CN110930864A - Method for manufacturing image display device - Google Patents

Method for manufacturing image display device Download PDF

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CN110930864A
CN110930864A CN201910848015.6A CN201910848015A CN110930864A CN 110930864 A CN110930864 A CN 110930864A CN 201910848015 A CN201910848015 A CN 201910848015A CN 110930864 A CN110930864 A CN 110930864A
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Prior art keywords
light
image display
resin layer
curable resin
layer
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CN201910848015.6A
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CN110930864B (en
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高桥宏
渡边明彦
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Dexerials Corp
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Dexerials Corp
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    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F9/00Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1339Gaskets; Spacers; Sealing of cells
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065After-treatment
    • B05D3/067Curing or cross-linking the coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/24Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/08Macromolecular additives
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J4/00Adhesives based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; adhesives, based on monomers of macromolecular compounds of groups C09J183/00 - C09J183/16
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/1303Apparatus specially adapted to the manufacture of LCDs
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/133308Support structures for LCD panels, e.g. frames or bezels
    • G02F1/133331Cover glasses
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/84Passivation; Containers; Encapsulations
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F2202/00Materials and properties
    • G02F2202/28Adhesive materials or arrangements

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  • Physics & Mathematics (AREA)
  • Nonlinear Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mathematical Physics (AREA)
  • Organic Chemistry (AREA)
  • Theoretical Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Plasma & Fusion (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Polymerisation Methods In General (AREA)
  • Laminated Bodies (AREA)
  • Liquid Crystal (AREA)
  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)

Abstract

The invention provides a method for manufacturing an image display device with good adhesive property during temporary curing. The method for manufacturing an image display device according to the present technology includes the steps of: a step a of forming a curable resin layer 2 made of a photocurable resin composition on the surface of the front panel 4 or the image display member 1; a step B of irradiating the curable resin layer 2 with light from a UV-LED to form a temporary cured layer 5; a step C of bonding the front panel 4 to the image display member 1 via the temporary cured layer 5; and a step D of forming the cured resin layer 6 by irradiating the temporarily cured layer 5 with light through the front panel 4. The light irradiated in the step B includes the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345 nm. In step B, the 1 st light is irradiated to the curable resin layer 2 to irradiate the 2 nd light to the portion of the curable resin layer 2 where oxygen inhibition occurs.

Description

Method for manufacturing image display device
Technical Field
The present technology relates to a method of manufacturing an image display device.
Background
Patent document 1 describes a method for manufacturing a display device, the method including: a first irradiation step (temporary curing step) of irradiating the adhesive applied to at least one of the display panel and the substrate with light; a bonding step of bonding the display panel and the substrate after the first irradiation step; and a second irradiation step (main curing step) of further irradiating the adhesive with light after the bonding step.
The cured state of the outermost surface of the resin in the temporary curing step is important for maintaining the alignment at the time of bonding. Regarding the cured state of the outermost surface of the resin, the curing rate decreases as the influence of oxygen inhibition (oxygen inhibition) upon temporary curing increases, and accordingly the adhesive function also tends to decrease. Therefore, as the ultraviolet irradiation device, a device having a wide wavelength range and a high output, such as a metal halide lamp or a high-pressure mercury lamp, is preferable.
However, in recent years, due to the requirement of high life performance of ultraviolet irradiation devices, there is a tendency to use, for example, a UV-LED having a peak in a wavelength range of 360 to 430nm as a light source. Since such UV-LEDs are used at a single wavelength, there is a concern that the adhesion performance at the time of temporary curing may be lowered due to the influence of oxygen inhibition.
Documents of the prior art
Patent document
Patent document 1: international publication No. WO 2009/054168.
Disclosure of Invention
Problems to be solved by the invention
The present technology has been made in view of such conventional circumstances, and provides a method for manufacturing an image display device having excellent adhesion performance in the temporary curing.
Means for solving the problems
The method for manufacturing an image display device according to the present technology includes the steps of: a step A of forming a curable resin layer made of a photocurable resin composition on the surface of a front panel or an image display member; a step (B) of irradiating the curable resin layer with light from a UV-LED to form a temporary cured layer; a step C of bonding the front panel to the image display member via the temporary cured layer; and a step D of irradiating the temporary cured layer with light through the front panel to form a cured resin layer, wherein the light irradiated in the step B includes a 1 st light having a peak in a wavelength range of 360 to 430nm and a 2 nd light having a peak in a wavelength range of 200 to 345nm, and the curable resin layer is irradiated with the 1 st light to generate a 2 nd light of the oxygen-inhibited curable resin layer.
Effects of the invention
According to this technique, the adhesion performance at the time of temporary curing can be improved.
Drawings
Fig. 1 is a sectional view for explaining an example of a step of forming a curable resin layer made of a photocurable resin composition on a surface of an image display member.
Fig. 2 is a cross-sectional view for explaining an example of a step of forming a temporary cured layer by irradiating light to a curable resin layer with a UV-LED.
