CN112666647A - Method for manufacturing optical member - Google Patents
Method for manufacturing optical member Download PDFInfo
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- CN112666647A CN112666647A CN202011093671.9A CN202011093671A CN112666647A CN 112666647 A CN112666647 A CN 112666647A CN 202011093671 A CN202011093671 A CN 202011093671A CN 112666647 A CN112666647 A CN 112666647A
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- 230000003287 optical effect Effects 0.000 title claims abstract description 39
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 238000005520 cutting process Methods 0.000 claims abstract description 88
- 239000012788 optical film Substances 0.000 claims abstract description 22
- 239000012790 adhesive layer Substances 0.000 claims description 19
- 238000010030 laminating Methods 0.000 claims description 8
- 238000003754 machining Methods 0.000 claims description 7
- 239000010408 film Substances 0.000 description 49
- 230000001681 protective effect Effects 0.000 description 29
- 238000003475 lamination Methods 0.000 description 12
- 239000010410 layer Substances 0.000 description 11
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 9
- 229920005989 resin Polymers 0.000 description 9
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- 239000000203 mixture Substances 0.000 description 8
- 238000005498 polishing Methods 0.000 description 8
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- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 1
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- NNLVGZFZQQXQNW-ADJNRHBOSA-N [(2r,3r,4s,5r,6s)-4,5-diacetyloxy-3-[(2s,3r,4s,5r,6r)-3,4,5-triacetyloxy-6-(acetyloxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6s)-4,5,6-triacetyloxy-2-(acetyloxymethyl)oxan-3-yl]oxyoxan-2-yl]methyl acetate Chemical compound O([C@@H]1O[C@@H]([C@H]([C@H](OC(C)=O)[C@H]1OC(C)=O)O[C@H]1[C@@H]([C@@H](OC(C)=O)[C@H](OC(C)=O)[C@@H](COC(C)=O)O1)OC(C)=O)COC(=O)C)[C@@H]1[C@@H](COC(C)=O)O[C@@H](OC(C)=O)[C@H](OC(C)=O)[C@H]1OC(C)=O NNLVGZFZQQXQNW-ADJNRHBOSA-N 0.000 description 1
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Images
Classifications
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
-
- 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
-
- 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
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
- B32B2038/0016—Abrading
Landscapes
- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Polarising Elements (AREA)
- Milling Processes (AREA)
- Laminated Bodies (AREA)
Abstract
The invention provides a method for manufacturing an optical member. A method for manufacturing an optical member, comprising a cutting step of cutting a laminated structure (2) by a pair of rotary knives (b1) and (b2), wherein the laminated structure (2) comprises a plurality of laminated bodies (4) laminated to each other, the laminated bodies (4) comprise a plurality of optical films laminated to each other, the laminated structure (2) has two opposite end faces (f1) and (f2), the laminated structure (2) is held by a jig (12) in contact with the upper face (tf) and the lower face (uf) of the laminated structure, one rotary knife (b1) is in contact with one end face (f1) of the laminated structure (2), and the other rotary knife (b2) is in contact with the other end face (f2) of the laminated structure (2), the opposing end faces (f1) and (f2) are cut substantially simultaneously by a pair of rotary knives (b1) and (b2) so that at least a part of at least one of the end faces does not become a plane.
Description
Technical Field
The present invention relates to a method for manufacturing an optical member.
Background
A polarizing plate, which is one of optical members, is used in an image display device such as a liquid crystal display, an organic EL display, a smart phone, a smart watch, or an instrument panel of a vehicle. The polarizing plate is a laminate of a plurality of optical films such as a polarizing plate film and a protective film. With the miniaturization and miniaturization of image display devices, high precision is required for the shape and size of polarizing plates.
For example, japanese patent application laid-open No. 2004-148419 discloses a method of improving the accuracy of the shape and dimension of each laminate by cutting the end surface (cut surface) of a laminate structure composed of a plurality of laminates stacked on each other with a rotary knife.
Disclosure of Invention
Since the types and applications of image display devices are various, the light receiving surface of the polarizing plate may be shaped in some cases in accordance with the design requirements of the image display devices. The irregular shape is a shape different from a complete quadrangle in which all corners are right angles. For example, in order to match the shape of the polarizing plate with the structure of the image display device, four corners of a rectangular polarizing plate are chamfered, a cutout (notch) is formed in an end portion of the polarizing plate, or the entire end portion of the polarizing plate is processed into a curved line.
When the above-described rotary cutter for a laminated structure is machined into a deformed shape, the rotary cutter is pressed against an end face of the laminated structure and cuts the end face while the laminated structure is fixed by a jig in the laminating direction of the laminated structure. In order to precisely machine each laminate constituting the laminated structure into a deformed shape, it is necessary to control the relative position and relative movement speed of the rotary cutter with respect to the end face of the laminated structure more precisely than in the case where the entire end face of the laminated structure is machined into a flat surface. However, in the process of cutting the end face of the laminated structure, a moment is easily generated at a portion of the end face of the laminated structure, which is in contact with the rotating knife, due to a force applied to the end face of the laminated structure by the rotating knife. Due to the force or torque applied by the rotary blade, a part or the whole of the laminated structure is displaced from a predetermined position, or a part or the whole of the laminated structure is rotated around a rotation axis substantially parallel to the lamination direction of the laminated body, thereby twisting the laminated structure. Due to the positional deviation or distortion of the laminated structure as described above, it is difficult to precisely control the relative position and the relative movement speed of the rotary knife with respect to the end face of the laminated structure. For the above reasons, in the conventional cutting method using the rotary cutter, it is difficult to precisely cut the end face of the laminated structure, and it is difficult to improve the accuracy of the shape and the dimension of each laminated body having a deformed shape. Optical members other than the polarizing plate are also processed into a special shape according to the use thereof. Therefore, the above technical problem may occur in the production of optical members other than polarizing plates.
