CN115723382A

CN115723382A - Method for producing adhesive-attached optical film

Info

Publication number: CN115723382A
Application number: CN202211499633.2A
Authority: CN
Inventors: 岩本正树; 友寄隆太; 藤原新; 仲井宏太; 野中崇弘; 大瀬雄基
Original assignee: Nitto Denko Corp
Current assignee: Nitto Denko Corp
Priority date: 2017-08-07
Filing date: 2018-08-07
Publication date: 2023-03-03
Also published as: KR20190015987A; TWI773802B; CN109385222A; JP2019032415A; JP6951902B2; KR102530197B1; TW201910884A; CN109385222B

Abstract

The invention provides a method for manufacturing an optical film with an adhesive. A longitudinal mother substrate (155) having an optical film and a patterned adhesive sheet on a carrier base material is manufactured by bonding the optical film (1) and a laminate (154) having the patterned adhesive sheet (21) on a longitudinal carrier base material (4) by a roll-to-roll process. The optical film and the adhesive sheet of the mother substrate are cut into a cut line (32 a) ₁ 、32a ₂ ) And a single sheet of a predetermined shape surrounded thereby to obtain an adhesive-attached optical film having a non-adhesive region where the first adhesive sheet is not provided on a part of the main surface of the optical film.

Description

Method for producing optical film with adhesive

The present application is a divisional application of an application having an application date of 2018, 8 and 7, and an application number of 201810891553.9, entitled "method for manufacturing an optical film with an adhesive".

Technical Field

The present invention relates to a method for producing an optical film with an adhesive, the method for producing a single sheet of the optical film having a patterned adhesive sheet.

Background

Liquid crystal display devices and organic EL display devices are widely used as various image display devices such as mobile phones, smart phones, car navigation devices, monitors, and televisions. The liquid crystal display device is provided with a polarizing plate on the visual perception side surface of the liquid crystal cell according to its display principle. In some self-luminous display devices such as organic EL devices, a circularly polarizing plate (a laminate of a polarizing plate and a 1/4 wavelength plate) is disposed on the visual perception side surface of a liquid crystal cell in order to suppress external light from being reflected by a metal electrode (cathode) and to look like a mirror. Generally, the image display unit and the polarizing plate are bonded together with a sheet-like adhesive.

An image display device in which a front surface transparent member such as a touch sensor or a cover glass is provided on a visual perception side surface of an image display panel has been widely used. In an image display device having a front surface transparent member, a polarizing plate on the surface of an image display panel and the front surface transparent member are bonded together with an adhesive, whereby the difference in refractive index at the interface is reduced, and deterioration in visual perception due to reflection and scattering can be suppressed.

As a method for disposing a front surface transparent member on a visual perception side surface of an image display panel via an adhesive sheet, there is known one of the following methods: an adhesive sheet cut out in accordance with the size of a screen is attached to a polarizing plate on the surface of an image display panel, and a front surface transparent member is disposed on the adhesive sheet (for example, patent document 1). Patent document 2 proposes a polarizing plate using a double-sided adhesive tape in forming an image display device having a front surface transparent member. The double-sided adhesive polarizing plate has an adhesive sheet for bonding to an image display unit on one surface of the polarizing plate, and an adhesive sheet for bonding to a front transparent member on the other surface of the polarizing plate. As described in patent document 2, when a polarizing plate with an adhesive agent is used in which an adhesive sheet is provided in advance on the surface of the polarizing plate, the alignment and attachment of the adhesive sheet can be omitted when forming an image display device, and therefore, the process can be simplified.

Patent document 1 discloses a configuration in which the end face of the pressure-sensitive adhesive sheet is located inside the end face of the protective sheet temporarily adhered to the surface of the pressure-sensitive adhesive sheet. Patent document 2 shows an embodiment in which the end face of the pressure-sensitive adhesive sheet is located inside the end faces of the polarizing plate and the protective sheet bonded to the pressure-sensitive adhesive sheet. By positioning the end face of the pressure-sensitive adhesive sheet inside the end face of the polarizing plate or the protective sheet, the pressure-sensitive adhesive can be prevented from overflowing from the end face during transportation or processing, and contamination, glue shortage, and the like caused by the pressure-sensitive adhesive can be prevented.

Documents of the prior art

Patent document

Patent document 1: WO2013-161666 No.

Patent document 2: japanese laid-open patent publication No. 2014-115468

Disclosure of Invention

Problems to be solved by the invention

The polarizing plate with an adhesive is generally formed by bonding a polarizing plate in a long sheet shape and an adhesive sheet by a roll-to-roll process. The adhesive-attached polarizing plate for forming an image display device is obtained by cutting out a vertically long mother substrate in a size corresponding to the screen size of the image display device.

When the polarizing plate and the adhesive sheet are cut out from a vertically long mother substrate in a predetermined size, the polarizing plate and the adhesive sheet are cut simultaneously. Therefore, the adhesive sheet is attached to the entire main surface of the polarizing plate in the single adhesive-attached polarizing plate. In order to obtain a polarizing plate with an adhesive having a region on the main surface of the polarizing plate where no adhesive sheet is provided, it is necessary to bond the adhesive sheet cut into individual pieces to the polarizing plate as shown in patent document 1, which results in a significant reduction in productivity.