Fig. 3 is a cross-sectional view for explaining an example of a step of forming a temporary cured layer by irradiating light to a curable resin layer with a UV-LED.
Fig. 4 is a sectional view for explaining an example of the step of bonding the front panel and the image display member via the temporary cured layer.
Fig. 5 is a cross-sectional view for explaining an example of a step of forming a cured resin layer by irradiating light to the temporary cured layer through the front panel.
FIG. 6 is a cross-sectional view showing an example of an image display device.
FIG. 7 FIGS. 7(A) to (H) are views for explaining the procedure of preparing a test sample.
Fig. 8 is a perspective view for explaining a method of measuring the shear strength of the temporarily cured layer.
FIG. 9 is a graph showing the results of measuring the shear strength of the temporarily solidified layer in the test samples obtained in examples 1 to 6 and comparative examples 1 and 2.
FIG. 10 is a graph showing the results of measuring the shear strength of the temporarily solidified layer in the test samples obtained in example 7 and comparative examples 3 to 5.
FIG. 11 is a graph showing the results of measuring the shear strength of the temporarily solidified layer in the test samples obtained in example 8 and comparative examples 6 to 8.
FIG. 12 is a graph showing the results of measuring the shear strength of the temporarily solidified layer in the test samples obtained in example 9 and comparative examples 9 to 11.
Fig. 13 is a graph showing the measurement results of the shear strength of the temporarily solidified layer in the test samples obtained in example 10 and comparative example 12.
Fig. 14 is a graph showing the measurement results of the shear strength of the cured resin layer obtained by main curing the temporary cured layer in the test sample obtained in example 9.
Detailed Description
Hereinafter, a method for manufacturing an image display device according to the present technology (hereinafter, also referred to as the present manufacturing method) will be described in detail. In the following description, a (meth) acrylate includes both acrylates and methacrylates. In addition, the (meth) acryloyl group includes both acryloyl and methacryloyl groups.
The manufacturing method comprises the following steps: a step A of forming a curable resin layer made of a photocurable resin composition on the surface of a front panel or an image display member; a step (B) of irradiating the curable resin layer with light from a UV-LED to form a temporary cured layer; a step C of bonding the front panel to the image display member via the temporary cured layer; and a step D of forming a cured resin layer by irradiating the temporarily cured layer with light through the front panel. The light irradiated in the step B includes the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345 nm. In step B, a part of the curable resin layer, which is irradiated with the 1 st light to generate oxygen inhibition, is irradiated with the 2 nd light. The energy of the 1 st light having a peak in a wavelength range of 360 to 430nm is smaller than that of the 2 nd light having a peak in a wavelength range of 200 to 345nm, and reaches the deep part of the curable resin layer. On the other hand, the energy of the 2 nd light having a peak in the wavelength range of 200 to 345nm is larger than that of the 1 st light having a peak in the wavelength range of 360 to 430nm, and the energy does not reach the deep part of the curable resin layer but reaches only the surface layer part of the curable resin layer. By using the combination of the 1 st light having a peak in the wavelength range of 360 to 430nm and the 2 nd light having a peak in the wavelength range of 200 to 345nm as the light irradiated in the step B, the influence of oxygen inhibition can be reduced as compared with the case of irradiating only the 1 st light having a peak in the wavelength range of 360 to 430nm, and the adhesion performance at the time of temporary curing can be improved.
< Process A >
In step a of the present manufacturing method, as shown in fig. 1, a curable resin layer 2 made of a photocurable resin composition is formed on the surface of the image display member 1. For example, in step a, the photocurable resin composition is preferably applied over the entire surface of the image display member 1 so as to be flat, thereby forming the curable resin layer 2. The thickness of the curable resin layer 2 is preferably such that a step (step) formed by the light-shielding layer 3 described later and the light-shielding layer-forming side surface of the front panel 4 is eliminated, and may be 2.5 to 40 times, 2.5 to 12.5 times, or 2.5 to 4 times the thickness of the light-shielding layer 4. For example, the thickness of the curable resin layer 2 may be 25 to 350 aμm, may be 50 to 150μAnd m is selected. The number of times of applying the photocurable resin composition is not particularly limited as long as the coating is performed to obtain a necessary resin thickness, and may be 1 time or more.
The image display member 1 is, for example, an image display panel in which a polarizing plate (polarizing plate) is formed on the viewing side surface of the image display unit. Examples of the image display unit include a liquid crystal unit and an organic EL unit. Examples of the liquid crystal cell include a reflective liquid crystal cell and a transmissive liquid crystal cell. The image display unit 1 is, for example, a liquid crystal display panel, an organic EL display panel, a touch panel, or the like. The Touch panel is an image display/input panel in which a display element such as a liquid crystal display panel and a position input device such as a Touch pad (Touch pad) are combined.
The photocurable resin composition for forming the curable resin layer 2 contains, for example, a photoradical reactive component, at least one of a plasticizer and a tackifier component, and a photopolymerization initiator. The photocurable resin composition may further contain other components within a range not to impair the technical effects.
