CN107924019B - Method and apparatus for manufacturing polarizing plate - Google Patents
Method and apparatus for manufacturing polarizing plate Download PDFInfo
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- CN107924019B CN107924019B CN201780002930.2A CN201780002930A CN107924019B CN 107924019 B CN107924019 B CN 107924019B CN 201780002930 A CN201780002930 A CN 201780002930A CN 107924019 B CN107924019 B CN 107924019B
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
- B23C3/12—Trimming or finishing edges, e.g. deburring welded corners
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Abstract
The invention provides a method and an apparatus for manufacturing a special-shaped polarizing plate, wherein the method is a method for manufacturing a special-shaped polarizing plate having a concave rounded portion and/or a hole portion with a small diameter, and the method suppresses cracks, bending, and discoloration during processing. The method for manufacturing the special-shaped polarizing plate is a method for manufacturing the special-shaped polarizing plate with the concave fillet part, and the method for manufacturing the special-shaped polarizing plate comprises a step of forming the concave fillet part by using a cutting unit, wherein the cutting unit is used for cutting a cutting surface from a transverse direction by a blade.
Description
Technical Field
The present invention relates to a method and an apparatus for manufacturing a profiled polarizing plate. More particularly, the present invention relates to a method and an apparatus for manufacturing a profiled polarizing plate having a concave rounded portion and/or a hole portion. In addition, the invention also relates to an optical film using the special-shaped polarizing plate. Further, the present invention relates to an image display device such as a liquid crystal display device, an organic EL display device, and a PDP, which uses the polarizing plate or the optical film.
Background
In recent years, polarizing plates have been desired to be used also in instrument displays of automobiles, smartwatches, and the like. In addition, from the viewpoint of design of a smartphone and the like, it is also desirable to use a polarizing plate having a shape other than a rectangular shape, form a through hole in the polarizing plate, and the like. In addition, in these profile working, there is an increasing demand for finer and more sophisticated working treatments or more complicated working treatments, as has not been seen in the past, and small-diameter reentrant fillet working or small-diameter hole working is sometimes performed.
Examples of the polarizing plate to be subjected to the profile processing include: the polarizing plate is punched by forming a special-shaped blade die, and is cut by laser irradiation. However, in the former punching process, the following problems are known: the damage of the polarizing plate due to the press-cutting causes cracks or bends in the polarizing plate. In the latter laser processing, it is known that the polarizing plate is discolored by heat. Among them, the present inventors found, in particular, that: there is a tendency that cracks or bending occurs in the recess-worked portion such as small-diameter hole working or small-diameter recess/fillet working.
Further, proposals have been made so far regarding final processing of the end faces of polarizing plates (see, for example, patent documents 1 and 2). However, the above proposals are merely proposals related to the final processing of the edge portion of the cut-out portion after the polarizing plate is cut into a rectangular shape, and are not techniques for performing the recessing or the like on the polarizing plate itself. In the above proposal, there is no disclosure of the problem that cracks or bending occurs when the polarizing plate is subjected to fine recessing.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2004-148461
Patent document 2: japanese laid-open patent publication No. 2004-148419
Disclosure of Invention
Problems to be solved by the invention
The invention aims to: in this way, a method for manufacturing a special-shaped polarizing plate, particularly a method for manufacturing a special-shaped polarizing plate having a small-diameter concave rounded portion and/or hole portion, in which the occurrence of cracks, bending, and discoloration of the special-shaped polarizing plate during processing are suppressed, and an apparatus for manufacturing the same are provided.
Means for solving the problems
The present inventors have conducted extensive studies to solve the above problems, and as a result, have found that the above object can be achieved by the following production method, and the like, and have completed the present invention.
The invention provides a method for manufacturing a special-shaped polarizing plate having a concave rounded portion,
the manufacturing method includes a step of forming the concave rounded portion by using a cutting means that cuts the cutting surface by abutting a blade from a lateral direction.
The method for manufacturing the special-shaped polarizing plate of the present invention is capable of suppressing the occurrence of cracks, bending, and discoloration which have been difficult to suppress so far and which are generated during the processing of the polarizing plate, particularly, the special-shaped polarizing plate having a small-diameter concave rounded portion, by means of abutting the cut surface of the polarizing plate from the lateral direction using a blade.
In the present invention, the concave rounded portion refers to a portion having a concave portion and a curved portion, and the corner portion of the concave portion includes a curved portion such as a circle, an ellipse, or a substantially circle. The convex rounded portion is a portion having a convex portion and a curved portion, and the corner portion of the convex portion includes a curved portion such as a circle, an ellipse, or a substantially circle. Examples thereof include a concave rounded portion and a convex rounded portion as shown in FIG. 1.
In the method for manufacturing the polarizing plate having a modified shape according to the present invention, the radius of the concave rounded portion is preferably 5mm or less. By using the above-described manufacturing method, even when the radius of the concave rounded portion is 5mm or less, it is possible to suppress the occurrence of cracks, bending, and discoloration during the processing of the polarizing plate, and it is possible to manufacture a special-shaped polarizing plate having a concave rounded portion with a minute diameter such that the radius of the concave rounded portion is 5mm or less. The radius of the concave rounded portion is defined as a radius of a circle when the rounded portion is circular, and a radius of curvature when the rounded portion is not circular, such as elliptical or substantially circular.