In patent document 2, there is provided a method of: the adhesive sheet is cut out in a state in which the adhesive is overflowed from the end face by pressing from the main surface side, whereby the end face of the adhesive sheet is positioned inside the end face of the polarizing plate or the protective sheet. However, in this method, it is difficult to accurately control the distance from the end face of the polarizing plate to the end face of the adhesive sheet. In the single adhesive-attached polarizing plate obtained by this method, the end face of the adhesive sheet is positioned inward of the end face of the polarizing plate in the center of the adhesive sheet in the thickness direction, and the position of the end face of the adhesive sheet and the position of the end face of the polarizing plate are aligned in the vicinity of the bonding interface between the adhesive sheet and the polarizing plate. That is, this method cannot obtain a single polarizing plate with an adhesive, which has a region on the polarizing plate where no adhesive sheet is attached.

The invention provides a method for efficiently manufacturing a single adhesive-attached optical film having a region, which is not attached with an adhesive sheet, in a local area on an optical film such as a polarizing plate by cutting from a vertically long mother substrate.

Means for solving the problems

A long mother substrate is manufactured by bonding an optical film and a laminate having a patterned adhesive sheet on a long carrier base material by a roll-to-roll process. The pattern shape of the adhesive sheet is not particularly limited. For example, the adhesive sheet is patterned so that a region where the adhesive is not provided is in a strip shape extending in the longitudinal direction. As the optical film, a polarizing plate, a laminated film in which a polarizing plate and another film are laminated, or the like can be used.

The carrier substrate and the adhesive sheet may be directly laminated. A protective sheet may be provided between the carrier substrate and the adhesive sheet. In the case where the protective sheet is provided between the carrier substrate and the pressure-sensitive adhesive sheet, the peeling force at the interface between the protective sheet and the pressure-sensitive adhesive sheet is preferably larger than the peeling force between the protective sheet and the carrier substrate.

The mother substrate has a patterned adhesive sheet on a main surface of the optical film. The optical film with adhesive and the adhesive sheet of the mother substrate are cut into individual sheets of a predetermined shape surrounded by a cutting line, thereby obtaining the adhesive-attached optical film. When the sheet is cut into individual sheets, a cut line is formed so as to include a region where the adhesive sheet is not provided. In the formation of the cutting line, the carrier base material may be half-cut so that at least a part thereof in the thickness direction is not cut.

Since the patterned region of the adhesive sheet (the void portion after removal of the adhesive) is present in the region surrounded by the cutting line, the single adhesive-attached optical film has a region (non-adhesive region) where the main surface of the optical film is exposed without providing the adhesive sheet, in a part of the main surface of the optical film. For example, if a cut line is formed in a portion of the optical film that is laminated on a region of the mother substrate where no adhesive sheet is provided, an adhesive-attached optical film having a non-adhesive region at the periphery of a single optical film can be obtained.

In the non-bonded region, the optical film is exposed because no adhesive is provided on the optical film. Since the optical film has the non-adhesive region, physical interference between a component of the image display device such as a flexible wiring board and the adhesive can be avoided in forming the image display device, and the space of the device can be effectively used.

The method of patterning the adhesive sheet is not particularly limited. For example, a laminated adhesive sheet having an unpatterned adhesive sheet on a carrier sheet is cut, and the adhesive sheet in the region surrounded by the cut line is peeled off from the carrier sheet and removed to obtain a laminated body having a patterned adhesive sheet on a carrier sheet. When the adhesive sheet is cut, the carrier base material may be half-cut so that at least a part of the carrier base material in the thickness direction is not cut.

The light release sheet may be temporarily bonded to the pressure-sensitive adhesive sheet by laminating the pressure-sensitive adhesive sheet. When the light release sheet is temporarily adhered to the adhesive sheet, the light release sheet and the adhesive sheet are cut off from the carrier sheet, the light release sheet and the adhesive sheet are peeled off and removed from the portion of the adhesive sheet surrounded by the cutting line, and then the adhesive sheet and the optical film are laminated to obtain a mother substrate. Preferably, the peel force at the interface between the carrier sheet and the adhesive sheet is greater than the peel force at the interface between the adhesive sheet and the light-peeling sheet.

The method of the present invention can also be applied to the production of a double-sided adhesive optical film having adhesive sheets on both sides of an optical film, and having the adhesive sheet on at least one side patterned. In the production of the double-sided adhesive optical film, the following operations are required: adhesive sheets are provided on both sides of an optical film, a mother substrate in which at least one adhesive sheet is patterned is produced, and the optical film is cut out from the mother substrate in a region surrounded by a cutting line.

ADVANTAGEOUS EFFECTS OF INVENTION

In the method of the present invention, after patterning the adhesive sheet on a long carrier substrate, the adhesive sheet and the optical film are bonded to each other by a roll-to-roll process to obtain a long mother substrate. By adjusting the position of the cutting line when cutting out the single piece from the mother substrate, an adhesive-attached optical film having a patterned adhesive sheet is obtained. In the method of the present invention, since the bonding and cutting are performed on the long carrier base material by the roll-to-roll process, the step of aligning and bonding the optical film and the adhesive sheet after the cutting into individual sheets is not required. The method of the present invention enables easy and efficient mass production of a single adhesive-equipped optical film having a patterned adhesive sheet.