< photo radical reactive component >
The photo radical reactive component contains at least one of a (meth) acrylate oligomer and a (meth) acrylate monomer. The (meth) acrylate oligomer preferably has polyisoprene, polyurethane, polybutadiene or the like in the skeleton, and particularly a urethane (meth) acrylate oligomer. The (meth) acrylate oligomer preferably has 1 to 4 (meth) acrylate groups, and more preferably 2 to 3 (meth) acrylate groups. As commercially available urethane (meth) acrylate oligomers, for example, CN9014 (manufactured by Sartomer corporation), EBECRYL 230, EBECRYL 270 (manufactured by daicel allnex, mentioned above), and the like can be used.
The (meth) acrylate monomer is used as a reactive diluent for imparting sufficient reactivity, coatability, and the like to the photocurable resin composition. The (meth) acrylate monomer may be a monofunctional (meth) acrylate, a bifunctional (meth) acrylate, or a polyfunctional (meth) acrylate. For example, from the viewpoint of compatibility with other components, the (meth) acrylate ester monomer preferably contains: examples of the (meth) acrylate monomer include a (meth) acrylate monomer having a hydroxyl group (e.g., 4-hydroxybutyl acrylate), a (meth) acrylate monomer having a cyclic structure (e.g., isobornyl acrylate, dicyclopentenyloxyethyl methacrylate), an alkyl (meth) acrylate monomer having 5 to 20 carbon atoms (e.g., n-octyl acrylate, isodecyl acrylate, lauryl acrylate, isostearyl acrylate), a polyfunctional (meth) acrylate monomer (e.g., pentaerythritol (tri/tetra) acrylate, neopentyl glycol hydroxypivalate diacrylate), and the like.
The total content of the (meth) acrylate oligomer and the (meth) acrylate monomer in the photocurable resin composition may be 95% by mass or less, and may be 90% by mass or less. The total content of the (meth) acrylate oligomer and the (meth) acrylate monomer in the photocurable resin composition may be 20 mass% or more, 30 mass% or more, or 35 mass% or more. The (meth) acrylate oligomer and/or the (meth) acrylate monomer may be used alone or in combination of two or more. When two or more (meth) acrylate oligomers and/or (meth) acrylate monomers are used in combination, the total content thereof is preferably within the above range.
< photopolymerization initiator >
As the photopolymerization initiator, a known photo radical polymerization initiator can be used. As the photopolymerization initiator, an alkyl-benzophenone-based photopolymerization initiator, an acylphosphine oxide-based photopolymerization initiator, a benzophenone-based photopolymerization initiator, an intramolecular hydrogen abstraction-type photopolymerization initiator, or the like can be used. Specific examples thereof include 2,4, 6-trimethylbenzoyldiphenylphosphine oxide, 1-hydroxycyclohexylphenyl ketone, and methyl phenylglyoxylate. Examples of commercially available products include LUCIRIN TPO, Irgacure184, IRGACURE MBF (manufactured by BASF Co., Ltd.), and Esacure TZT (manufactured by Lamberti Co., Ltd.).
The content of the photopolymerization initiator in the photocurable resin composition may be 10% by mass or less in total, 8% by mass or less, or 6% by mass or less. The content of the photopolymerization initiator in the photocurable resin composition may be 0.1 mass% or more, 1 mass% or more, or 2 mass% or more in total. The photopolymerization initiator may be used alone or in combination of two or more. When two or more photopolymerization initiators are used in combination, the total content thereof is preferably within the above range.
< plasticizers and tackifiers >
The plasticizer and the tackifier are substances that do not substantially react with the (meth) acrylate oligomer and the (meth) acrylate monomer by light irradiation. Examples of the thickening component include a solid thickening agent and a liquid oil component. As the solid tackifier, there can be mentioned: terpene resins such as terpene resin, terpene phenol resin and hydrogenated terpene resin; rosin resins such as natural rosin, polymerized rosin, rosin ester, and hydrogenated rosin; a terpene-based hydrogenated resin. Examples of the liquid oil component include polybutadiene-based oil and polyisoprene-based oil. Examples of commercially available plasticizers and tackifiers include CLEARON M105 (manufactured by YASUHARA CHEMICAL Co.), GI-1000, GI-3000 (manufactured by Nippon Cauda Co., Ltd.).
When the photocurable resin composition contains at least one of a plasticizer and a tackifier, the total content of the plasticizer and the tackifier in the photocurable resin composition may be 70% by mass or less, 65% by mass or less, 60% by mass or less, or 58% by mass or less. The total content of the plasticizer and the tackifier in the photocurable resin composition may be 0.5 mass% or more, and may be 2 mass% or more, and may be 4 mass% or more, and may be 5 mass% or more, and may be 7 mass% or more. The plasticizer and/or tackifier may be used singly or in combination of two or more. In the case where two or more plasticizers and/or tackifiers are used in combination, the total content of the plasticizers and/or tackifiers is preferably within the above range.