The invention aims to provide a method for manufacturing an optical member with excellent shape and size precision.
In a method for manufacturing an optical member according to an aspect of the present invention, the method for manufacturing an optical member includes a cutting step of cutting a laminated structure by a pair of rotary knives, the laminated structure includes a plurality of laminated bodies laminated to each other, the laminated body includes a plurality of optical films laminated to each other, the laminated structure has two opposing end faces, the two opposing end faces of the laminated structure are substantially parallel to a laminating direction of the laminated body, an upper face and a lower face of the laminated structure are substantially perpendicular to the laminating direction, the laminated structure is held by a jig in contact with the upper face and the lower face of the laminated structure, the rotary knives extend in the laminating direction, side faces of the rotary knives are substantially parallel to the end faces of the laminated structure, a rotation axis of the rotary knives is substantially parallel to side faces of the rotary knives, the side faces of one rotary knife are in contact with the end face of one of the laminated structure, and the side faces of the other, two opposing end surfaces of the laminated structure are cut substantially simultaneously by a pair of rotary knives so that at least a part of at least one of the end surfaces does not become a plane.
The two opposing end surfaces of the laminated structure may be substantially parallel to the longitudinal direction of each of the upper surface and the lower surface of the laminated structure.
The position of the pair of rotary knives may be changed during the cutting of the entire end face of the stacked structure by the rotary knives, and the jig may not be rotated about the rotation axis substantially parallel to the stacking direction at all times during the cutting of the entire end face of the stacked structure by the rotary knives.
In the cutting step, the pair of rotary blades may be moved along the two opposing end surfaces of the laminated structure.
In the cutting step, the interval between the pair of rotary blades may be varied, and in the cutting step, the jig may be moved in a direction substantially parallel to the two facing end surfaces of the laminated structure.
In the method of manufacturing an optical member according to one aspect of the present invention, the method of manufacturing an optical member may further include a machining step performed before the cutting step, wherein the upper surface and the lower surface of the laminated structure before the machining step are each a quadrangle having all corners at right angles, and the laminated structure is machined in the machining step such that the upper surface and the lower surface of the laminated structure are each a shape different from the quadrangle.
In the cutting step, the two opposing end surfaces of the laminated structure may be cut substantially simultaneously by the pair of rotary knives so that the upper surface and the lower surface of the laminated structure have shapes different from the quadrangle.
The laminate may include at least one adhesive layer.
Alternatively, the rotary cutter may be an end mill.
Effects of the invention
According to the present invention, a method for manufacturing an optical member having excellent shape and dimensional accuracy is provided.
Drawings
Fig. 1 is a schematic side view of a stacked structure, a jig, and a rotary knife.
Fig. 2 is a cross-sectional view of each laminate constituting the laminated structure shown in fig. 1, and the cross-section shown in fig. 2 is substantially parallel to the lamination direction of the laminate.
Fig. 3 (a) is a schematic view showing the upper surface of the laminated structure after the corner portion has been chamfered and the rotary cutter that has been brought into contact with the end face of the laminated structure in the cutting step, and fig. 3 (b) is a schematic view showing the upper surface of the laminated structure before the corner portion has been chamfered.
Fig. 4 is a schematic view showing the upper surface of the laminated structure in the cutting step and the rotary blade that is in contact with the end surface of the laminated structure in the cutting step.
Fig. 5 (a) is a schematic view showing an upper surface of the stacked structure having the cutout portion formed therein and the rotary blade which is brought into contact with the end surface of the stacked structure in the cutting step, and fig. 5 (b) is a schematic view showing an upper surface of the stacked structure in which the entire pair of end surfaces is processed into a curved surface and the rotary blade which is brought into contact with the end surface of the stacked structure in the cutting step.
Fig. 6 is a schematic view showing an upper surface of a laminated structure in which the entire one end surface is processed into a curved surface, and a rotary cutter which is brought into contact with the end surface of the laminated structure in a cutting step.
Fig. 7 (a) is a plan view of the stacked structure rotated about a rotation axis substantially parallel to the stacking direction of the stacked structure, and fig. 7 (b) is a plan view of the twisted stacked structure.
Description of reference numerals:
2, 4, 6a first protective sheet, 6b second protective sheet, 8a, 8b, 8c, 8d, 8e optical film, 10a, 10b optical film (adhesive layer), 12 jig, 12a first polishing pad, 12b second polishing pad, a1 rotation axis of first rotary knife, a12 rotation axis substantially parallel to the lamination direction of the laminate, a2 rotation axis of second rotary knife, b1 first rotary knife, b2 second rotary knife, f1 first end face, f2 second end face, f3 third end face, f4 fourth end face, tf upper face, uf lower face.
