CN108700695B - Method for manufacturing laminated optical film - Google Patents

Method for manufacturing laminated optical film Download PDF

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Publication number
CN108700695B
CN108700695B CN201780012810.0A CN201780012810A CN108700695B CN 108700695 B CN108700695 B CN 108700695B CN 201780012810 A CN201780012810 A CN 201780012810A CN 108700695 B CN108700695 B CN 108700695B
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Prior art keywords
optical film
width
adhesive layer
film
laminated
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CN108700695A (en
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仲俊之
川上武志
安藤卓也
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/04—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B23/08—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/42—Polarizing, birefringent, filtering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Polarising Elements (AREA)
  • Liquid Crystal (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Provided is a method for manufacturing a laminated optical film, which can manufacture a laminated optical film, wherein when a part of layers are peeled off from the laminated optical film provided with optical films having a plurality of layers which can be peeled off from each other, other layers are not easy to break. A method for manufacturing a laminated optical film, wherein a first optical film (2), an adhesive layer (5), and a second optical film (3) having a plurality of layers that can be peeled off from each other are introduced between a pair of rotating bonding rollers (7 a, 7 b) to bond the first optical film (2) and the second optical film (3), and the width W of the adhesive layer (5) is the width W at the time of bondingAIs the width W of the first optical film 21As described above, the first optical film 2 is located at the position in the width direction of the adhesive layer 5 by the existence width WAThe width W of the second optical film 22Is the width W of the adhesive layer 5AIn the above, the second optical film 2 is disposed at the position where the adhesive layer 5 is present and the width WA。

Description

Method for manufacturing laminated optical film
Technical Field
The present invention relates to a method for manufacturing a laminated optical film.
Background
Conventionally, a method for producing a laminated optical film in which a plurality of optical films are pressure-bonded via an adhesive layer or an adhesive layer between a pair of bonding rollers has been known (for example, see patent document 1). The adhesive layer or layers are typically provided by applying an adhesive or bonding agent to either side of the optical film to be laminated.
On the other hand, it is known that: a polarizing plate is manufactured by laminating another optical film on an optical film including a plurality of layers that can be peeled from each other, for example, a resin base and a polarizer, via an adhesive layer or an adhesive layer (see, for example, patent document 2).
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open No. 2014-172290
Patent document 2: japanese patent laid-open No. 2014-44355
Disclosure of Invention
Problems to be solved by the invention
For example, when the resin base material is peeled off from the polarizing plate, the polarizing plate facing the adhesive layer or the pressure-sensitive adhesive layer tends to be broken.
The purpose of the present invention is to provide a method for producing a laminated optical film, which can produce a laminated optical film that is less likely to break in other layers when a part of the layers are peeled from a laminated optical film including optical films having a plurality of layers that can be peeled from each other.
Means for solving the problems
The present invention provides a method for manufacturing a laminated optical film, wherein a first optical film, an adhesive layer or an adhesive layer, and a second optical film, which have a plurality of layers that can be peeled off from each other, are introduced between a pair of rotating laminating rollers in a state of being sequentially arranged in a direction connecting the pair of laminating rollers, so as to laminate the first optical film and the second optical film.
In this manufacturing method, the width of the adhesive layer or the pressure-sensitive adhesive layer is equal to or greater than the width of the first optical film having a plurality of layers that are peelable from each other, and the position of the first optical film in the width direction is within the existing width of the adhesive layer or the pressure-sensitive adhesive layer. Therefore, when a part of the layers is to be peeled off from the first optical film in the manufactured laminated optical film, the layer remaining on the laminated optical film side is sufficiently maintained by the adhesive layer or the pressure-sensitive adhesive layer. Therefore, according to this manufacturing method, it is possible to manufacture a laminated optical film in which when a part of layers are peeled off from a laminated optical film including optical films having a plurality of layers that are peelable from each other, the other layers are less likely to be broken.
The manufacturing method can also be as follows: the width of the bonding roller on the first optical film side is equal to or greater than the width of the first optical film, and the position of the first optical film in the width direction is within the existing width of the bonding roller on the first optical film side. At this time, the entire width of the first optical film in the width direction is pressed by the bonding roller, and thus, the adhesiveness or adhesiveness between the first optical film and the second optical film is improved.
The manufacturing method can also be as follows: the third optical film having a width larger than the width of the adhesive layer or the adhesive layer is interposed between the bonding roller on the first optical film side and the first optical film so as to cover the width of the adhesive layer or the adhesive layer. In the conventional manufacturing method, there is a possibility that the adhesive or the pressure-sensitive adhesive may overflow from the end portion in the width direction of the first optical film and adhere to the bonding roller to contaminate the bonding roller at the time of bonding, and the adhesive or the pressure-sensitive adhesive may be prevented from adhering to the bonding roller by interposing the wide third optical film therebetween.