< other ingredients >
The photocurable resin composition may contain, for example, a polymer component (a polymer component other than the above-mentioned radical photoreactive component, plasticizer and tackifier), an antioxidant, a light stabilizer, a silane coupling agent, and the like, in addition to the above-mentioned components, within a range not to impair the technical effects. Examples of the polymer component include HITALOID7927 (manufactured by hitachi chemical company). The HITALOID7927 is an ultraviolet curable resin containing a polymer as a main component and an acrylic monomer as a reactive diluent, but the polymer as a main component functions as a thickener. In the present invention, when the photocurable resin composition contains HITALOID7927, the content of HITALOID7927 in the photocurable resin composition is calculated as the content of the above-described thickener. As the antioxidant, for example, a hindered phenol-based antioxidant can be used. As a commercially available product of the antioxidant, for example, IRGANOX 1520L, IRGANOX 1010 (manufactured by BASF) can be used. Examples of the light stabilizer include hindered amine light stabilizers. As a commercially available product of the light stabilizer, for example, ADK STAB LA-52 (manufactured by ADEKA) can be used. Examples of the silane coupling agent include 3-acryloxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, and 3-mercaptopropyltrimethoxysilane. Commercially available silane coupling agents include, for example, KBM5103, KBM503, and KBM803 (manufactured by shin-over Silicone corporation).
< Process B >
In step B of the present manufacturing method, as shown in fig. 2, light is irradiated by a UV-LED to the curable resin layer 2 to form a temporary cured layer 5 as shown in fig. 3. In the step B, the curable resin layer 2 formed in the step A is irradiated with the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345 nm.
The light irradiation in the step B is preferably performed so that the reaction rate of the temporary cured layer 5 becomes 10 to 90%, more preferably 40 to 90%, and still more preferably 70 to 90%. The reaction rate is a numerical value defined as a ratio (consumption ratio) of the amount of (meth) acryloyl groups present after light irradiation to the amount of (meth) acryloyl groups present in the curable resin layer before light irradiation. The larger the value of the reaction rate, the more advanced the curing. Specifically, the reaction rate can be determined by setting the distance from the base line to 1640-1620 cm in an FT-IR measurement chart of the curable resin layer before light irradiation-1The absorption peak height (X) of (A) and the distance from the base line in the FT-IR measurement chart of the curable resin layer (cured resin layer 6) after light irradiation are 1640 to 1620cm-1The absorption peak height (Y) of (A) is calculated by substituting the following equation.
Reaction rate (%) = [ (X-Y)/X ]. times.100
In the step B, it is preferable that the curable resin layer 2 is irradiated with the 1 st light having a peak in a wavelength range of 360 to 430nm to generate oxygen-inhibition, specifically, the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345nm are irradiated on the surface of the curable resin layer 2.
In the step B, the light is preferably irradiated so that the cumulative light amount of the 1 st light having a peak in a wavelength range of 360 to 430nm is larger than the cumulative light amount of the 2 nd light having a peak in a wavelength range of 200 to 345 nm. This makes it possible to improve the adhesion performance during temporary curing. For example, the cumulative light amount of the 1 st light having a peak in a wavelength range of 360 to 430nm is preferably 2000 to 5000mJ/cm2In the range of (1), and the cumulative light quantity of the 2 nd light having a peak in the wavelength range of 200 to 345nm is 20mJ/cm2More than and less than 1000mJ/cm2The range of (1). In the step B, the illumination intensity is preferably 100 to 500mW/cm2For example, a light having an emission wavelength of 365 + -5 nm is irradiated as a 1 st light having a peak in a wavelength range of 360 to 430 nm. In the step B, the illumination intensity is preferably 10 to 100mW/cm2Under the condition (2), for example, a light having an emission wavelength of 280. + -.5 nm is irradiated as a 2 nd light having a peak in a wavelength range of 200 to 345 nm. As the UV-LED used in the step B, for example, an LED having an emission peak wavelength in the range of 360 to 430nm (an emission wavelength of 365. + -.5 nm is an example) and an LED having an emission peak wavelength of 200 to 345nm (an emission wavelength of 280. + -.5 nm is an example) can be used.
In the step B, the 1 st light having a peak in a wavelength range of 360 to 430nm may be irradiated simultaneously with the 2 nd light having a peak in a wavelength range of 200 to 345 nm. In the step B, the 1 st light having a peak in a wavelength range of 360 to 430nm may be irradiated and then the 2 nd light having a peak in a wavelength range of 200 to 345nm may be irradiated. In the step B, the 2 nd light having a peak in a wavelength range of 200 to 345nm may be irradiated and then the 1 st light having a peak in a wavelength range of 360 to 430nm may be irradiated.
In the present manufacturing method, it is preferable that the temporary solidified layer 5 is kept in a state in which no dripping or deformation occurs when the bonding operation in step C described later is performed. For example, in the step B, it is preferable that before the curable resin layer 2 is irradiated with the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345nm, the curable resin layer 2 is irradiated with light so that the viscosity of the curable resin layer 2 becomes 20Pa · S or more (cone-plate rheometer, 25 ℃, cone-and-plate C35/2, rotation speed of 10 rpm).