In the method for manufacturing a polarizing plate having a modified shape according to the present invention, the cutting means is preferably an end mill. By using the above manufacturing method, it is particularly suitable for the case of performing small-diameter concave fillet machining.
In the method for producing the polarizing plate having a modified shape according to the present invention, the cutting angle formed between the processing direction and the blade surface of the blade is preferably 60 ° or more. By using the above-described manufacturing method, the occurrence of delamination of the profiled polarizing plate can be suppressed.
The apparatus for manufacturing a profiled polarizing plate of the present invention is a manufacturing apparatus for a profiled polarizing plate having a concave rounded portion,
the manufacturing apparatus includes a cutting unit that cuts a cutting surface by bringing a blade into contact with the cutting surface from a lateral direction.
By using the above-described manufacturing apparatus, the occurrence of cracks and bending and discoloration during the processing of the polarizing plate can be suppressed, and in particular, the production of the irregularly shaped polarizing plate having a small-diameter concave rounded portion can be easily performed.
In the apparatus for manufacturing the polarizing plate having a modified shape according to the present invention, the radius of the concave rounded portion is preferably 5mm or less. By using the above-described manufacturing apparatus, even when the radius of the concave rounded portion is 5mm or less, it is possible to suppress the occurrence of cracks, bending, and discoloration during the processing of the polarizing plate, and it is possible to easily manufacture the irregularly shaped polarizing plate having the concave rounded portion with a minute diameter such that the radius of the concave rounded portion is 5mm or less.
In the apparatus for manufacturing a profiled polarizing plate according to the present invention, the cutting means is preferably an end mill, and the apparatus is particularly suitable for small-diameter concave fillet processing.
In the apparatus for manufacturing a profiled polarizing plate according to the present invention, a cutting angle formed by the processing direction of the cutting means and the blade surface of the blade is preferably 60 ° or more. By using the manufacturing apparatus, the occurrence of delamination of the profiled polarizing plate can be suppressed.
The method for manufacturing the special-shaped polarizing plate of the present invention is a method for manufacturing a special-shaped polarizing plate having a hole portion,
the manufacturing method includes a step of forming the hole portion using an end mill.
In the above-described manufacturing method, particularly, by means of abutting the cutting surface of the polarizing plate from the lateral direction using the blade, the occurrence of cracks, bending, and discoloration, which have been difficult to suppress so far, which are generated during the processing of the polarizing plate, are suppressed, and in particular, a special-shaped polarizing plate having a hole portion with a small diameter can be manufactured.
In the present invention, the hole portion refers to a portion having a hole of, for example, a circular shape, an elliptical shape, a substantially circular shape, an angular shape, or the like, and refers to a portion penetrating through the polarizing plate. Examples thereof include the hole portion shown in FIG. 1.
In the above method for manufacturing the polarizing plate having a modified shape, the hole preferably has a radius of 5mm or less. By using the above-described manufacturing method, even when the hole has a radius of 5mm or less, cracks, bending, and discoloration during processing of the polarizing plate can be suppressed, and a polarizing plate having a hole with a minute diameter such that the hole has a radius of 5mm or less can be manufactured. The radius of the hole is defined as the radius of a circle when the hole is circular, and the radius of curvature when the hole is non-circular, such as elliptical or substantially circular.
In the method for manufacturing the polarizing plate having a modified shape, the cutting angle formed between the processing direction and the edge surface of the end mill is preferably 60 ° or more. By using the above-described manufacturing method, the occurrence of delamination of the profiled polarizing plate can be suppressed.
The manufacturing apparatus for the special-shaped polarizing plate according to the present invention is an apparatus for manufacturing a special-shaped polarizing plate having a hole, and the manufacturing apparatus includes an end mill.
By using the above-described manufacturing apparatus, the occurrence of cracks and bending and discoloration during the processing of the polarizing plate can be suppressed, and in particular, the production of a special-shaped polarizing plate having a small-diameter hole portion can be easily performed.
In the manufacturing apparatus of the polarizing plate having a modified shape of the present invention, the radius of the hole is preferably 5mm or less. By using the above-described manufacturing apparatus, even when the hole has a radius of 5mm or less, the occurrence of cracks, bending, and discoloration during the processing of the polarizing plate can be suppressed, and the production of the special-shaped polarizing plate having a hole with a minute diameter such that the hole has a radius of 5mm or less can be easily performed.
In the apparatus for manufacturing a profiled polarizing plate according to the present invention, the cutting angle formed between the processing direction and the edge surface of the end mill is preferably 60 ° or more. By using the manufacturing apparatus, the occurrence of delamination of the profiled polarizing plate can be suppressed.
Drawings
Fig. 1 shows an example of a polarizing plate having a modified shape obtained by the method for producing a polarizing plate having a modified shape of the present invention.
Fig. 2 shows an example of the embodiment of the method for manufacturing the polarizing plate having a modified shape of the present invention.
Fig. 3 shows an example of the embodiment of the method for manufacturing the polarizing plate having a modified shape of the present invention.