The manufacturing method can be as follows: the first optical film has a resin base material and an optical function layer provided on one or both surfaces of the resin base material, the resin base material and the optical function layer have the same width and have both ends aligned, the first optical film is disposed so that the optical function layer side faces the adhesive layer or the pressure-sensitive adhesive layer side, and the second optical film is a protective film. In this case, the resin base material and the optical function layer have the same width and are aligned at both ends, and therefore, the film thickness of the end portion in the width direction as the first optical film is stable.
In this production method, the optically functional layer may be a polarizing plate, and in this case, the polarizing plate may be provided by coating the resin substrate with the polarizing plate.
In another aspect of the present invention, there is provided a method for producing a laminated optical film, comprising introducing a resin base material, an optical functional layer, an adhesive layer or an adhesive layer, and a protective film provided on one or both surfaces of the resin base material, between a pair of rotating laminating rollers, the laminating rollers being arranged in this order in a direction connecting the pair of laminating rollers, and bonding the optical functional layer and the protective film, wherein, in the step of bonding, a width of the optical functional layer is smaller than a width of the resin base material, a width of the adhesive layer or the adhesive layer is equal to or larger than the width of the optical functional layer and smaller than the width of the resin base material, a position of the optical functional layer in the width direction is within a width of the adhesive layer or the adhesive layer, and the resin base material is positioned so as to wrap the optical functional layer and the adhesive layer or the adhesive layer, the width of the protective film is not less than the width of the adhesive layer or the pressure-sensitive adhesive layer, and the position of the adhesive layer or the pressure-sensitive adhesive layer in the width direction is within the existing width of the protective film.
In this manufacturing method, the width of the adhesive layer or the pressure-sensitive adhesive layer is equal to or greater than the width of the optical functional layer, and the position of the optical functional layer in the width direction is within the existing width of the adhesive layer or the pressure-sensitive adhesive layer. Therefore, when it is desired to peel off the resin base material or the optical functional layer in the produced laminated optical film, the layer remaining on the laminated optical film side is sufficiently held by the adhesive layer or the pressure-sensitive adhesive layer.
Therefore, according to this manufacturing method, it is possible to manufacture a laminated optical film in which when a part of layers is peeled off from a laminated optical film including an optical film having a resin base material and an optical function layer, the other layers are not easily broken. In this manufacturing method, the width of the optical functional layer is smaller than the width of the resin base material, and the resin base material is positioned so as to include the optical functional layer and the adhesive layer or the pressure-sensitive adhesive layer by the width, so that the adhesive or the pressure-sensitive adhesive can be prevented from adhering to the bonding roller on the resin base material side.
The manufacturing method can also be as follows: the width of the bonding roller on the resin substrate side is equal to or greater than the width of the optical function layer, and the position of the optical function layer in the width direction is within the existing width of the bonding roller on the resin substrate side. In this case, the entire width of the optical function layer is pressed by the bonding roller, and thus the adhesiveness or adhesiveness between the optical function layer or the resin base material and the protective film is improved.
In this production method, the optically functional layer may be a polarizing plate, and in this case, the polarizing plate may be provided by being applied to a resin base material.
Effects of the invention
According to the present invention, it is possible to provide a method for manufacturing a laminated optical film which can manufacture a laminated optical film in which when a part of layers is peeled off from a laminated optical film including optical films having a plurality of layers which can be peeled off from each other, the other layers are less likely to be broken.
Drawings
Fig. 1 is a sectional view of a laminated optical film manufactured by the manufacturing method of the first embodiment.
Fig. 2 is a diagram illustrating a manufacturing method of the first embodiment.
FIG. 3 is a sectional view III-III of FIG. 2, showing a state of lamination at the time of bonding of the first embodiment.
Fig. 4 is a sectional view of a laminated optical film manufactured by the manufacturing method of the second embodiment.
Fig. 5 is a diagram illustrating a manufacturing method of the second embodiment.
FIG. 6 is a sectional view taken along line VI-VI in FIG. 5, showing the laminated state in the bonding of the second embodiment.
Fig. 7 is a sectional view of a laminated optical film manufactured by the manufacturing method of the third embodiment.
Fig. 8 is a diagram showing a laminated state at the time of bonding of the third embodiment.
Detailed Description
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and overlapping description will be omitted. The dimensional ratios in the drawings do not necessarily match the actual dimensional ratios, and the thicknesses and widths of the films are exaggeratedly drawn.