< Process C >
In step C, for example, as shown in fig. 4, the front panel 4 is bonded to the image display member 1 via the temporary cured layer 5. For example, in the step C, the front panel 4 is bonded to the image display member 1 from the side of the temporary cured layer 5. The bonding can be performed by applying pressure at 10 to 80 ℃ using a known pressing device, for example.
The front panel 4 may have such a light-transmitting property that an image formed on the image display member 2 can be recognized, and examples thereof include a plate-like material or a sheet-like material such as glass, acrylic resin, polyethylene terephthalate, polyethylene naphthalate, and polycarbonate. These materials may be subjected to a hard coating treatment, an antireflection treatment, or the like on one side or both sides thereof. The physical properties such as the thickness and the elastic modulus of the front panel 4 can be appropriately determined depending on the purpose of use. The front panel 4 may be a panel in which various sheets or films are laminated, such as a touch panel module.
A light shielding layer 3 may be provided at a peripheral portion of the front panel 4 to improve the contrast of an image. The light-shielding layer 3 can be formed by applying a black colored paint by, for example, screen printing, and drying and curing the paint. The thickness of the light-shielding layer 3 is usually 5 to 100μm。
< Process D >
In step D, the temporarily cured layer 5 shown in fig. 5 is irradiated with light through the front panel 4, for example, to form a cured resin layer 6 shown in fig. 6. The reason why the temporary cured layer 5 is subjected to the main curing in the step D is that: the temporary cured layer 5 is sufficiently cured to bond and laminate the image display member 1 and the front panel 4. As shown in fig. 6, by performing the step D, the image display device 7 including the image display member 1, the cured resin layer 6, and the front panel 4 in this order can be obtained.
The main curing (light irradiation) in the step D is preferably performed by curing the resin layerThe reaction rate of 6 is preferably 90% or more, more preferably 97% or more. The type, output, illuminance, accumulated light amount, and the like of the light source used for main curing are not particularly limited, and the photoradical polymerization process conditions of the (meth) acrylate by known ultraviolet irradiation can be used. For example, the ultraviolet irradiation is preferably carried out by using an ultraviolet irradiation machine (metal halide lamp, high-pressure mercury lamp, UV-LED, etc.) at an illuminance of 50 to 300mW/cm2The accumulated light amount is 1000-6000 mJ/cm2Under the conditions of (1). In particular, in the step D, it is preferable to irradiate the 1 st light having a peak in a wavelength range of 360 to 430nm with a UV-LED, because of the requirement of high life performance of the ultraviolet irradiation apparatus as described above.
In the step D, the temporary cured layer 5 between the light-shielding layer 3 of the front panel 4 and the image display member 1 is irradiated with light as necessary, whereby the temporary cured layer 5 can be completely cured.
In the cured resin layer 6 of the image display device 7 obtained by the present manufacturing method, the transmittance in the visible light region is preferably 90% or more. By satisfying such a range, the visibility of the image formed on the image display unit 1 can be further improved. The refractive index of the cured resin layer 6 is preferably almost equal to the refractive index of the image display member 1 or the front panel 4. The refractive index of the cured resin layer 6 is preferably 1.45 or more and 1.55 or less, for example. This can improve the brightness and contrast of image (video) light from the image display unit 1, thereby improving visibility. The thickness of the cured resin layer 6 may be, for example, 25 to 200 aμAnd m is about.
According to the production method described above, the adhesion performance at the time of temporary curing can be improved.
In the step a, instead of applying the photocurable resin composition to the surface of the image display member 1, the photocurable resin composition may be applied to the surface of the front plate 4 on which the light shielding layer 3 is formed. As the front panel, a front panel without the light shielding layer 3 may be used.
Examples
Hereinafter, examples of the present technology will be described. The present technology is not limited to these examples.
< preparation of Photocurable resin composition >
The respective components were uniformly mixed in the blending amounts (parts by mass) shown in table 1 to prepare a photocurable resin composition.
[ Table 1]
Figure 648439DEST_PATH_IMAGE001
The abbreviations in table 1 refer to the following compounds.