Fig. 4 shows an example of an end mill in the method for manufacturing the polarizing plate having a modified shape according to the present invention.
Fig. 5 shows an example of an end mill in the method for manufacturing the polarizing plate having a modified shape according to the present invention.
Fig. 6 shows a machined shape implemented in an example of the present invention.
Fig. 7 shows a machined shape implemented in an example of the present invention.
Detailed Description
Hereinafter, embodiments of the present invention will be described.
The invention provides a method for manufacturing a special-shaped polarizing plate having a concave rounded portion,
the manufacturing method includes a step of forming the concave rounded portion by using a cutting means that cuts the cutting surface by abutting a blade from a lateral direction.
The method for manufacturing the special-shaped polarizing plate of the present invention is a method for manufacturing a special-shaped polarizing plate having a hole portion,
the manufacturing method includes a step of forming the hole portion using an end mill.
The method for manufacturing the polarizing plate having a modified shape according to the present invention includes a step of forming the concave rounded portion and/or the hole portion by using a cutting means for cutting the polarizing plate by bringing a blade into contact with a cutting surface from a lateral direction. In particular, by means of using a blade to abut against the cutting surface of the polarizing plate from the lateral direction, cracks, bending, and discoloration which have been difficult to suppress in the past and which occur during processing of the polarizing plate are suppressed, and in particular, a special-shaped polarizing plate having a small-diameter concave rounded portion and/or hole portion can be manufactured. In addition, as the cutting means for cutting the cutting surface by abutting the blade from the lateral direction, for example: a method using a router (machining in which a machining surface is scraped in parallel by a tool having a rotary shaft parallel to the machining surface and provided to protrude), an end mill machining, or the like. In the method for manufacturing the polarizing plate according to the present invention, it is particularly preferable that the cutting means is an end mill when small-diameter concave round corner machining or small-diameter hole machining is performed. In particular, in the method for manufacturing the polarizing plate having a hole portion, an end mill is used as the cutting means.
An end mill is a type of cutting tool that can machine in a direction perpendicular to a rotation axis, unlike a drill that machines only in a shaft direction (exclusively for drilling).
Hereinafter, an embodiment using end mill machining will be described as an example with reference to fig. 2. The polarizing plate to be formed with the concave rounded portion and/or the hole portion is cut by bringing the blade into contact with the cutting surface of the polarizing plate from the lateral direction while rotating the blade portion of the end mill corresponding to the blade at this time. The cutting process of the polarizing plate is continued while the blade portion of the end mill is rotated and moved in the processing direction, and the polarizing plate is processed into a predetermined irregularly shaped polarizing plate.
In the case of the end mill, the blade portion for cutting may be rotated about a rotation axis parallel to the cutting surface (for example, the rotation axis is perpendicular to the surface of the polarizing plate) as shown in fig. 2, and the polarizing plate may be cut by the end mill in the machining direction while continuously, stepwise or intermittently rotating the blade portion. At this time, the edge portion of the end mill is cut in a state of being in contact with the cutting surface from the lateral direction. In the punching process or the like in which punching is performed by a conventional knife blade, the blade is brought into contact with the polarizing plate from the upper surface (the direction parallel to the cutting surface and the direction perpendicular to the polarizing plate surface in fig. 2) of the polarizing plate to perform the cutting process.
For example, when the planer machining is used as the cutting means, the edge portion of the planer machining may be brought into contact with the cutting surface from the lateral direction to perform cutting in place of the edge portion of the end mill shown in fig. 2.
For example, in the case of hole machining, not only the hole may be formed by using an end mill or the like as it is, but also a hole having a desired shape may be formed by additionally performing end face cutting with an end mill or the like in addition to a hole formed by other punching or the like before and enlarging the hole.
In addition, by using the method for manufacturing a polarizing plate having a modified shape of the present invention, even when the concave rounded portion is small in diameter or fine, the occurrence of cracks and bending and discoloration during processing can be suppressed, and manufacturing processing can be suitably performed.
Therefore, in the method for manufacturing the polarizing plate having a modified shape according to the present invention, even if the radius of the concave rounded portion is 5mm or less, for example, the manufacturing process can be easily performed. For example, the radius may be 1mm to 5mm, 1mm to 4mm, or 2mm to 3 mm. By using the above-described manufacturing method, even when the radius of the concave rounded portion is 5mm or less, the occurrence of cracks, bending, and discoloration during the processing of the polarizing plate can be suppressed, and the polarizing plate having a concave rounded portion with a minute diameter such that the radius of the concave rounded portion is 5mm or less can be manufactured.
Therefore, in the apparatus for manufacturing the polarizing plate having a modified shape of the present invention, even if the radius of the hole is 5mm or less, for example, the manufacturing process can be easily performed. For example, the radius may be 1mm or more and 5mm or less, may be 1mm or more and 4mm or less, or may be 2mm or more and 3mm or less. By using the above-described manufacturing method, even when the radius of the hole portion is 5mm or less, the generation of cracks, bending, and discoloration during the processing of the polarizing plate can be suppressed, and a special-shaped polarizing plate having a hole portion with a minute diameter such that the radius of the hole portion is 5mm or less can be manufactured.
