Application No. 2012-114125, filed on May 18, 2012, the entire disclosure of which is incorporated herein.

2‧‧‧Fiber substrate

6‧‧‧Transportation means

21‧‧‧Immersion Department

30‧‧‧Laminated sheet manufacturing equipment

31‧‧‧Immersion formation means

61‧‧‧belt conveyor

311‧‧‧ Coating means

312‧‧‧ hardening means

Claims (13)

A method for producing a laminated sheet, comprising: preparing an elongated fibrous base material, wherein the organic material is impregnated in a longitudinal direction of the fibrous base material at a predetermined interval inside the fibrous base material to form a plurality of a step of impregnating the fiber substrate in the width direction; and supplying the resin layer to the surface or the back side of the fiber substrate such that the region between the impregnation portions of the fiber substrate faces the resin layer a step of transporting the fiber base material and the resin layer along the longitudinal direction of the fiber base material into the chamber; and allowing the region between the impregnation portions of the fiber base material and the resin layer to be located in the chamber a step of stopping the conveyance of the fiber base material and the resin layer in a region on the downstream side in the conveyance direction and a region on the upstream side in a region between the impregnation portion of the fiber base material in a state of being located outside the chamber; And decompressing the chamber, heating the fiber substrate and the resin layer in the chamber, and impregnating the resin layer with the resin substrate Department of steps. The method for producing a laminated sheet according to claim 1, wherein the laminated sheet is a laminated sheet for a printed wiring board. The method for producing a laminated sheet according to claim 1 or 2, wherein the fibrous base material is made of any one of glass, polyparaphenylene benzobisoxazole, and polyarsenamide resin. The method for producing a laminated sheet according to claim 1, wherein in the step of supplying the resin layer to the fibrous base material, the end surface along the longitudinal direction of the fibrous base material is not covered by the resin layer. According to another aspect of the invention, the resin layer is disposed on the fiber base material, and the pressure-reducing means for decompressing the chamber is provided in the chamber by the pressure reducing means for decompressing the chamber inside the fiber substrate. The end surface of the fiber base material in the longitudinal direction attracts the gas inside the fiber base material. The method of manufacturing a laminated sheet according to claim 1, wherein the chamber includes a first structure and a second structure that form a space to be decompressed so as to face each other, and the first structure and the second The structure is configured to be relatively separable and close to each other, and an inlet and an outlet are formed between the first structure and the second structure, and the fiber base material and the resin layer are oriented along a longitudinal direction of the fiber base material In the above-described step of transporting the chamber, the first structure body and the second structure body are separated from each other, and the fiber base material and the resin layer are transported from the inlet into the chamber to impregnate the resin layer with the resin layer. The aforementioned steps inside the substrate In the first step, the first structure and the second structure are adjacent to each other, and the portion of the inlet of the first structure and the second structure is partitioned, and the impregnation portion of the fiber substrate is sandwiched Portions of the first structure and the outlet of the second structure sandwich the other impregnation portions of the fibrous base material. The method for producing a laminated sheet according to claim 1, wherein in the step of forming the impregnated portion, after the curable organic material is impregnated into the inside of the fibrous base material, the organic material is cured to form the impregnated portion. The method for producing a laminated sheet according to claim 6, wherein the curable organic material is a photocurable organic material, and after the organic material is impregnated into the inside of the fibrous base material, the organic material is photocured. The method for producing a laminated sheet according to claim 1, wherein the fiber substrate and the resin layer in the chamber are pressurized and heated in the step of impregnating the resin layer with the resin substrate. The resin layer is impregnated inside the fiber base material. The method for producing a laminated sheet according to claim 1, wherein in the step of supplying the resin layer to the fibrous base material, the resin layer is disposed relative to the fibrous base material so as to be adjacent to the fibrous base material. One of the long sides is exposed to the impregnation portion. The method for producing a laminated sheet according to claim 9, comprising: a step of detecting a position of the impregnation portion; and a step of determining whether the detected position of the impregnation portion is a predetermined position; and determining that the impregnation portion is a predetermined one At the time of the position, the step of stopping the conveyance of the fiber base material and the resin layer is performed, and when it is determined that the impregnation portion is not at a predetermined position, the fiber base material and the resin layer are not stopped. A manufacturing apparatus for a laminated sheet, comprising: an impregnation portion forming means, wherein the organic material is impregnated in a longitudinal direction of the fibrous base material at a predetermined interval in the longitudinal direction of the fibrous base material, and a plurality of the plurality of layers are formed in the foregoing An impregnation portion extending in a width direction of the fiber base material; and a supply means for supplying the resin layer to the surface or the back surface of the fiber base material such that a region between the impregnation portions of the fiber base material faces the resin layer a conveying means for conveying the fiber base material and the resin layer in the chamber along the longitudinal direction of the fiber base material; and the control means The region between the impregnation portions of the fiber base material and the resin layer are located in the chamber, and the region on the downstream side in the conveyance direction and the region on the upstream side in the region between the impregnation portions of the fiber base material are located in the cavity In the state of the outdoor unit, the driving means is stopped; a decompression means for depressurizing the chamber; and a heating means for heating the fiber substrate and the resin layer in the chamber to impregnate the resin layer inside the fiber substrate. The apparatus for manufacturing a laminated sheet according to claim 11, wherein the laminated sheet is a laminated sheet for a printed wiring board. The apparatus for manufacturing a laminated sheet according to claim 11 or 12, wherein the chamber includes a first structure and a second structure that form a space to be decompressed so as to face each other, the first structure and the The second structure is configured to be relatively separable and close to each other, and an inlet and an outlet are formed between the first structure and the second structure, and a detection means for detecting a position of the impregnation portion and a determination means are provided. Determining whether a position of the impregnation portion detected by the detecting means is a position facing a portion of the inlet or the outlet that partitions the first structure and the second structure; and determining by the discriminating means When the position of the impregnated portion detected by the detecting means is at a position facing a portion of the inlet or the outlet of the first structure and the second structure, the control means stops driving the conveying means. The determining means determines that the position of the impregnation portion detected by the detecting means is not the first structure and the first portion When the portion of the inlet or the outlet of the two structures is opposed to the position, the driving means is not stopped.