Detailed Description
Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. In the drawings, the same components are denoted by the same reference numerals. The present invention is not limited to the following embodiments. X, Y and Z in the drawings are three coordinate axes orthogonal to each other. Directions indicated by XYZ coordinate axes in the respective drawings are common to the respective drawings.
The method for manufacturing the optical member of the present embodiment may be a method for manufacturing a polarizing plate (including a reflective polarizing plate), a retardation film, a brightness enhancement film, a film with an anti-glare function, a film with a surface reflection preventing function, a reflective film, a semi-transmissive reflective film, or a viewing angle compensating film, for example.
Fig. 1 to 4 show an outline of the method for manufacturing an optical member according to the present embodiment. The method of manufacturing an optical member according to the present embodiment includes a cutting step of cutting the laminated structure 2 with a pair of rotary blades (the first rotary blade b1 and the second rotary blade b 2). In the cutting step, the two opposing end faces (the first end face f1 and the second end face f2) of the laminated structure 2 are cut substantially simultaneously (in parallel) by the pair of rotary knives so that at least a part of at least one of the end faces does not become a plane. In other words, the upper surface and the lower surface of the laminated structure 2 after the cutting step have shapes different from a complete quadrangle in which all corners are perpendicular. A shape different from a complete quadrangle in which all corners are right angles is referred to as "special shape". The specific shape of the profile is not limited. If at least one of the end surfaces after cutting is not a flat surface, the shape and size of the end surface of one of the end surfaces simultaneously cut may be the same as those of the end surface of the other end surface simultaneously cut, or the shape and size of the end surface of one of the end surfaces simultaneously cut may be different from those of the end surface of the other end surface simultaneously cut. A portion of the cut end surface is not planar, and the other portion of the cut end surface may be planar. Details of the laminated structure 2 and the cutting step are as follows.
The laminated structure 2 includes a plurality of laminated bodies 4 laminated to each other, and each of the laminated bodies 4 includes a plurality of optical films laminated to each other. The laminated direction (Z-axis direction) of the laminated body 4 in the laminated structure 2 is the same as the lamination direction of the optical films in each laminated body 4. The optical film is a film-like (layered) member constituting an optical member. The optical film may be, for example, at least one film (layer) selected from the group consisting of a polarizer film, a protective film, an adhesive layer, a release film, an optical compensation layer, a hard coat layer, a touch sensor layer, an antistatic layer, and an antifouling layer. The laminated structure of the laminated structure 2 is not limited.
The laminated structure 2 shown in fig. 1, 3, and 4 has a substantially rectangular parallelepiped shape. The laminated structure 2 has a first end face f1, a second end face f2, a third end face f3, and a fourth end face f 4. The first end face f1 and the second end face f2 are opposed to each other and are substantially parallel to each other. The third end surface f3 and the fourth end surface f4 are opposed to each other and are substantially parallel to each other. The first end face f1 and the second end face f2 are substantially parallel to the longitudinal direction (Y-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, respectively. The third end face f3 and the fourth end face f4 are substantially parallel to the short side direction (X-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, respectively. The first end surface f1, the second end surface f2, the third end surface f3, and the fourth end surface f4 are substantially parallel to the stacking direction (Z-axis direction) of the stacked body 4. The upper surface tf and the lower surface uf of the laminated structure 2 are substantially perpendicular to the laminating direction (Z-axis direction). The first end face f1 and the second end face f2 that face each other are substantially the same in shape and size. The third end surface f3 and the fourth end surface f4, which are opposed to each other, have substantially the same shape and size. The opposing upper and lower surfaces tf, uf are substantially identical to each other in shape and size. The first polishing pad 12a is in contact with the upper surface tf of the laminated structure 2, and the second polishing pad 12b is in contact with the lower surface uf of the laminated structure 2. The laminated structure 2 is clamped and fixed in the lamination direction (Z-axis direction) by a jig 12 composed of a first polishing pad 12a and a second polishing pad 12 b. Each end face of the laminated structure 2 polished in the cutting step protrudes outward from between the first polishing pad 12a and the second polishing pad 12 b.
As shown in fig. 1, the laminated structure 2 is composed of a first protective sheet 6a, a plurality of laminated bodies 4, and a second protective sheet 6 b. The plurality of stacked bodies 4 are stacked between the first protective sheet 6a and the second protective sheet 6 b. The adjacent pair of stacked bodies 4 are not bonded to each other and can be separated from each other. The first protective sheet 6a and the laminate 4 are not bonded to each other and can be separated from each other. The second protective sheet 6b and the laminate 4 are also not adhered to each other and can be separated from each other. The first protective sheet 6a and the second protective sheet 6b may be made of resin such as polystyrene.
As shown in fig. 2, each laminate 4 includes a plurality of optical films 8a, 8b, 8c, 8d, 8e, 10a, and 10b stacked. The laminated structure of the laminated body 4 is not limited. The laminated structure of the laminated body 4 may be the same as that of the completed optical member. For example, in the case where the optical member is a polarizing plate, the laminated structure of the laminate 4 may be the same as that of the polarizing plate. That is, the laminated bodies 4 may be polarizing plates, respectively. For example, the optical film 8a may be a polarizer film. The optical film 8b may be a first protective film. The optical film 8c may be a second protective film. The optical film 10a may be a first adhesive layer and the optical film 10b may be a second adhesive layer. That is, the laminated structure 2 may include an adhesive layer as the optical film. The optical film 8d may be a first release film. The optical film 8e may be a second release film. The first protective film (8b) may be formed directly on one surface of the polarizer film (8 a). The first protective film (8b) may be bonded to one surface of the polarizer film (8a) with an adhesive such as an ultraviolet curable resin. The second protective film (8c) may be formed directly on the other surface of the polarizer film (8 a). The second protective film (8c) may be bonded to the other surface of the polarizer film (8a) with an adhesive such as an ultraviolet curable resin.