In the method for producing the polarizing plate having a modified shape according to the present invention, the cutting angle formed between the processing direction and the blade surface of the blade is preferably 60 ° or more. The cutting angle is preferably 60 ° to 90 °, 65 ° to 90 °, 70 ° to 85 °, and 70 ° to 80 °. By using the above-described manufacturing method, the occurrence of delamination of the profiled polarizing plate can be suppressed.
In the present invention, the cutting angle is based on the cutting angle formed by the cutting direction of the cutting means and the edge surface of the cutting edge, and fig. 3 shows an example of machining with an end mill. When machining is performed such that the direction of the rotation axis of the end mill is perpendicular to the machining direction as shown in fig. 3, the angle formed by subtracting the helix angle of the cutting edge of the end mill from 90 ° is referred to as a cutting angle.
The apparatus for manufacturing a profiled polarizing plate of the present invention is a manufacturing apparatus for a profiled polarizing plate having a concave rounded portion,
the manufacturing apparatus includes a cutting unit that cuts a cutting surface by bringing a blade into contact with the cutting surface from a lateral direction.
In the manufacturing apparatus of the irregularly shaped polarizing plate with the concave rounded portion according to the present invention, the cutting means including the end mill and having the blade for cutting by abutting against the cutting surface from the lateral direction can be suitably provided in the apparatus by a known method.
In the apparatus for manufacturing the polarizing plate having a modified shape according to the present invention, even if the radius of the concave rounded portion is 5mm or less, for example, the manufacturing process can be easily performed. For example, the radius may be 1mm or more and 5mm or less, may be 1mm or more and 4mm or less, or may be 2mm or more and 3mm or less. By using the above-described manufacturing method, even when the radius of the concave rounded portion is 5mm or less, the occurrence of cracks, bending, and discoloration during the processing of the polarizing plate can be suppressed, and the polarizing plate having a concave rounded portion with a minute diameter such that the radius of the concave rounded portion is 5mm or less can be manufactured.
In the apparatus for manufacturing a profiled polarizing plate according to the present invention, a cutting angle formed by the processing direction of the cutting means and the blade surface of the blade is preferably 60 ° or more. The cutting angle is preferably 60 ° to 90 °, 65 ° to 90 °, 70 ° to 85 °, and 70 ° to 80 °. By using the manufacturing apparatus, the occurrence of delamination of the profiled polarizing plate can be suppressed.
The apparatus for manufacturing a profiled polarizing plate of the present invention is an apparatus for manufacturing a profiled polarizing plate having a hole,
the manufacturing apparatus includes an end mill.
In the apparatus for manufacturing a profiled polarizing plate having a hole according to the present invention, the end mill may be suitably provided in the apparatus by a known method.
In the apparatus for manufacturing the polarizing plate having a modified shape according to the present invention, even if the radius of the hole is 5mm or less, for example, the manufacturing process can be easily performed. For example, the radius may be 1mm or more and 5mm or less, may be 1mm or more and 4mm or less, or may be 2mm or more and 3mm or less. By using the above-described manufacturing method, even when the radius of the hole portion is 5mm or less, the generation of cracks, bending, and discoloration during the processing of the polarizing plate can be suppressed, and a special-shaped polarizing plate having a hole portion with a minute diameter such that the radius of the hole portion is 5mm or less can be manufactured.
In the apparatus for manufacturing a profiled polarizing plate according to the present invention, a cutting angle formed by the processing direction of the cutting means and the blade surface of the blade is preferably 60 ° or more. The cutting angle is preferably 60 ° to 90 °, 65 ° to 90 °, 70 ° to 85 °, and 70 ° to 80 °. By using the manufacturing apparatus, the occurrence of delamination of the profiled polarizing plate can be suppressed.
As the end mill, for example, the end mill shown in fig. 4 and 5 can be suitably used. Fig. 5 shows examples in which the number of blades is 2, 3, 4, or 6.
The shape of the end mill is preferably 1 to 6 blades, and the number of blades may be 1 to 4 blades.
The rake angle of the edge portion of the end mill is preferably 0 ° or more and less than 15 °, and may be 3 to 12 °. If the rake angle is 15 ° or more, the blade is likely to be chipped.
The cutting edge of the end mill preferably has a clearance angle of more than 0 ° and less than 20 °, and may be 3 to 15 °. If the above-mentioned relief angle is 0 °, the blade is rubbed against the film, and if the above-mentioned relief angle is 20 ° or more, the blade is easily broken.
The helix angle of the cutting edge of the end mill is preferably-75 to 75 °, and may be-65 to 65 °. If the helix angle is out of the above range, the chips are likely to be discharged poorly.
Further, the diameter (outer diameter) of the edge of the end mill
Preferably 3 to 30mm, and may be 5 to 25 mm. If the diameter of the above-mentioned tool
When the diameter is less than 3mm, the bending becomes easy, and the diameter of the cutter is set to be smaller than
If it exceeds 30mm, it will be difficult to perform fine profile working.
In addition, as the manufacturing conditions when the end mill is used for manufacturing, the feed speed of the edge portion of the end mill is preferably 100 to 10000 mm/min, and may be 200 to 8000 mm/min.