< first embodiment >
(laminated optical film)
As shown in fig. 1, in a laminated optical film 1A produced by the method for producing a laminated optical film according to the first embodiment, a second optical film 3 is laminated on one surface of a first optical film 2 with an adhesive layer 5 interposed therebetween. The first optical film 2 includes two layers, i.e., a resin substrate 21 and a polarizing plate 22 provided on one surface of the resin substrate 21, and they are separable from each other.
In the first optical film 2, the resin base 21 and the polarizing plate 22 have the same width and are aligned at both ends, and the first optical film 2 is disposed so that the polarizing plate 22 side faces the adhesive layer 5 side. In the present specification, the "width" of each optical film means a width of each optical film in a direction perpendicular to the conveyance direction and in the extending direction of the bonding roller in the production of the laminated optical film 1A. In addition, for the relative magnitude relationship (width-width relationship) of the widths of the respective films, expressions of "large" and "small" are used.
The laminated optical film 1A is used as a polarizing plate 10 provided with a polarizing plate 22 and a second optical film (protective film described later) 3, with the resin base 21 removed. The polarizing plate 10 may be newly provided with a protective film or another optical film on the resin base material 21 side and the second optical film side 3 after peeling, via an adhesive layer or an adhesive layer, as necessary.
The relationship in size and positional relationship of the width of the first optical film 2, the second optical film 3, and the adhesive layer 5 are as described below, and the center axes of these layers in the respective width directions are substantially coincident with each other. That is, in the cross-sectional view shown in fig. 1, the layered form is substantially bilaterally symmetrical.
Here, the structure of each film and the adhesive layer will be described. As the material of the polarizer 22, known materials conventionally used for manufacturing polarizing plates can be used, and examples thereof include polyvinyl alcohol resins, polyvinyl acetate resins, ethylene/vinyl acetate (EVA) resins, polyamide resins, polyester resins, and the like. Among them, polyvinyl alcohol resins are preferred. The film-shaped polarizing plate 22 can be obtained by subjecting these materials to stretching treatment, and then dyeing with iodine or a dichroic dye and boric acid treatment. A laminate obtained by bonding one or both surfaces of the resin substrate 21 with an adhesive may be used as the first optical film 2.
As a method for forming the polarizing plate 22, a coating liquid in which a material of the polarizing plate 22 is dissolved may be applied in a film form (film form) on one surface or both surfaces of the resin substrate 21, dried, and then subjected to a stretching treatment together with the resin substrate 21, and then subjected to a dyeing with iodine or a dichroic dye and a boric acid treatment. Thereafter, the resin base material 21 may be cut into an arbitrary size together as the first optical film 2.
Examples of the stretching method include: longitudinal stretching in which stretching is performed in the film length direction (film transport direction), transverse stretching in which stretching is performed in the film width direction, oblique stretching, or the like. Examples of the longitudinal stretching method include inter-roll stretching and compression stretching, and examples of the transverse stretching method include a tenter method. In the stretching treatment, both wet stretching and dry stretching methods can be used, and the dry stretching method is preferably used from the viewpoint of being able to select the stretching temperature from a wide range.
The thickness of the polarizing plate 22 is preferably 2 to 75 μm, more preferably 2 to 50 μm, and still more preferably 2 to 30 μm.
The resin substrate 21 functions as a support for coating the polarizing plate 22 in a film form (film form) and as a protective member for protecting the surface of the polarizing plate 22, and various resin materials can be used. Examples of the material of the resin substrate 21 include polyethylene terephthalate (PET) resin, polypropylene resin, and polycarbonate resin.
The thickness of the resin base material 21 is preferably 20 to 500. mu.m, more preferably 30 to 300. mu.m, and still more preferably 50 to 200. mu.m.
The second optical film 3 is here a protective film 3.
The protective film 3 is a film for preventing cracks and scratches on the main surface and the end portions of the polarizing plate 22. Here, the "protective film" refers to a film that is directly laminated with an adhesive among various films that can be laminated on the polarizing plate 22.
The protective film 3 may be composed of various transparent resin films known in the field of polarizing plates. For example, cellulose-based resins typified by triacetyl cellulose, polyolefin-based resins typified by polypropylene-based resins, cycloolefin-based resins typified by norbornene-based resins, acrylic-based resins typified by polymethyl methacrylate-based resins, and polyester-based resins typified by polyethylene terephthalate-based resins are used. Among them, cellulose-based resins are typical.
The protective film 3 may be a film having no optical function, or may be a film having an optical function such as a retardation film or a brightness enhancement film.