The polarizer film may be a polyvinyl alcohol (PVA) resin film produced through the steps of stretching, dyeing, crosslinking, and the like. The thickness of the polarizer film may be, for example, 1 μm or more and 50 μm or less. The longitudinal width and the transverse width of the polarizer film may be, for example, 30mm to 600mm, respectively. The thickness of the laminate 4 may be, for example, 10 μm or more and 1200 μm or less.
The first protective film and the second protective film may be made of a light-transmitting thermoplastic resin. The resin constituting each of the first protective film and the second protective film may be, for example, a chain polyolefin resin, a cyclic olefin polymer resin (COP resin), a cellulose ester resin (cellulose triacetate or the like), a polyester resin, a polycarbonate resin, (meth) acrylic resin, a polystyrene resin, or a mixture or a copolymer thereof. The composition of the first protective film may be the same as that of the second protective film. The composition of the first protective film may be different from that of the second protective film. The thickness of the first protective film may be, for example, 5 μm or more and 90 μm or less. The thickness of the second protective film may be, for example, 5 μm or more and 90 μm or less.
The first adhesive layer and the second adhesive layer may be each a layer made of an adhesive. The first Adhesive layer and the second Adhesive layer may each be an Optically Clear Adhesive (OCA) film. For example, the first pressure-sensitive adhesive layer and the second pressure-sensitive adhesive layer may each be composed of a pressure-sensitive adhesive such as an acrylic pressure-sensitive adhesive, a rubber pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, or a polyurethane pressure-sensitive adhesive. The composition of the first adhesive layer may also be different from the composition of the second adhesive layer. The thickness of the first pressure-sensitive adhesive layer may be, for example, 2 μm or more and 500 μm or less. The thickness of the second pressure-sensitive adhesive layer may be, for example, 2 μm or more and 500 μm or less.
The resin constituting each of the first and second release films may be the same as the resin constituting the first or second protective film. The composition of the first release film may be the same as that of the second release film. The composition of the first release film may also be different from the composition of the second release film. The thickness of the first release film may be, for example, 5 μm or more and 200 μm or less. The thickness of the second release film may be, for example, 5 μm or more and 200 μm or less.
The first rotary knife b1 and the second rotary knife b2 each extend along the stacking direction (Z-axis direction) of the stacked body 4. The side surface s1 of the first rotary knife b1 is substantially parallel to each end surface of the laminated structure 2. The side surface s2 of the second rotary knife b2 is also substantially parallel to each end surface of the laminated structure 2. The rotational axis a1 of the first rotary knife b1 is substantially parallel to the side s1 of the first rotary knife b 1. The rotational axis a2 of the second rotary knife b2 is substantially parallel to the side s2 of the second rotary knife b 2.
The first rotary knife b1 has a blade edge formed on its side s 1. The side surface s1 of the first rotary knife b1 rotating about the rotation axis a1 is pressed against the end surface of the laminated structural body 2, whereby the end surface of the laminated structural body 2 is cut. The second rotary knife b2 also has a blade edge (edge) formed on its side surface s 2. The side surface s2 of the second rotary knife b2 rotating about the rotation axis a2 is pressed against the end surface of the laminated structural body 2, whereby the end surface of the laminated structural body 2 is cut. The width of each rotating blade in the stacking direction (Z-axis direction) of the stacked body 4 may be equal to or greater than the width of the stacked structure 2 in the stacking direction.
The first rotating knife b1 and the second rotating knife b2 may be end mills (endmills). However, the first and second rotary blades b1 and b2 are not limited to end mills. For example, the first rotary blade b1 and the second rotary blade b2 may be rotary blades having a planer tool disposed on the side surface thereof.
In the cutting step, the first end face f1 and the second end face f2, which are substantially parallel to the longitudinal direction (Y-axis direction) of each of the upper surface tf and the lower surface uf of the laminated structure 2, are cut by the following method.
As shown in fig. 3 (a), the side surface s1 of the first rotary knife b1 cuts the entire first end surface f1 of the laminated structure 2 while contacting the first end surface f 1. The side surface s2 of the second rotating knife b2 cuts the entire second end surface f2 while contacting the second end surface f2 opposite to the first end surface f 1.
In the cutting step, the cutting of the first end face f1 by the first rotary cutter b1 and the cutting of the second end face f2 by the second rotary cutter b2 are performed substantially simultaneously, and after the cutting step, corners at both ends of the first end face f1 and corners at both ends of the second end face f2 are chamfered, and both ends of the first end face f1 and both ends of the second end face f2 are curved surfaces. In other words, the upper surface tf and the lower surface uf of the laminated structure 2 having undergone the cutting step are not completely rectangular, but have a shape in which four corners have curvatures.