The rotation speed of the edge of the end mill is preferably 1000 to 120000rpm, 2000 to 60000rpm, or 3000 to 50000 rpm. If the rotation speed is slower than 1000rpm, the crack may be caused, and if the rotation speed is faster than 60000rpm, the heat may be generated to cause damage to the polarizing plate and the like.
The polarizing plate used in the present invention is not particularly limited, and a known polarizing plate can be suitably used. Examples of the polarizing plate include a polarizing plate manufactured by stretch molding, a polarizing plate manufactured by coating molding, and the like.
The polarizing plate is not particularly limited, and various polarizing plates can be used. Examples of the polarizing plate include: a film obtained by uniaxially stretching a hydrophilic polymer film such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film, or an ethylene-vinyl acetate copolymer partially saponified film, by adsorbing a dichroic material such as iodine or a dichroic dye thereon; and polyene-based oriented films such as dehydrated polyvinyl alcohol and desalted polyvinyl chloride. Among them, a polarizing plate containing a polyvinyl alcohol film and a dichroic material such as iodine is preferable.
Polyvinyl alcohol or a derivative thereof is used as a material of a polyvinyl alcohol film applied to a polarizing plate. Examples of the polyvinyl alcohol derivative include polyvinyl formal, polyvinyl acetal, and the like, and in addition to these, they include: olefins such as ethylene and propylene; alkyl esters of unsaturated carboxylic acids such as acrylic acid, methacrylic acid, and crotonic acid, and modified products thereof with acrylamide. Generally, a polyvinyl alcohol film having a degree of polymerization of polyvinyl alcohol of about 1000 to 10000 and a degree of saponification of about 80 to 100 mol% is used.
The polyvinyl alcohol film (unstretched film) is subjected to at least uniaxial stretching treatment and iodine dyeing treatment according to a conventional method. Further, boric acid treatment and iodide ion treatment may be performed. The polyvinyl alcohol film (stretched film) subjected to the above treatment is dried by a conventional method to form a polarizing plate.
The polarizing plate used in the present invention may be a polarizing plate in which a protective film is bonded to at least one surface of a polarizer via an adhesive. The protective film may be attached to one side or both sides of the polarizing plate. The protective film may have other optical functions at the same time, or may be formed by further stacking other layers.
When the polarizing plate has protective films on both surfaces of the polarizer, the protective film on one surface may be the same as or different from the protective film on the other surface. Further, at least 1 layer of the protective film may be used on each surface, or a laminate of 2 or more layers may be used.
The thickness of the protective film may be appropriately determined, but is generally about 1 to 500 μm in view of workability such as strength and workability, and thin layer property. Particularly preferably 1 to 300 μm, and more preferably 5 to 200 μm.
Examples of the material constituting the protective film include thermoplastic resins having excellent transparency, mechanical strength, thermal stability, and moisture barrier properties. When the protective film is required to have optical isotropy, a resin having low intrinsic birefringence is preferably selected. Specific examples of such thermoplastic resins include polyester resins, polyether sulfone resins, polysulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, (meth) acrylic resins, norbornene resins, polyarylate resins, and mixtures thereof. In addition, a thermosetting resin such as a (meth) acrylic resin or an ultraviolet curable resin may be used. Among the above, from the viewpoint of moisture permeability and optical characteristics, (meth) acrylic resins, polyimide resins, and norbornene resins are preferably used.
As the protective film, a protective film on the display device (japanese: セル) side may have a retardation function for viewing angle compensation, and the opposite side of the protective film on the display device side may have or not have a retardation.
The surface of the protective film to be bonded to the polarizing plate may be subjected to an easy-bonding treatment. As the easy adhesion treatment, there are: dry treatments such as plasma treatment and corona treatment; chemical treatments such as alkali treatment (saponification treatment); coating treatment for forming an easy adhesion layer, and the like. Among them, coating treatment or alkali treatment for forming an adhesive layer is preferable. For the formation of the easy adhesion layer, various easy adhesion materials such as a polyol resin, a polycarboxylic acid resin, and a polyester resin can be used. The thickness of the easy-adhesion layer is usually about 0.001 to 10 μm, more preferably about 0.001 to 5 μm, and particularly preferably about 0.001 to 1 μm.
The surface of the protective film to which the polarizing plate is not bonded may be subjected to a hard coat layer, an antireflection treatment, or a treatment for the purpose of blocking prevention, diffusion prevention, or antiglare treatment.
The adhesive constituting the polarizing plate is not particularly limited as long as it is optically transparent, and various types of adhesives such as aqueous, solvent, hot melt, and radical curing adhesives can be used, but an aqueous adhesive or a radical curing adhesive is preferable.
The water-based adhesive for forming the adhesive layer is not particularly limited, and examples thereof include vinyl polymer-based adhesives, gelatin-based adhesives, vinyl latex-based adhesives, polyurethane-based adhesives, isocyanate-based adhesives, polyester-based adhesives, epoxy-based adhesives, and the like.
Examples of the radical curing type adhesive include various adhesives such as an active energy ray curing type such as an electron ray curing type and an ultraviolet ray curing type, and a thermosetting type, but an active energy ray curing type which can be cured in a short time is preferable.