The thickness of the protective film 3 is preferably 5 to 90 μm, more preferably 5 to 80 μm, and further preferably 5 to 50 μm.
As the adhesive for forming the adhesive layer 5, various adhesives conventionally used for manufacturing polarizing plates can be used. For example, from the viewpoint of weather resistance, refractive index, cationic polymerization, and the like, an epoxy resin containing no aromatic ring in the molecule is preferable. Further, an adhesive which can be cured by irradiation with an active energy ray (ultraviolet ray or heat ray) is preferable.
As the epoxy resin, for example, hydrogenated epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, and the like are preferable. The epoxy resin composition for coating can be used by adding a polymerization initiator (for example, a photo cation polymerization initiator for polymerization under ultraviolet irradiation, a thermal cation polymerization initiator for polymerization under heat ray irradiation) and other additives (such as a sensitizer) to the epoxy resin.
As the adhesive, acrylic resins such as acrylamide, acrylate, urethane acrylate, and epoxy acrylate, and polyvinyl alcohol-based water-based adhesives may be used.
The polarizing plate 10 is bonded to one surface or both surfaces of a display unit (image display element) such as a liquid crystal unit. The polarizing plate may further include other optical layers stacked on the protective film. Examples of other optical layers include: a reflective polarizing film that transmits a certain polarized light and reflects a polarized light showing a property opposite to that of the polarized light; a film having an antiglare function and having a concavo-convex shape on the surface; a film having a surface antireflection function; a reflective film having a reflective function on a surface thereof; a semi-transmissive reflective film having both a reflective function and a transmissive function; a viewing angle compensation film, and the like.
The thickness of the polarizing plate 10 formed of the polarizer 22 and the protective film 3 is preferably 10 to 500. mu.m, more preferably 10 to 300. mu.m, and still more preferably 10 to 200. mu.m.
(method for producing laminated optical film)
As a method for manufacturing the laminated optical film 1A, as shown in fig. 2 and 3, the first optical film 2, the adhesive layer 5, and the protective film 3 are introduced between the pair of rotating bonding rollers 7a and 7b in a state of being sequentially arranged in a direction connecting the pair of bonding rollers 7a and 7b, and the first optical film 2 and the protective film 3 are bonded.
Here, the polarizing plate 22 in the first optical film 2 is provided as follows: after being applied to the resin base 21 and dried, the adhesive layer 5 is provided by being applied to the protective film 3, followed by stretching the resin base 21, dyeing with iodine or a dichroic dye, boric acid treatment, washing with water, drying, and cutting the widthwise ends to align the ends so that the width of the resin base 21 and the width of the polarizing plate 22 are equal to each other, and the two ends are aligned with each other. In fig. 2, the adhesive layer 5 is not shown.
The first optical film 2 and the protective film 3 are laminated to form a laminate 4A, and the laminate 4A is then cured with the adhesive layer 5, thereby completing a laminated optical film 1A shown in fig. 1.
The existence form of each member at the time of bonding will be explained. As shown in fig. 3, the widths of the films and the adhesive layer 5 between the pair of bonding rollers 7a and 7b satisfy the following relationship. In fig. 3, the bonding rollers 7a and 7b are depicted as being separated from the laminate 4A so as to make the drawing easier to see.
When the adhesive tape is attached to the base material,
width W of adhesive layer 5AIs a first optical film 2Width W of1The above. (W)A≥W1)
The first optical film 2 is located at the position in the width direction and has the existence width W of the adhesive layer 5AWithin.
Width W of protective film 32Is the width W of the adhesive layer 5AThe above. (W)2≥WA)
The protective film 3 is disposed at a position where the width W of the adhesive layer 5 is presentA。
Here, the "inner bag" means that the positions of both end portions of one member are at the same positions as the positions of both end portions of the other member in the width direction, or at positions outside.
The manufacturing method according to the first embodiment satisfies the following relationship, but is not necessarily required.
Width W of the bonding roller 7a on the first optical film 2 sideR1Is equal to the width W of the laminating roller 7b on the side of the protective film 3R2。(WR1＝WR2)
Width W of the bonding roller 7a on the first optical film 2 sideR1Is the width W of the first optical film 21The above. (W)R1≥W1)
The existing width W of the bonding roller 7a of which the position of the first optical film 2 in the width direction is on the first optical film 2 sideR1Within.