Urethane acrylate oligomer: the number average molecular weight is 20000;
CN 9014: urethane acrylate oligomer, manufactured by Sartomer corporation;
HITALOID 7927: manufactured by Hitachi chemical Co., Ltd;
4 HBA: 4-hydroxybutyl acrylate, manufactured by BASF corporation;
and (3) ISTA: isostearyl acrylate, manufactured by osaka organic chemical corporation;
miramer M210: hydroxypivalic acid neopentyl glycol diacrylate manufactured by MIWON corporation;
PETIA: pentaerythritol (tri/tetra) acrylate;
NOA: n-octyl acrylate;
IDA: isodecyl acrylate;
IBXA: isobornyl acrylate;
FA-512M: dicyclopentenyloxyethyl methacrylate;
LA: lauryl acrylate;
m105: terpene resin, product name; CLEARON M105 manufactured by YASUHARA CHEMICAL CORPORATION;
GI-1000: hydrogenated polybutadiene having hydroxyl groups at both ends, manufactured by Nippon Caoda corporation;
GI-3000: hydrogenated polybutadiene having hydroxyl groups at both ends, manufactured by Nippon Caoda corporation;
terpene resin: the number average molecular weight is 800;
TPO: 2,4, 6-trimethylbenzoyldiphenylphosphine oxide, product name: LUCIRIN TPO manufactured by BASF corporation;
irg 184D: 1-hydroxycyclohexyl phenyl ketone, product name; irgacure184, manufactured by BASF corporation;
MBF: methyl phenylglyoxylate, product name; IRGACURE MBF, BASF corporation;
TZT: the name of the product; escapure TZT, Lamberti Co.
[ example 1]
< preparation of test sample Using resin A >
As shown in FIG. 7A, the photocurable resin composition 12 was applied from the slit nozzle 11 from one end side to the other end side of the surface of the PET film 10 (thickness 130mm) to a thickness of 33μm, then irradiating the applied photocurable resin composition 12 with light having a peak at a wavelength of 365nm from a UV-LED13 to obtain a cumulative light amount of 500mJ/cm2. The light irradiation is performed for the purpose of suppressing dripping of the applied photocurable resin composition. Thereby, the curable resin layer 14A of the 1 st layer was formed. Next, as shown in fig. 7(B), the photocurable resin composition 12 is applied onto the curable resin layer 14A from the slit nozzle 11 to a thickness of 33 aμm, then irradiating the coated photocurable resin composition 12 with light having a peak at a wavelength of 365nm from a UV-LED13 to obtain a cumulative light amount of 500mJ/cm2Thereby, the curable resin layer 14B of the 2 nd layer is formed. The light irradiation is also performed for the purpose of suppressing dripping of the applied photocurable resin composition. Next, as shown in fig. 7(C), the photocurable resin composition 12 is applied onto the curable resin layer 14B from the slit nozzle 11 to a thickness of 33 aμm, and then irradiating the applied photocurable resin composition 12 with light having a peak at a wavelength of 365nm by a UV-LED13 to obtain a cumulative light amount of 500mJ/cm2Thereby, the curable resin layer 14C of the 3 rd layer was formed. The light irradiation is also performed for the purpose of suppressing dripping of the applied photocurable resin composition. Thus, the PET film 10 having a thickness of about 100 a was obtainedμm curable resin layer 14.
As shown in FIG. 7D, 200mW/cm of light was irradiated to the curable resin layer 14 of the laminate from UV-LEDs (manufactured by CCS, Inc., having a device with a plurality of LEDs having an emission wavelength of 365nm and a plurality of LEDs having an emission wavelength of 280nm, irradiation range of 80 mm. times.80 mm)2Light having a peak at 365nm in intensity gives a cumulative light amount of 5000mJ/cm2And 20mW/cm irradiation2Light having a peak at a wavelength of 280nm of intensity gives a cumulative light amount of 20mJ/cm2. Thus, a laminate in which the temporary cured layer 15 was formed on the PET film 10 was obtained. The distance from a base line in an FT-IR measurement chart is 1640-1620 cm-1The curing rate of the temporarily cured layer 15 is about 80 to 90% when the absorption peak height of (a) is determined as an index.
As shown in fig. 7(E), the laminate was cut so that the width of the laminate became 25 mm. The cut laminate was attached to a glass slide 16 (width 25mm, thickness 1mm) as shown in FIG. 7F. As shown in fig. 7(G), a 2kg load roller 17 was used to apply pressure from the laminate side. Thus, a test sample 18 shown in fig. 7(H), that is, a test sample 18 in which the PET film 10 and the slide glass 16 were bonded to each other through the temporary cured layer 15(10mm × 25mm, thickness 0.1mm) was obtained.
< measurement of shear Strength of temporary cured layer >
The shear strength of the temporarily solidified layer 15 in the test sample 18 was measured in accordance with the method shown in fig. 8. Specifically, the shear strength of the temporary cured layer 15 when the PET film 10 positioned on the lower side of the test sample 18 was fixed with a jig 19 and the slide glass 16 positioned on the upper side was peeled off at a speed of 5 mm/min in the vertical direction via the jig 20 was measured using a bench-top precision universal tester (manufactured by shimadzu corporation, autograph). The results are shown in FIG. 9 and Table 2.
Examples 2 to 6 and comparative examples 1 and 2
A test sample was produced in the same manner as in example 1 except that the cumulative light amount of light irradiated to the curable resin layer 14 of the laminate was as shown in the following table, and the shear strength of the temporary cured layer in the test sample was measured. The results are shown in FIG. 9 and Table 2.