Since the first end surface f1 and the second end surface f2 are opposed to each other, the pressure applied to the first end surface f1 by the first rotating knife b1 and the pressure applied to the second end surface f2 by the second rotating knife b2 are easily balanced with each other, and the moment applied to the first end surface f1 by the first rotating knife b1 and the moment applied to the second end surface f2 by the second rotating knife b2 are easily cancelled with each other. Therefore, a part or the whole of the laminated structure 2 is less likely to deviate in a direction (XY plane direction) substantially perpendicular to the lamination direction (Z axis direction) of the laminated body 4. For the same reason, it is difficult for a part or the whole of the laminated structure 2 to rotate about the rotation axis a12 (central axis of the jig) substantially parallel to the lamination direction (Z-axis direction) of the laminated body 4. That is, the first end face f1 and the second end face f2 that face each other are cut substantially simultaneously, whereby positional deviation and warpage of the laminated structure 2 are suppressed. Therefore, the relative position and the relative movement speed of each rotary blade with respect to each end face of the laminated structure 2 can be precisely controlled, and the first end face f1 and the second end face f2 can be cut with high precision. According to the above mechanism, the accuracy of the shape and the size of each of the laminated structures 2 and 4 is improved. That is, the upper surface tf and the lower surface uf of the multilayer structure 2 and each multilayer body 4 are processed into a special shape with high accuracy. For example, the interval of the first end face f1 and the second end face f2 of the portion that is not chamfered is uniformly controlled. In addition, the intersection angle of the flat portion of the first end face f1 and the flat portion of the third end face f3, the intersection angle of the flat portion of the first end face f1 and the flat portion of the fourth end face f4, the intersection angle of the flat portion of the second end face f2 and the flat portion of the third end face f3, and the intersection angle of the flat portion of the second end face f2 and the flat portion of the fourth end face f4 are uniformly controlled. For example, when the number of the stacked bodies 4 constituting the stacked structure 2 is 100, the total ratio of the thickness of the adhesive layer to the thickness of the stacked structure 2 in the stacking direction (Z-axis direction) is 17%, the thickness of each stacked body 4 is 190 μm, the length of the long side of each stacked body 4 before the cutting step (width of the stacked body 4 in the Y-direction) is 155mm, and the length of the short side of each stacked body 4 before the cutting step (width of the stacked body 4 in the X-direction) is 75mm, the deviation width of the length of the short side of the stacked body 4 after the cutting step from the design value is about 0.008mm at the maximum, and the deviation width of the intersection angle from 90 ° is about 0.16 ° at the maximum. On the other hand, when the first end surface f1 and the second end surface f2 are cut at the same time, and the first end surface f1 and the second end surface f2 are cut by one rotary cutter, the deviation width of the length of the short side of the stacked body 4 from the design value is about 0.044mm at the maximum, and the deviation width of the intersection angle from 90 ° is about 0.29 °.
The widths of the first end face f1 and the second end face f2 are larger than the widths of the third end face f3 and the fourth end face f4 in a direction (XY plane direction) perpendicular to the stacking direction (Z axis direction). The larger the width of the end face in the direction (XY plane direction) perpendicular to the stacking direction (Z axis direction), the more easily the rotary knife applies a moment to the end face. Therefore, if the wide first end face F1 and the wide second end face F2 are cut separately and non-simultaneously by using only one rotary cutter, the entire laminated structure 2 is rotated about the rotation axis a12 (the center axis of the jig 12) substantially parallel to the lamination direction (Z-axis direction) by the force F applied to the laminated structure 2 by the rotary cutter (b1) as shown in fig. 7 (a), and the laminated structure 2 is easily displaced from a predetermined position, and each of the laminated bodies 4 constituting the laminated structure 2 is rotated about the rotation axis a12 (the center axis of the jig 12) substantially parallel to the lamination direction (Z-axis direction) as shown in fig. 7 (b), and the laminated structure 2 is easily twisted. In particular, the central portion of the laminated structure 2 in the lamination direction (Z-axis direction) is particularly easy to rotate, and the positional deviation and twisting of the laminated structure 2 are more likely to occur as the number of the laminated bodies 4 constituting the laminated structure 2 is larger. In particular, when each laminate 4 includes adhesive layers such as a first adhesive layer and a second adhesive layer as the optical films 10a and 10b, the laminated structure 2 is easily twisted because the adhesive layers are softer than the other optical films. As a result, in the cutting step, it is difficult to precisely control the shapes of the first end face f1 and the second end face f2, and it is difficult to precisely machine the upper surface tf, the lower surface uf, and each laminate 4 of the laminate structure 2 into the irregular shapes. On the other hand, in the case of the present embodiment, the positional deviation and twisting of the laminated structure 2 during cutting of the first end face f1 and the second end face f2 having a large width can be suppressed by the above-described mechanism.
Since the positional deviation and twisting of the laminated structure 2 are suppressed according to the above-described mechanism, the number of the laminated bodies 4 constituting the laminated structure 2 can be increased according to the present embodiment. By increasing the number of stacked bodies 4 cut together, the time required for the cutting process is shortened, and the productivity of the optical member is improved. In addition, according to the present embodiment, even when each of the laminates 4 constituting the laminated structure 2 includes the adhesive layer, it is possible to easily suppress the positional deviation and the distortion of the laminated structure 2.