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the adhesive layer 5A。(WR2＞WA)
The bonding roller 7b on the side of the protective film 3 is disposed so as to cover the width W of the adhesive layer 5 in the width directionA。
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the protective film 32。(WR2＞W2)
The bonding roller 7b on the protective film 3 side is positioned so as to cover the width W of the protective film 3 in the width direction2。
Here, the "width of the bonding roller" refers to the entire width of a portion extending to have the same diameter as a portion serving as an effective contact surface contributing to bonding. For example, when there is a portion where a portion in the width direction is reduced in diameter on the end portion side of the bonding rollers 7a and 7b so as not to contact the first optical film 2 or the protective film 3, the width of the portion excluding the reduced diameter portion is defined as the entire width of the bonding rollers 7a and 7 b.
The width W of the adhesive layer 5 is set so that the first optical film 2 is more firmly held by the adhesive layer 5APreferably greater than the width W of the first optical film 21(WA＞W1). At this time, the width W of the adhesive layer 5APreferably, the width W of the first optical film 210.5 to 100mm in size, more preferably 1 to 50mm in size. In addition, the width W of the protective film 3 is set so that the adhesive layer 5 is more firmly held by the protective film 32Preferably greater than the width W of the adhesive layer 5A(W2＞WA)。
In this manufacturing method, the width W of the adhesive layer 5AThe width W of the first optical film 2 having the resin substrate 21 and the polarizing plate 22 which can be peeled off from each other1As described above, the first optical film 2 is located at the position in the width direction of the adhesive layer 5 by the width WAWithin. Therefore, when the resin base 21 is to be peeled from the first optical film 2 in the manufactured laminated optical film 1A, the layer (polarizing plate 22) remaining on the laminated optical film 1A side is sufficiently held by the adhesive layer 5. Therefore, the laminated optical film 1A produced by this production method is less likely to break the polarizing plate 22 when the resin substrate 21 is peeled.
In addition, the first optical film 2 is positioned in the width direction by the existing width W of the laminating roller 7a on the first optical film 2 sideR1Inner, and thus, the first optical film 2 has a width W1The entire range in the direction is pressed by the bonding roller, and the adhesiveness between the first optical film 2 and the protective film 3 is improved.
Further, since the resin base 21 and the polarizing plate 22 constituting the first optical film 2 have the same width and are aligned at both ends, the film thickness of the end portion in the width direction is stable as the first optical film 2.
In the first embodiment, the width W of the laminating roller 7a on the first optical film 2 side is shownR1Is equal to the width W of the laminating roller 7b on the side of the protective film 3R2But their widths may also be different. Further, as long as the first optical film 2 and the protective film 3 can be sufficiently bonded, their widths can be freely changed.
< second embodiment >
A second embodiment of the present invention will be described below. The following description mainly deals with differences from the first embodiment.
(laminated optical film)
As shown in fig. 4, in the laminated optical film 1B produced by the method for producing a laminated optical film according to the second embodiment, the third optical film 6 is laminated on the resin base material 21 side of the first optical film 2.
Here, the third optical film 6 is a temporary protective film 6.
The temporary protective film 6 is a film for preventing an adhesive from adhering to the bonding roller, and is a film for protecting the surface of the member (here, the first optical film 2) on which the temporary protective film 6 is laminated from being damaged, abraded, or the like. As the material of the temporary protective film 6, the same materials as those of the above-described protective films can be used, and among them, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polyethylene isophthalate, and polybutylene terephthalate are preferable.
The temporary protective film 6 may have a weakly adhesive pressure-sensitive adhesive layer laminated on the surface of the film other than the film serving as the base material.
The thickness of the temporary protective film 6 is preferably 5 to 200 μm, more preferably 5 to 100 μm, and further preferably 5 to 50 μm.
(method for producing laminated optical film)
As a method for manufacturing the laminated optical film 1B, as shown in fig. 5 and 6, the first optical film 2, the adhesive layer 5, and the protective film 3 are introduced between the pair of rotating bonding rollers 7a and 7B in a state of being sequentially arranged in a direction connecting the pair of bonding rollers 7a and 7B, and the first optical film 2 and the protective film 3 are bonded. At this time, the temporary protective film 6 is sandwiched between the first optical film 2 and the bonding roller 7a on the first optical film 2 side.
The first optical film 2, the protective film 3, and the temporary protective film 6 are laminated to form a laminate 4B, and the laminate 4B is then cured with the adhesive layer 5, thereby completing a laminated optical film 1B shown in fig. 4.
The existence form of each member at the time of bonding will be explained. As shown in fig. 6, the widths of the films and the adhesive layers between the pair of bonding rollers 7a and 7b satisfy the following relationship.
In fig. 6, the bonding rollers 7a and 7B are depicted as being separated from the laminate 4B for the sake of easy viewing of the drawing.