[ Table 2]
Figure 45922DEST_PATH_IMAGE002
Example 7 and comparative examples 3 to 5
A test sample was produced in the same manner as in example 1 except that the resin B was used and the cumulative light amount of light irradiated to the curable resin layer 14 of the laminate was as shown in the following table, and the shear strength of the temporarily cured layer in the test sample was measured. The results are shown in FIG. 10 and Table 3.
[ Table 3]
Figure 774844DEST_PATH_IMAGE003
Example 8 and comparative examples 6 to 8
A test sample was produced in the same manner as in example 1 except that the resin C was used and the cumulative light amount of light irradiated to the curable resin layer 14 of the laminate was as shown in the following table, and the shear strength of the temporarily cured layer in the test sample was measured. The results are shown in FIG. 11 and Table 4.
[ Table 4]
Figure 853658DEST_PATH_IMAGE004
Example 9 and comparative examples 9 to 11
A test sample was produced in the same manner as in example 1 except that the resin D was used and the cumulative light amount of light irradiated to the curable resin layer 14 of the laminate was as shown in the following table, and the shear strength of the temporarily cured layer in the test sample was measured. In comparative example 10, only 600mW/cm was irradiated with UV-LED2Light having a peak at 365nm in intensity gives a cumulative light amount of 6000mJ/cm2. The results are shown in FIG. 12 and Table 5.
[ Table 5]
Figure 413952DEST_PATH_IMAGE005
[ example 10 and comparative example 12]
A test sample was produced in the same manner as in example 1 except that the resin E was used and the cumulative light amount of light irradiated to the curable resin layer 14 of the laminate was as shown in the following table, and the shear strength of the temporarily cured layer in the test sample was measured. The results are shown in FIG. 13 and Table 6.
[ Table 6]
Figure 185599DEST_PATH_IMAGE006
From the results of examples 1 to 10 and comparative examples 1 to 12, it is clear that: the light irradiated in the step of irradiating the curable resin layer with light from a UV-LED to form the temporary cured layer includes the 1 st light having a peak in a wavelength range of 360 to 430nm and the 2 nd light having a peak in a wavelength range of 200 to 345nm, so that the shear strength of the temporary cured layer is good, that is, the adhesive property during temporary curing is good. In addition, from the results of example 9 and comparative example 11, it is clear that: in example 9, the adhesion performance at the time of temporary curing was equal to or higher than that at the time of irradiation with a metal halide lamp. Furthermore, from the results of examples 1 to 10, it is clear that: the tendency to improve the adhesion performance during the temporary curing is not dependent on the composition ratio of the photocurable resin composition.
From the results of examples 1 to 6, it is clear that: when the resin A is used, in the step of irradiating the curable resin layer with light from a UV-LED to form the temporary cured layer, the cumulative light amount of the 1 st light having a peak in the wavelength range of 360 to 430nm is preferably 2000 to 5000mJ/cm2In the range of (1), and the cumulative light quantity of the 2 nd light having a peak in the wavelength range of 200 to 345nm is 20mJ/cm2More than and less than 1000mJ/cm2More preferably, the cumulative light quantity of the 2 nd light having a peak in the wavelength range of 200 to 345nm is 500mJ/cm2More than and less than 1000mJ/cm2The range of (1).
Therefore, the following steps are carried out: in example 8 and comparative examples 6 to 8, since the resin C containing a photopolymerization initiator showing a relatively smooth reactivity and having a large proportion of a plasticizer was used, the shear strength at the time of temporary curing tends to be less exhibited than in the case of using another resin, but the shear strength in example 8 was 2 times or more as high as in comparative examples 6 to 8.
Therefore, the following steps are carried out: in comparative examples 1 to 12, the light irradiated in the step of irradiating the curable resin layer with light from the UV-LED to form the temporary cured layer included only light having a peak in a wavelength range of 360 to 430nm or only light having a peak in a wavelength range of 200 to 345nm, and therefore, the adhesive property during temporary curing was not good.
Therefore, the following steps are carried out: in comparative example 4, the cumulative light quantity of light from the UV-LED having a peak in the wavelength range of 360 to 430nm was set to 8000mJ/cm2However, since light having a peak in a wavelength range of 200 to 345nm was not irradiated, the shear strength was very low as compared with example 7. In addition, it can also be known that: in comparative example 5 in which only light having a peak in a wavelength range of 200 to 345nm was irradiated, the shear strength was very low as compared with example 7. From the above results, it can be seen that: in consideration of the curability in the deep part of the curable resin layer, it is necessary to use light having a peak in a wavelength range of 360 to 430nm and light having a peak in a wavelength range of 200 to 345nm in combination in the step of forming the temporary cured layer.
Therefore, the following steps are carried out: in comparative example 10, the illuminance of light having a peak at a wavelength of 360 to 430nm from a UV-LED was as high as 600mW/cm2And the accumulated light quantity is up to 6000mJ/cm2However, the measurement result of the shear strength was inferior to that of example 9 because the light having a peak in the wavelength range of 200 to 345nm was not irradiated.