As shown in fig. 3 (a), the broken lines and arrows extending from the first rotary knife b1 indicate the movement path and the movement direction of the first rotary knife b1 in the cutting process. The moving path and the moving direction of the first rotary knife b1 may be relative to the stacked structural body 2. That is, the first rotary knife b1 itself may move, and the stacked structural body 2 itself may also move. As shown in fig. 3 (a), the broken lines and arrows extending from the second rotary knife b2 indicate the movement path and the movement direction of the second rotary knife b2 in the cutting process. The moving route and the moving direction of the second rotary knife b2 may be relative to the stacked structural body 2. That is, the second rotary knife b2 itself may move, and the stacked structural body 2 itself may also move. As indicated by the dashed lines and arrows extending from the first rotary knife b1 and the second rotary knife b2, respectively, the first rotary knife b1 and the second rotary knife b2 may translate along the first end surface f1 and the second end surface f2 that are opposite to each other in the cutting process. By moving the first rotary knife b1 and the second rotary knife b2 in parallel, the moments acting on the first end face f1 and the second end face f2 tend to cancel each other out, and the rotation and twisting of the laminated structure 2 are easily suppressed. For the same reason, the pressure applied to the first end surface f1 by the first rotary knife b1 may be substantially equal to the pressure applied to the second end surface f2 by the second rotary knife b2, and the moving speed of the first rotary knife b1 in the direction substantially parallel to the first end surface f1 may be substantially equal to the moving speed of the second rotary knife b2 in the direction substantially parallel to the second end surface f 2. During the cutting of the first and second end surfaces f1 and f2, the interval between the first rotary knife b1 and the second rotary knife b2 can be freely changed. The first end surface f1 and the second end surface f2 are each precisely machined into a shape other than a plane by controlling the distance between the first rotary knife b1 and the second rotary knife b 2. During the cutting of the first and second end faces f1 and f2, the position of the jig 12 may be fixed. During the cutting of the first end surface f1 and the second end surface f2, the positions of the first rotary blade b1 and the second rotary blade b2 in the direction substantially parallel to the first end surface f1 and the second end surface f2 (Y-axis direction) may be fixed, and the jig 12 may be moved in the direction substantially parallel to the first end surface f1 and the second end surface f2 (Y-axis direction). That is, the stacked structural body 2 clamped by the clamp 12 may pass between the first rotary knife b1 and the second rotary knife b 2.
The method of manufacturing an optical member may further include a machining step performed before the cutting step. As shown in fig. 3 (b), the upper surface tf ' and the lower surface of the laminated structure 2 ' before the processing step may be square-shaped with all corners being right angles, and in the processing step, the laminated structure 2 ' may be processed such that the upper surface tf ' and the lower surface of the laminated structure 2 ' are irregularly shaped. The processing step may be, for example, punching or cutting of the laminated structure 2'. The cutting mechanism used in the machining process may be a tool or a laser (e.g., a CO2 gas laser or an excimer laser).
The method of manufacturing the optical member may not include the above-described processing step. In the case where the method of manufacturing an optical member does not include the above-described machining step, as shown in fig. 3 (b), the upper surface tf ' and the lower surface of the laminated structure 2 ' used in the cutting step may be each a quadrangle having all right angles, and in the cutting step, the two opposing end surfaces (the first end surface f1 ' and the second end surface f2 ') of the laminated structure 2 ' may be cut substantially simultaneously (in parallel) by a pair of rotary knives (the first rotary knife b1 and the second rotary knife b2) so that the upper surface tf ' and the lower surface of the laminated structure 2 ' are each irregularly shaped.
The third end face f3 and the fourth end face f4, which are substantially parallel to the respective short side directions (X-axis directions) of the upper surface tf and the lower surface uf of the laminated structure 2, can be cut substantially simultaneously (in parallel) by a pair of rotary blades (a first rotary blade b1 and a second rotary blade b2) in the same manner as the first end face f1 and the second end face f 2. The third end face f3 and the fourth end face f4 may also be cut using the first rotary knife b1 or the second rotary knife b2, respectively, non-simultaneously.
Preferably, the jig 12 does not always turn around the rotation axis a12 (the central axis of the jig 12) substantially parallel to the stacking direction (Z-axis direction) in a series of cutting all the end faces (the first end face f1, the second end face f2, the third end face f3, and the fourth end face f4) of the stacked structure 2 with the above-described rotary knife. That is, it is preferable that the jig 12 does not turn from the time when the end face of the laminated structure 2 starts to be cut to the time when the cutting of the entire end face is completed. The jig 12 may be turned around at a timing when any one end surface of the laminated structure 2 is not cut at all. After the cutting of all the end faces of the laminated structure 2 is completed, the jig 12 may be turned. If the jig 12 has rotated in a series of processes of cutting all the end faces of the laminated structure 2 with the rotary cutter, each of the laminated bodies 4 constituting the laminated structure 2 rotates about the rotation axis a12 (the center axis of the jig 12) substantially parallel to the lamination direction (Z-axis direction) in conjunction with the jig 12 as shown in fig. 7 (b), and the laminated structure 2 is likely to twist. On the other hand, in the process of cutting the entire end face of the laminated structural body 2 with the rotary cutter, the distortion of the laminated structural body 2 is suppressed without the jig 12 being turned around all the time. As a result, it is easy to precisely control the shape of all the end faces of the laminated structure 2, and it is easy to precisely machine the upper surface tf, the lower surface uf, and each laminated body 4 of the laminated structure 2 into irregular shapes.