The method for manufacturing a profiled polarizing plate according to the present invention is a method for manufacturing a profiled polarizing plate having a concave rounded portion and/or a hole portion, the method including the steps of: and forming the concave rounded portion by using a cutting unit that cuts by abutting a cutting surface from the lateral direction with a blade such as an end mill.
The polarizing plate itself used in the present invention in the previous stage of forming the concave rounded portions and/or the holes can be suitably produced by a known method. In the method of manufacturing the polarizing plate according to the present invention, the step of forming the concave rounded portion by using the cutting means for cutting the polarizing plate from the lateral direction by abutting the cutting surface with a blade such as an end mill may be performed after the polarizing plate itself is manufactured, or may be performed in the step of manufacturing the polarizing plate itself in some cases.
In the manufacturing stage of the polarizing plate itself before the formation of the concave rounded portions and/or the holes, a known method may be suitably used for cutting or the like. For example, in a stage of forming the recess portions and/or the hole portions to a certain size before the microfabrication, the recess portions and/or the hole portions may be formed into a rectangular shape by a conventional method using a laser or the like. In the former stage, the shape of the polarizing plate at the time of cutting is not particularly limited, and is generally a quadrangle, and it is sufficient if the cutting is performed in the absorption axis direction and the transmission axis direction of the polarizing plate. In the former stage, for example, laser-based cutting may be performed on at least 1 end edge, but it is preferable to perform cutting in the absorption axis direction or the transmission axis direction, or both of them.
For example, the polarizing plate itself can be produced by a process of producing a polarizing plate by bonding the polarizer and the protective film with the adhesive. In the polarizing plate obtained, a protective film may be provided on one side or both sides of the polarizer via an adhesive layer formed using the polarizing plate adhesive.
In practical use, the polarizing plate may be used in the form of an optical film laminated with another optical layer. The polarizing plate in the method for producing a polarizing plate having a special shape of the present invention includes a polarizing plate having a special shape, a special-shaped optical film in which at least 1 polarizing plate layer is laminated, and the like. In the manufacturing method of the present invention, the optical film may be formed after the polarizing plate itself is shaped, or the optical film may be formed and then shaped, or both may be appropriately used.
The optical layer is not particularly limited, and for example, an optical layer used in the formation of a liquid crystal display device or the like may be used, such as a 1-layer or 2-layer or more reflective plate, a semi-transmissive plate, a retardation plate (including a wavelength plate such as 1/2 or 1/4), a viewing angle compensation film, or the like. In particular, a reflective polarizing plate or a semi-transmissive polarizing plate in which a reflective plate or a semi-transmissive reflective plate is further laminated on the polarizing plate, an elliptical polarizing plate or a circular polarizing plate in which a retardation plate is further laminated on the polarizing plate, a wide-viewing-angle polarizing plate in which a viewing angle compensation film is further laminated on the polarizing plate, or a polarizing plate in which a brightness enhancement film is further laminated on the polarizing plate is preferable.
The polarizing plate or the optical film in which at least 1 polarizing plate is laminated may be provided with an adhesive layer for adhesion to other members such as a liquid crystal display device. The adhesive agent for forming the adhesive layer is not particularly limited, and an adhesive agent based on a polymer such as an acrylic polymer, a silicone polymer, a polyester, a polyurethane, a polyamide, a polyether, a fluorine-based polymer, or a rubber-based polymer can be suitably selected and used. In particular, an adhesive such as an acrylic adhesive, which has excellent optical transparency, exhibits adhesive properties such as appropriate wettability, cohesiveness and adhesiveness, and has excellent weather resistance, heat resistance and the like, can be preferably used.
The adhesive layer may be attached to one or both sides of the polarizing plate or the optical film by an appropriate method. Examples thereof include: a method in which a base polymer or a composition thereof is dissolved or dispersed in a solvent comprising a single substance or a mixture of suitable solvents such as toluene and ethyl acetate to prepare an adhesive solution of about 10 to 40% by weight, and the adhesive solution is directly applied to a polarizing plate or an optical film in a suitable developing method such as a casting method or a coating method; alternatively, an adhesive layer may be formed on the spacer as described above and then transferred to a polarizing plate or an optical film.
The adhesive layer may be provided on one or both sides of the polarizing plate or the optical film as a stacked layer of adhesive layers of different compositions, kinds, or the like. When the polarizing plate or the optical film is provided on both surfaces, adhesive layers having different compositions, types, thicknesses, and the like may be formed on the front surface and the back surface of the polarizing plate or the optical film. The thickness of the adhesive layer may be suitably determined depending on the purpose of use, adhesion, etc., and is generally 1 to 500 μm, preferably 5 to 200 μm, and particularly preferably 10 to 100 μm.
The exposed surface of the adhesive layer is protected by temporarily attaching a spacer for the purpose of preventing contamination or the like until the adhesive layer is put into practical use. This prevents contact with the adhesive layer in a normal processing state. As the spacer, in addition to the above thickness conditions, for example, a conventional suitable spacer such as a spacer obtained by coating a suitable sheet such as a plastic film, a rubber sheet, paper, cloth, nonwoven fabric, a net, a foamed sheet, a metal foil, or a laminate thereof with a suitable release agent such as silicone-based, long-chain alkyl-based, fluorine-based, or molybdenum sulfide, as necessary, can be used.