< determination of shear Strength of cured resin layer >
[ example 9-1]
The temporarily cured layer of the test sample in example 9 was irradiated with 200mW/cm using a metal halide lamp (manufactured by USIO Co.) with a conveyor belt2Light with intensity such that the cumulative light amount reaches 5000mJ/cm2. Thereby, the temporarily cured layer is completely cured to form a cured resin layer. The curing rate of the cured resin layer was 97%. The shear strength of the cured resin layer was measured in the same manner as in the above-described temporary cured layer. The results are shown in FIG. 14. In fig. 14, N1 to N4 represent 4 samplesThe test samples show the results of measuring the shear strength of 4 test samples. The average (×) in fig. 14 represents the average of the results of shear strength measurements from N1 to N4.
[ example 9-2]
The temporarily cured layer of the test sample in example 9 was irradiated with 200mW/cm using a UV-LED2Light with intensity having peak at 365nm wavelength, so as to reach 5000mJ/cm of accumulated light quantity2. Thereby, the temporarily cured layer is completely cured to form a cured resin layer. The curing rate of the cured resin layer was 97%. The shear strength of the cured resin layer was measured in the same manner as in the above-described temporary cured layer. The results are shown in FIG. 14.
Comparative example 9-1
The shear strength of the cured resin layer was measured in the same manner as in example 9-1, except that the test sample in comparative example 9 was used. The results are shown in FIG. 14.
Comparative examples 9 and 2
The shear strength of the cured resin layer was measured in the same manner as in example 9-2, except that the test sample in comparative example 9 was used. The results are shown in FIG. 14.
From the results of examples 9-1 and 9-2 and comparative examples 9-1 and 9-2, it is understood that: the strength of the cured resin layer is almost the same. This is believed to be due to: the difference in chemical adhesion is further added after the main curing, as opposed to the difference in physical adhesion (influence of oxygen inhibition) during the temporary curing.
Description of the symbols
1: an image display section; 2: a curable resin layer; 3: a light-shielding layer; 4: a front panel; 5: temporarily curing the layer; 6: curing the resin layer; 7: an image display device; 10: a PET film; 11: a slit nozzle; 12: a photocurable resin composition; 13: a UV-LED; 14: a curable resin layer; 15: temporarily curing the layer; 16: a glass slide; 17: a load roller; 18: a test sample; 19: a clamp; 20: and (4) clamping.

Claims (9)

1. A method for manufacturing an image display device, comprising the steps of:
a step A of forming a curable resin layer made of a photocurable resin composition on the surface of a front panel or an image display member;
a step (B) of irradiating the curable resin layer with light from a UV-LED to form a temporary cured layer;
a step C of bonding the front panel and the image display member via the temporary cured layer; and
a step D of forming a cured resin layer by irradiating the temporarily cured layer with light through the front panel,
wherein the light irradiated in the step B includes a 1 st light having a peak in a wavelength range of 360 to 430nm and a 2 nd light having a peak in a wavelength range of 200 to 345nm,
in the step B, the 2 nd light is irradiated to a portion of the curable resin layer where the 1 st light is irradiated to generate oxygen inhibition.
2. The method of manufacturing an image display device according to claim 1, wherein in the step B, the 1 st light and the 2 nd light are irradiated to the curable resin layer so that a cumulative light amount of the 1 st light is larger than a cumulative light amount of the 2 nd light.
3. The method of manufacturing an image display device according to claim 1 or 2, wherein in the step B, the 1 st light and the 2 nd light are irradiated to the surface of the curable resin layer.
4. The method for manufacturing an image display device according to any one of claims 1 to 3, wherein the thickness of the curable resin layer is 25 to 350μm。
5. The method of manufacturing an image display device according to any one of claims 1 to 4, wherein in the step B, the cumulative light amount of the 1 st light is 2000 to 5000mJ/cm2The cumulative light amount of the above 2 nd light is 20mJ/cm2More than and less than 1000mJ/cm2The range of (1).
6. The method for manufacturing an image display device according to any one of claims 1 to 5, wherein the photocurable resin composition contains a photoradical reactive component, a photopolymerization initiator, and at least one of a plasticizer and a tackifier component.
7. The method of manufacturing an image display device according to claim 6, wherein the photo radical reactive component contains at least one of a (meth) acrylate oligomer and a (meth) acrylate monomer.
8. A method for manufacturing an image display device according to claim 6 or 7, wherein said photopolymerization initiator comprises at least one of an alkylphenone-based photopolymerization initiator, an acylphosphine oxide-based photopolymerization initiator, a benzophenone-based photopolymerization initiator, and an intramolecular hydrogen abstraction-type photopolymerization initiator.
9. The method for manufacturing an image display device according to any one of claims 6 to 8, wherein the photocurable resin composition contains 30 to 90 mass% of the photoradical reactive component, 2 to 6 mass% of the photopolymerization initiator, and 5 to 58 mass% of at least one of the plasticizer and the tackifier component in total.
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