The jig 12 is not rotated at all times during the cutting of the entire end face of the stacked structure 2 by the rotary blade, and the positions at which the first rotary blade b1 and the second rotary blade b2 are provided can be freely changed during the cutting of the entire end face of the stacked structure 2 by the rotary blade. For example, as shown in fig. 4, the first rotary blade b1 may be provided at one end of the fourth end surface f4 (position p2), and the fourth end surface f4 may be cut by the first rotary blade b1 moving from the position p2 to the position p 1. After the fourth end surface f4 is cut, the first rotary blade b1 may be provided at one end of the fourth end surface f4 (position p1), and the second rotary blade b2 may be provided at the other end of the fourth end surface f4 (position p2), so that the first end surface f1 may be cut by the first rotary blade b1 and the second end surface f2 may be cut by the second rotary blade b2 substantially simultaneously. After the first end surface f1 and the second end surface f2 are simultaneously cut, the second rotary knife b2 may be provided at one end of the third end surface f3 (position p3), and the third end surface f3 may be cut by the second rotary knife b2 moving from the position p3 to the position p 4. However, as long as the two opposing end surfaces are cut substantially simultaneously by the pair of rotary knives so that at least a part of at least one end surface does not become a plane, the order of cutting the first end surface f1, the second end surface f2, the third end surface f3, and the fourth end surface f4 is not limited, and the combination of each end surface and the rotary knife that cuts each end surface is also not limited.
In the process of cutting the entire end face of the stacked structure 2 with the rotary blade, the jig 12 may be freely rotated at all times, and the positions at which the first rotary blade b1 and the second rotary blade b2 are provided may be freely changed. In the process of cutting the entire end face of the stacked structure 2 with the rotary blade, the jig 12 may be allowed to rotate freely at all times, and the positions where the first rotary blade b1 and the second rotary blade b2 are provided may be fixed.
The method of manufacturing an optical member may further include a step of forming a hole penetrating the laminated structure 2 in the lamination direction of the laminated body 4. Before the cutting step, a hole may be formed to penetrate the laminated structure 2 or 2'. After the cutting step, a hole may be formed to penetrate the laminated structure 2. The mechanism for forming the hole penetrating the laminated structure 2 or 2' may be a punching device, a rotary cutter such as a drill, or a laser. The laser may be, for example, a CO2 gas laser or an excimer laser. The inner wall of the hole penetrating the stacked structural body 2 or 2' may be cut by the first rotary knife b1 or the second rotary knife b 2.
The laminated structure 2 having undergone the above steps can be used as one laminated optical film. Each of the laminates 4 constituting the laminated structure 2 having undergone the above steps can be used as an optical member.
The present invention is not necessarily limited to the above-described embodiments. The present invention can be variously modified within a range not departing from the gist of the present invention. The following modifications are also included in the present invention.
The shape of each end face after the cutting step is not limited as long as at least a part of at least one of the two opposing end faces of the laminated structure is cut substantially simultaneously so as not to become a plane. The two opposing end surfaces may be cut substantially simultaneously by the pair of rotary knives so that only a part of the end surfaces after the cutting step does not become a plane. The opposite ends may be cut substantially simultaneously by the pair of rotary knives so that the entire end surface after the cutting step is not a plane. The shape of the laminated structure before the cutting step is not limited as long as the laminated structure is a column having two opposing end faces that are substantially parallel to the laminating direction of the laminated body. In the laminated structure before the cutting step, the two opposing end faces may not be parallel. In the laminated structure before the cutting step, at least one of the two facing end surfaces may not be a perfect plane.
As shown in fig. 5 (a), the third end surface f3 and the fourth end surface f4 having a narrow width can be cut at substantially the same time by the first rotary blade b1 or the second rotary blade b2, and a notch 50 (recess) extending in the stacking direction (Z-axis direction) of the stacked body 4 can be formed in the cut fourth end surface f 4. In the case of fig. 5 (a), the notch 50 has a substantially rectangular shape when viewed from the stacking direction (Z-axis direction) of the stacked body 4. However, the shape of the cutout portion 50 is not limited. For example, the shape of the cutout 50 viewed in the stacking direction (Z-axis direction) of the stacked body 4 may be a quadrangle other than a rectangle, a triangle, another polygon, a semicircle, a semi-ellipse, or another curve. The four corners of the laminated structure 2 shown in fig. 5 (a) may be chamfered by the same method as in the above embodiment. The cutout portion may be formed on both the third end surface f3 and the fourth end surface f 4. The shape and size of the cutout portion formed in the third end surface f3 may be the same as those of the cutout portion formed in the fourth end surface f 4. The shape and size of the notch formed in the third end surface f3 may be different from the shape and size of the notch formed in the fourth end surface f 4. The wide first end face f1 and second end face f2 may be cut at the same time, and a notch extending in the stacking direction (Z-axis direction) of the stacked body 4 may be formed in at least one of the cut first end face f1 and second end face f 2. The cutout portion extending in the stacking direction (Z-axis direction) of the stacked body 4 may be formed in both the first end face f1 and the second end face f2 after cutting.