The polarizing plate and the optical film can be preferably used for formation of various devices such as a liquid crystal display device.
Examples
Hereinafter, examples and the like which specifically show the configuration and effects of the present invention will be described.
[ examples, comparative examples ]
The working in examples 1 to 2 and comparative examples 1 to 3 was carried out under the conditions shown in table 1 below and with the working shapes shown in fig. 6. A laminate obtained by laminating a surface protection film (PPF-100T) manufactured by ritong electrical corporation on a polarizing plate (NPF-CWQ1463VDUAG380-ACJ) manufactured by ritong electrical corporation was used as a processed body. Note that the unit in fig. 6 is mm.
[ Table 1]
(measurement and evaluation of degree of freedom of shape)
The degrees of freedom of the shapes of the polarizing plates processed and manufactured in examples and comparative examples were measured and evaluated in the following manner. In each of the examples and comparative examples, the polarizing plate was processed to produce irregular parts such as convex rounded portions, concave rounded portions, and hole portions shown in fig. 1, and as a result, the case where the processed portion could be formed was evaluated as "o", and the case where the processed portion could not be formed was evaluated as "x". When the processing portion can be formed, the minimum value that can be formed is measured using a three-dimensional size measuring instrument QV-Apex606 manufactured by Mitutoyo corporation.
(measurement of dimensional accuracy and verticality accuracy)
The dimensional accuracy and the verticality accuracy of the various types of polarizers manufactured and manufactured in the examples and comparative examples were measured as follows. The dimensional accuracy was calculated by observation using an optical microscope BX51 manufactured by olapus and a three-dimensional size measuring instrument QV-Apex606 manufactured by Mitutoyo. The results were the same.
(measurement/evaluation of terminal position)
The end part quality of each of the different-type polarizing plates processed and manufactured in examples and comparative examples was measured and evaluated in the following manner. In each of the examples and comparative examples, the case where no crack, bend, or discoloration occurred in each end portion after processing or manufacturing was evaluated as "o", and the case where crack, bend, or discoloration occurred was evaluated as "x". When cracks, bends, or discoloration occur, the size of these defects and the like are measured using a microscope (an optical microscope BX51 manufactured by olapsus).
The results are shown in table 2 below.
[ Table 2]
In example 1, in the concave rounded corner, the rounded corner minimum was 3 mm. In addition, in example 2, in the concave round corner, the round corner minimum value was 62.5 mm. On the other hand, in comparative examples 1 and 2, cracks of 100 μm at maximum were generated. In comparative examples 1 and 2, a bend of 1000 μm at maximum was generated. In comparative example 3, discoloration occurred at 50 μm at the maximum.
As described above, when the manufacturing method in the embodiment of the present application is used, it is possible to easily obtain a polarizing plate having a small-diameter concave rounded portion and/or hole portion while suppressing the occurrence of cracks, bending, and discoloration. On the other hand, when the manufacturing method of the comparative example was used, cracks, bending, or discoloration occurred.
The working in examples 3 to 5 and comparative examples 4 to 5 was carried out under the conditions shown in table 3 below and with the working shapes shown in fig. 7. A laminate obtained by laminating a surface protection film (RP296C) manufactured by ritonavir electric corporation on a polarizing plate (APCFU4MS) manufactured by ritonavir electric corporation was used as a processed body. The processing conditions for thomson type in comparative example 5 are the same as in comparative example 1. Note that the round angle of the concave portion in fig. 7 is 3 mm.
(measurement of amount of delamination)
The measurement of the amount of delamination of each of the different-type polarizing plates processed and manufactured in examples and comparative examples was performed in the following manner. The obtained polarizing plates were observed with a microscope, and the distances of the corner portions, the linear portions, and the concave portions from the end portions to the deepest layers were measured.
The results are shown in table 3 below.
[ Table 3]
In examples 3 to 5, the maximum values of the delamination amounts were less than 0 μm in all of the corner portions, the linear portions, and the concave portions. On the other hand, in comparative examples 4 to 5, the maximum values of the delamination amounts in the corner portions, the linear portions, and the concave portions were all 60 μm or more.
When the processing is performed at a cutting angle of 60 ° or more as described above, the occurrence of delamination of the polarizing plate having a special shape can be more suitably suppressed.
Claims (16)
1. A method for manufacturing a special-shaped polarizing plate is characterized in that the method is a method for manufacturing a special-shaped polarizing plate with a concave fillet part,
the manufacturing method comprises a step of forming the concave fillet part by using a cutting unit, wherein the cutting unit is used for cutting a cutting surface from a transverse direction by abutting a blade,
the radius of the concave rounded part is less than 5mm,
the cutting unit is an end mill.
2. The method for manufacturing a profiled polarizing plate according to claim 1, wherein a cutting angle formed by a machine direction and the blade surface of the blade is 60 ° or more.
3. The method of manufacturing a profiled polarizing plate according to claim 1, wherein a cutting angle formed by the machine direction and the blade surface of the blade is 65 ° to 90 °.
4. The method of manufacturing a profiled polarizing plate according to claim 1, wherein a cutting angle formed by a machine direction and the blade face of the blade is 90 °.