Width W of adhesive layer 5AIs the width W of the first optical film 21The above. (W)A≥W1)
The first optical film 2 is located at the position in the width direction and has the existence width W of the adhesive layer 5AWithin.
Width W of protective film 32Is the width W of the adhesive layer 5AThe above. (W)2≥WA)
The protective film 3 is disposed at a position where the width W of the adhesive layer 5 is presentA。
Width W of temporary protective film 63Has a width W larger than that of the adhesive layer 5AIs measured. (W)3＞WA)
The temporary protective film 6 is provided at a position covering the width W of the adhesive layer 5A。
Width W of adhesive layer 5AIs greater than the width W of the first optical film 21In the case, the diameter is preferably 0.5 to 100mm, more preferably 1 to 50 mm.
The relationship between the width of the protective film 3 and the width of the temporary protective film 6 is arbitrary.
The manufacturing method according to the second embodiment satisfies the following relationship, but is not necessarily required.
Width W of the bonding roller 7a on the first optical film 2 sideR1Equal to the 3 side of the protective filmWidth W of the bonding roller 7bR2。(WR1＝WR2)
Width W of the bonding roller 7a on the first optical film 2 sideR1Is the width W of the first optical film 21The above. (W)R1≥W1)
The existing width W of the bonding roller 7a of which the position of the first optical film 2 in the width direction is on the first optical film 2 sideR1Within.
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the adhesive layer 5A。(WR2＞WA)
The bonding roller 7b on the side of the protective film 3 is disposed so as to cover the width W of the adhesive layer 5 in the width directionA。
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the protective film 32。(WR2＞W2)
The bonding roller 7b on the protective film 3 side is positioned so as to cover the width W of the protective film 3 in the width direction2。
In the manufacturing method of the first embodiment, the adhesive may overflow from the end in the width direction of the first optical film 2 and adhere to the bonding roller 7a at the time of bonding, and may contaminate the bonding roller 7a, and according to the manufacturing method of the second embodiment, the adhesive can be prevented from adhering to the bonding roller 7a by interposing the wide temporary protective film 6 therebetween.
In the second embodiment, the width W of the laminating roller 7a on the first optical film 2 side is shownR1Is equal to the width W of the laminating roller 7b on the side of the protective film 3R2The widths of the above-described members can be variously changed as in the case of the first embodiment.
(modification of the first and second embodiments)
The first and second embodiments described above can be implemented as the following embodiments. That is, the following can be adopted: the first optical film 2 is the laminated optical film 1A manufactured by the manufacturing method of the first embodiment, and the second optical film 3 is a spacer, and these are bonded by an adhesive instead of an adhesive. At this time, the laminated optical film obtained by laminating the spacer on the protective film 3 side of the laminated optical film 1A becomes a spacer-equipped polarizing plate. This embodiment will be explained below.
The pressure-sensitive adhesive layer functions when the polarizing plate is attached to another article (for example, a liquid crystal cell). The adhesive layer may be made of acrylic resin, silicone resin, polyester, polyurethane, polyether, or the like.
The thickness of the adhesive layer is preferably 2 to 500 μm, more preferably 2 to 200 μm, and further preferably 2 to 50 μm.
As a method for laminating the adhesive layer to the polarizing plate, for example, a method of coating a solution containing the above resin and optional additional components on the polarizing plate or a method of forming an adhesive layer on the spacer using the solution and laminating the adhesive layer to the polarizing plate may be used.
The spacer is a peelable film that is bonded for the purpose of protecting the adhesive layer, preventing adhesion of foreign matter, and the like, and is peeled off to expose the adhesive layer when the polarizing plate is used. The spacer may be made of, for example, a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, a polyester resin such as polyethylene terephthalate, or the like. Among them, stretched films of polyethylene terephthalate are preferable.
The spacer may be subjected to a mold release treatment with a silicone resin or the like on the surface to be in contact with the adhesive layer so as to be easily peelable when the polarizing plate is used.
The thickness of the spacer is preferably 10 to 500 μm, more preferably 10 to 300 μm, and still more preferably 10 to 200 μm.
Even in the above-described embodiment, the polarizing plate 22 can be prevented from being broken when the resin substrate 21 is peeled by the same operation as in the above-described embodiment.
< third embodiment >
A third embodiment of the present invention will be explained below. The following description mainly deals with differences from the first embodiment.
(laminated optical film)
As shown in fig. 7, in the laminated optical film 1C produced by the method for producing a laminated optical film according to the fourth embodiment, the width of the resin base 21 and the width of the polarizing plate 22 do not match in the first optical film 2, and the width of the resin base 21 is larger than the width of the polarizing plate 22.