As shown in fig. 5 (b), the first end surface f1 and the second end surface f2 having a wide width can be cut substantially simultaneously by the first rotary knife b1 or the second rotary knife b2, and the entire first end surface f1 and the entire second end surface f2 after the cutting process can be curved (convex). The first end face f1 and the second end face f2 after the cutting step may be concave as a whole. The entire first end surface f1 after the cutting process may be convex, and the entire second end surface f2 after the cutting process may be concave.
As shown in fig. 6, the first end surface f1 and the second end surface f2 having a wide width may be cut substantially simultaneously by the first rotating knife b1 or the second rotating knife b2, the first end surface f1 after the cutting process may be a flat surface, and the entire second end surface f2 after the cutting process may be a curved surface (convex surface). The entire second end face f2 after the cutting process may be a concave face.
In the cutting process, other rotary knives may be used in addition to the first rotary knife b1 or the second rotary knife b 2. That is, three or more rotary knives may be used in the cutting process.
Industrial applicability
The optical member obtained by the manufacturing method of the present invention can be used for an image display device such as a liquid crystal display, an organic EL display, a smart phone, a smart watch, or an instrument panel of a vehicle, for example.
Claims (9)
1. A method for manufacturing an optical member, wherein,
the method for manufacturing an optical member includes a cutting step of cutting the laminated structure by a pair of rotary blades,
the laminated structure includes a plurality of laminated bodies laminated to each other,
the laminate includes a plurality of optical films laminated to each other,
the laminated structure has two end faces opposed to each other,
the two opposing end faces of the laminated structure are substantially parallel to the laminating direction of the laminated body,
the upper surface and the lower surface of the laminated structure are substantially perpendicular to the laminating direction,
the laminated structure is held by a jig in contact with the upper surface and the lower surface of the laminated structure,
the rotating knife extends in the stacking direction,
a side surface of the rotary knife is substantially parallel to the end surface of the laminated structure,
the rotational axis of the rotating knife is substantially parallel to the side of the rotating knife,
the side surface of one of the rotary knives is in contact with one of the end surfaces of the laminated structure,
the side surface of the other rotary knife is in contact with the other end surface of the laminated structure,
the two opposing end surfaces of the laminated structure are cut substantially simultaneously by the pair of rotary blades so that at least a part of at least one of the end surfaces does not become a plane.
2. The method for manufacturing an optical member according to claim 1,
the two opposing end surfaces of the laminated structure are substantially parallel to the longitudinal direction of each of the upper surface and the lower surface of the laminated structure.
3. The method for manufacturing an optical member according to claim 1 or 2,
a position change of a pair of the rotary knives is provided in a process of cutting all end faces of the laminated structure by the rotary knives,
the jig does not always swivel about a rotation axis substantially parallel to the stacking direction in a process of cutting all end faces of the stacked structure by the rotary blade.
4. The method for manufacturing an optical member according to any one of claims 1 to 3,
in the cutting step, the pair of rotary knives moves along the two facing end surfaces of the laminated structure.
5. The method for manufacturing an optical member according to any one of claims 1 to 4,
in the cutting step, the interval between the pair of rotary knives varies,
in the cutting step, the jig is moved in a direction substantially parallel to the two facing end surfaces of the laminated structure.
6. The method for manufacturing an optical member according to any one of claims 1 to 5,
the method for manufacturing an optical member further includes a machining step performed before the cutting step,
wherein the upper surface and the lower surface of the laminated structure before the processing step are each a quadrangle having all corners thereof at right angles,
in the processing step, the laminated structure is processed so that the upper surface and the lower surface of the laminated structure have shapes different from the quadrangle.
7. The method for manufacturing an optical member according to any one of claims 1 to 5,
the upper surface and the lower surface of the laminated structure used in the cutting step are each a quadrangle having all corners thereof perpendicular to each other,
in the cutting step, the two opposing end surfaces of the laminated structure are cut substantially simultaneously by the pair of rotary blades so that the upper surface and the lower surface of the laminated structure have shapes different from the quadrangle.
8. The method for manufacturing an optical member according to any one of claims 1 to 7,
the laminate includes at least one adhesive layer.
9. The method for manufacturing an optical member according to any one of claims 1 to 8,
the rotary cutter is an end mill.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2019188478A JP7335125B2 (en) | 2019-10-15 | 2019-10-15 | Method for manufacturing optical member |
| JP2019-188478 | 2019-10-15 |
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| CN112666647A true CN112666647A (en) | 2021-04-16 |
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| CN202011093671.9A Pending CN112666647A (en) | 2019-10-15 | 2020-10-13 | Method for manufacturing optical member |
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|---|---|
| JP (1) | JP7335125B2 (en) |
| KR (1) | KR20210044708A (en) |
| CN (1) | CN112666647A (en) |
| TW (1) | TWI849238B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114609711A (en) * | 2022-03-09 | 2022-06-10 | 业成科技（成都）有限公司 | Manufacturing method of optical element, clamping device, display module and electronic equipment |
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Also Published As
| Publication number | Publication date |
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| JP7335125B2 (en) | 2023-08-29 |
| KR20210044708A (en) | 2021-04-23 |
| TWI849238B (en) | 2024-07-21 |
| TW202128320A (en) | 2021-08-01 |
| JP2021062447A (en) | 2021-04-22 |
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