5. A manufacturing device of the special-shaped polarizing plate is characterized in that the manufacturing device of the special-shaped polarizing plate is provided with a concave fillet part,
the manufacturing apparatus includes a cutting unit that cuts a cutting surface by abutting a blade from a lateral direction,
the radius of the concave rounded part is less than 5mm,
the cutting unit is an end mill.
6. The apparatus of claim 5, wherein a cutting angle between the cutting unit and the blade surface of the blade is 60 ° or more.
7. The apparatus of claim 5, wherein a cutting angle formed by the cutting unit and the blade surface of the blade is 65 ° to 90 °.
8. The apparatus of claim 5, wherein a cutting angle formed by the cutting unit based on the machine direction and the blade surface of the blade is 90 °.
9. A method for manufacturing a special-shaped polarizing plate having a hole portion,
the manufacturing method includes a step of forming the hole portion using an end mill,
the hole has a radius of 5mm or less.
10. The method for manufacturing a shaped polarizing plate according to claim 9, wherein a cutting angle formed by a processing direction and a blade surface of the end mill is 60 ° or more.
11. The method of manufacturing a profiled polarizing plate according to claim 9, wherein a cutting angle formed by a processing direction and a blade surface of the end mill is 65 ° to 90 °.
12. The method of manufacturing a profiled polarizing plate according to claim 9, wherein a cutting angle formed by a processing direction and a blade surface of the end mill is 90 °.
13. A manufacturing device of a special-shaped polarizing plate is characterized in that the manufacturing device is a manufacturing device of the special-shaped polarizing plate with a hole part,
the manufacturing device is provided with an end mill,
the hole has a radius of 5mm or less.
14. The apparatus for manufacturing a profiled polarizing plate according to claim 13, wherein a cutting angle formed by a processing direction and a blade surface of the end mill is 60 ° or more.
15. The apparatus for manufacturing a profiled polarizing plate according to claim 13, wherein a cutting angle formed by the processing direction and the blade surface of the end mill is 65 ° to 90 °.
16. The apparatus of claim 13, wherein a cutting angle between the processing direction and the edge surface of the end mill is 90 °.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016-144577 | 2016-07-22 | ||
| JP2016144577 | 2016-07-22 | ||
| JP2017-134354 | 2017-07-10 | ||
| JP2017134354A JP6899721B2 (en) | 2016-07-22 | 2017-07-10 | Polarizing plate manufacturing method and its manufacturing equipment |
| PCT/JP2017/026078 WO2018016520A1 (en) | 2016-07-22 | 2017-07-19 | Method for manufacturing polarizing plate and apparatus for manufacturing same |
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| Publication Number | Publication Date |
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| CN107924019A CN107924019A (en) | 2018-04-17 |
| CN107924019B true CN107924019B (en) | 2021-12-03 |
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| CN201780002930.2A Active CN107924019B (en) | 2016-07-22 | 2017-07-19 | Method and apparatus for manufacturing polarizing plate |
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| Country | Link |
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| JP (1) | JP6899721B2 (en) |
| KR (1) | KR102527432B1 (en) |
| CN (1) | CN107924019B (en) |
| TW (1) | TWI782918B (en) |
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| JP6612294B2 (en) * | 2017-07-20 | 2019-11-27 | 住友化学株式会社 | Cutting device and method of manufacturing polarizing plate |
| JP6634417B2 (en) * | 2017-07-20 | 2020-01-22 | 住友化学株式会社 | Manufacturing method of polarizing plate |
| KR102118378B1 (en) * | 2018-03-07 | 2020-06-03 | 주식회사 엘지화학 | Cutting apparatus and method for chamfering film stack using the same |
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| KR20190062331A (en) * | 2018-05-24 | 2019-06-05 | 동우 화인켐 주식회사 | Apparatus for forming hole in optical film and method of forming hole in optical film |
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| KR102320444B1 (en) * | 2018-11-06 | 2021-11-02 | 주식회사 엘지화학 | Apparatus and method for machining hole for optical film |
| JP2020098326A (en) * | 2018-12-11 | 2020-06-25 | 住友化学株式会社 | Polarizing plate |
| KR20210126006A (en) * | 2019-02-08 | 2021-10-19 | 닛토덴코 가부시키가이샤 | Manufacturing method of optical film |
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| JP6737932B1 (en) * | 2019-03-05 | 2020-08-12 | 住友化学株式会社 | Manufacturing method of machined film |
| JP2020181184A (en) * | 2019-03-14 | 2020-11-05 | 住友化学株式会社 | Polarizer |
| WO2020195269A1 (en) * | 2019-03-26 | 2020-10-01 | 日東電工株式会社 | Method for manufacturing optical film |
| JP2021028672A (en) * | 2019-08-09 | 2021-02-25 | 住友化学株式会社 | Polarizing plate |
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| KR20190027773A (en) | 2019-03-15 |
| KR102527432B1 (en) | 2023-04-28 |
| JP2018022140A (en) | 2018-02-08 |
| TW201805095A (en) | 2018-02-16 |
| CN107924019A (en) | 2018-04-17 |
| TWI782918B (en) | 2022-11-11 |
| JP6899721B2 (en) | 2021-07-07 |
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