The dimensional and positional relationships among the widths of the resin base 21, the polarizing plate 22, the protective film 3, and the adhesive layer 5 are as described below, and the center axes of these layers in the respective width directions are substantially coincident with each other. That is, in the cross-sectional view shown in fig. 7, the layered form is substantially bilaterally symmetrical.
(method for producing laminated optical film)
As a method for producing the laminated optical film 1C, as shown in fig. 2 and 8, a resin base material 21, a polarizing plate 22, an adhesive layer 5, and a protective film 3 are introduced between a pair of rotating bonding rollers 7a and 7b in a state of being sequentially arranged in a direction connecting the pair of bonding rollers 7a and 7b, and the polarizing plate 22 and the protective film 3 are bonded.
Here, the polarizing plate 22 in the first optical film 2 is provided as follows: the resin base material 21 is obtained by coating only the widthwise central portion of the resin base material 21 without coating both end portions, drying the coating, stretching the resin base material 21, dyeing with iodine or a dichroic dye, treating the resulting product with boric acid, washing the product with water, and drying the product.
The resin base 21, the polarizing plate 22, and the protective film 3 are laminated to form a laminate 4C, and the laminate 4C is then cured with the adhesive layer 5, thereby completing a laminated optical film 1C shown in fig. 7.
The existence form of each member at the time of bonding will be explained. As shown in fig. 8, the widths of the films and the adhesive layer 5 between the pair of bonding rollers 7a and 7b satisfy the following relationship. In fig. 8, the bonding rollers 7a and 7b are depicted as being separated from the laminate 4C for the sake of easy viewing of the drawing.
Width W of polarizing plate 2212Is smaller than the width W of the resin base material 2111。(W11＞W12)
Width W of adhesive layer 5AIs the width W of the polarizing plate 2212Above and smallWidth W of resin substrate 2111。(W11＞WA≥W12)
The polarizing plate 22 is located at the width W of the adhesive layer 5 in the width directionAWithin.
The resin base material 21 is positioned so that the width W of the internal polarizing plate 22 is present12And the width W of the adhesive layer 5A。
Width W of protective film 32Is the width W of the adhesive layer 5AThe above. (W)2≥WA)
Position W of adhesive layer 5 in the width directionAIs located at the existing width W of the protective film 32Within.
Width W of adhesive layer 5AIs larger than the width W of the polarizing plate 2212In the case of (2), the thickness is preferably 0.5 to 100mm, more preferably 1 to 50 mm.
The width W of the resin base 2112Width W of the protective film 32The magnitude relationship of (a) is arbitrary.
The manufacturing method according to the fourth embodiment satisfies the following relationship, but is not necessarily required.
Width W of the bonding roller 7a on the first optical film 2 sideR1Is equal to the width W of the laminating roller 7b on the side of the protective film 3R2。(WR1＝WR2)
Width W of the bonding roller 7a on the first optical film 2 sideR1Is the width W of the resin base material 2111And width W of the polarizing plate 2212The above. (W)R1≥W11And WR1≥W12)
The width W of the laminating roller 7a where the resin base 21 and the polarizing plate 22 are both positioned on the first optical film 2 side in the width directionR1Within.
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the adhesive layer 5A。(WR2＞WA)
The bonding roller 7b on the side of the protective film 3 is disposed so as to include the adhesive layer 5 in the position in the width directionIn the width WA。
Width W of the bonding roller 7b on the protective film 3 sideR2Is larger than the width W of the protective film 32。(WR2＞W2)
The bonding roller 7b on the protective film 3 side is positioned so as to cover the width W of the protective film 3 in the width direction2。
The width W of the adhesive layer 5 is set so that the polarizing plate 22 is more firmly held by the adhesive layer 5APreferably greater than the width W of the polarizer 2212(WA＞W12). In addition, the width W of the protective film 3 is set so that the adhesive layer 5 is more firmly held by the protective film 32Preferably greater than the width W of the adhesive layer 5A(W2＞WA)。
In this manufacturing method, the width W of the adhesive layer 5AIs not less than the width of the polarizing plate 22, and the polarizing plate 22 is located at the width W of the adhesive layer 5AWithin. Therefore, when the resin base 21 is to be peeled off from the produced laminated optical film 1C, the layer (polarizing plate 22) remaining on the laminated optical film 1C side is sufficiently held by the adhesive layer 5. Therefore, according to this manufacturing method, the laminated optical film 1C in which the other layers are not easily broken when the resin base material 21 is peeled can be manufactured.
In addition, in this manufacturing method, the width W of the polarizing plate 2212Is smaller than the width W of the resin base material 2111And the resin base material 21 is positioned so that the width W of the inclusion polarizing plate 22 is set12And the width W of the adhesive layer 5ATherefore, the adhesive can be prevented from adhering to the bonding roller 7a on the resin base material 21 side. Width W of the bonding roller 7aR1Is smaller than the width W of the resin base material 2111And the resin base material 21 is positioned so that the width W of the inner wrap bonding roller 7a is largerR1In this case, the adhesive can be further prevented from adhering to the bonding roller 7 a.
According to the above embodiments, the laminated optical films 1A to 1C in which other layers are not easily broken when the resin base material 21 is peeled can be manufactured. When the polarizing plate 22 is included in the first optical film 2, since the polarizing plate 22 is lower in strength than other constituent films and is likely to be scratched or broken, a portion (particularly, an end portion) of the polarizing plate 22 is likely to be broken when the resin substrate 21 is peeled. In the case of the present embodiment, since the layer (polarizing plate) remaining on the side of the laminated optical film is sufficiently held by the adhesive layer 5, even when the polarizing plate 22 having low strength is included in the first optical film 2, the occurrence of cracking can be sufficiently suppressed at the time of peeling the resin substrate 21.
Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above embodiments at all.
For example, in the above embodiments, the polarizing plate 22 is applied to one surface of the resin substrate 21, but the polarizing plate 22 may be applied to both surfaces of the resin substrate 21. In this case, after the laminated optical films 1A to 1C are manufactured, the polarizer 22 facing the adhesive layer 5 and the resin substrate 21 may be peeled off from each other, and the polarizer remaining on the resin substrate 21 side may be used for manufacturing another polarizing plate.
In the above embodiments, the description has been made using the example in which the first optical film of the polarizing plate 22 is provided on one surface of the resin substrate 21, but an optical function layer different from the polarizing plate 22 may be provided on one surface or both surfaces of the resin substrate 21. The optical function layer other than the polarizing plate 22 may be a retardation layer, a viewing angle compensation layer, or the like, and may be provided by applying or drying a liquid in which a material having a desired optical function is dissolved or dispersed on the resin base 21. Further, when the resin base material 21 is peeled off, the optical function layer can be prevented from being broken.
Description of the symbols
1A to 1C … laminated optical films, 2 … first optical films, 3 … protective films (second optical films), 4A to 4C … laminated bodies, 5 … adhesive layers, 6 … temporary protective films (third optical films), 7a … first optical film side bonding rolls, 7b … protective film side bonding rolls, 10 … polarizing plates, 21 … resin substrates, 22 … polarizing plates, W1… width of first optical film, W11… Width of resin base Material, W12… offsetWidth, W, of the vibrating piece2… width of protective film, W3… width of temporary protective film, WA… width of adhesive layer, WR1… width W of laminating roller on first optical film sideR2… protects the width of the film side conformable roller.

Claims (4)

1. A method for manufacturing a laminated optical film, wherein a first optical film having a plurality of layers that are mutually peelable, an adhesive layer or a pressure-sensitive adhesive layer, and a second optical film are introduced between a pair of rotating laminating rollers in a state of being sequentially arranged in a direction connecting the pair of laminating rollers, such that the first optical film is in direct contact with one of the pair of laminating rollers, and the first optical film and the second optical film are laminated,
in the method for manufacturing a laminated optical film,
when the adhesive tape is attached to the base material,
the width of the adhesive layer or the pressure-sensitive adhesive layer is not less than the width of the first optical film,
the position of the first optical film in the width direction is within the existing width of the adhesive layer or the adhesive layer,
the width of the second optical film is not less than the width of the adhesive layer or the pressure-sensitive adhesive layer,
the second optical film is positioned so as to wrap the adhesive layer or the adhesive layer,
the width of the bonding roller on the first optical film side is not less than the width of the first optical film,
the position of the first optical film in the width direction is within the existing width of the laminating roller on the first optical film side.
2. The method of manufacturing a laminated optical film according to claim 1,
the first optical film has a resin base material and an optical functional layer provided on one or both surfaces of the resin base material,
the resin base material and the optical function layer are equal in width to each other and aligned at both ends,
the first optical film is disposed so that the optically functional layer side faces the adhesive layer or the adhesive layer side,
the second optical film is a protective film.
3. The method of manufacturing a laminated optical film according to claim 2,
the optical function layer is a polaroid.
4. The method of manufacturing a laminated optical film according to claim 3,
the polarizing plate is provided by being applied to the resin base material.
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