Drawings

Fig. 1 (a) is a plan view of the adhesive-attached optical film, and fig. 1 (B) is a cross-sectional view of the adhesive-attached optical film.

Fig. 2 is a process diagram showing an example of a process for producing an optical film with an adhesive.

Fig. 3A is a cross-sectional view of a laminate used in the production of an optical film with an adhesive.

Fig. 3B is a cross-sectional view showing a state where the cutting unit cuts the adhesive sheet.

Fig. 3C is a sectional view of the laminate after removal of the cut piece.

Fig. 3D is a cross-sectional view of the laminate after removal of the cut pieces and the protective sheet.

Fig. 3E is a cross-sectional view for obtaining a laminate (mother substrate) with an adhesive optical film.

Fig. 3F is a cross-sectional view showing a state where the cutting unit cuts the laminate.

Fig. 3G is a sectional view of the laminate after removal of the cut pieces.

Fig. 4 is a plan view showing a state where the cutting unit cuts the adhesive sheet.

Fig. 5 is a plan view showing a state where the cutting unit cuts the optical film.

Fig. 6 is a cross-sectional view of a double-sided adhesive optical film.

Fig. 7 is a sectional view of a laminate (mother substrate) for obtaining a double-sided adhesive optical film.

Fig. 8 is a sectional view of the image display device.

Fig. 9 (a) is a plan view of the adhesive-attached optical film, and fig. 9 (B) is a cross-sectional view of the adhesive-attached optical film.

Fig. 10 is a cross-sectional view showing a state where the cutting unit cuts the laminate.

Fig. 11 is a cross-sectional view showing a state where the cutting unit cuts the stacked body.

Fig. 12 (a) is a plan view of the adhesive optical film, and fig. 12 (B) is a cross-sectional view of the adhesive optical film.

Fig. 13 is a cross-sectional view showing a state where the cutting unit cuts the stacked body.

Fig. 14 is a cross-sectional view showing a state where the cutting unit cuts the stacked body.

Fig. 15 is a cross-sectional view of a double-sided adhesive optical film.

Fig. 16 is a cross-sectional view of a laminate (mother substrate) for obtaining a double-sided adhesive optical film having non-adhesive regions on both sides.

Fig. 17 is a process diagram showing an example of a process for producing an optical film with an adhesive.

Fig. 18A is a cross-sectional view of a laminate used in the production of an optical film with an adhesive.

Fig. 18B is a sectional view showing a state where the cutting unit cuts the adhesive sheet.

Fig. 18C is a sectional view of the laminate after removal of the cut piece.

Fig. 18D is a cross-sectional view of the laminate after removal of the cut piece and the protective sheet.

Fig. 18E is a sectional view for obtaining a laminate (mother substrate) with an adhesive optical film.

Fig. 18F is a cross-sectional view showing a state where the cutting unit cuts the laminate.

Description of the reference numerals

51. 52, 56, 57, 59, adhesive-bearing optical film; 1. an optical film; 21. 22, an adhesive sheet; 2x, non-bonded area; 40. protective sheets (light release sheets); 41. a protective sheet (heavy release sheet); 42. a protective sheet; 4. 44, carrying a sheet;60. an image display unit; 71. a cover glass with a contact sensor; 91. a flexible printed wiring board; 801. an image display device; 31a, 31b, 531a, 531b, a cut line; 32a of ₁ 、32a ₂ 、32a ₃ 、32a ₄ 、532a ₁ 、532a ₂ 、532a ₃ 、532a ₄ 、732a ₁ 、732a ₂ Cutting off the line; 161. 661, cutting; 131. 132, 631, 632, cutting means; 155. 755, 955, laminate (mother substrate).

Detailed Description

(Structure of optical film with adhesive)

Fig. 1 (a) is a plan view of an adhesive-equipped optical film according to an embodiment, and fig. 1 (B) is a cross-sectional view taken along line B1-B2. The adhesive-attached optical film 51 has an adhesive sheet 21 on the first main surface of the optical film 1. The adhesive sheet 21 is patterned, and a region (adhesive region) where the adhesive sheet 21 is attached and a region (non-adhesive region) where the optical film is exposed without the adhesive sheet are present on the first main surface of the optical film 1. In the adhesive-attached optical film 51 shown in FIG. 1, the edge 1a of the optical film 1 is followed ₁ The peripheral edge region is formed as a non-bonded region 2x.

(optical film)

As the optical film 1, for example, a polarizing plate can be used. In a general polarizing plate, an appropriate transparent protective film is provided on one surface or both surfaces of a polarizer as necessary. As the polarizing plate, for example, a film obtained by adsorbing a dichroic substance such as iodine or a dichroic dye to a hydrophilic polymer film such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film, or an ethylene-vinyl acetate copolymer partially saponified film, and orienting the dichroic substance by stretching can be used. As the transparent protective film provided on the surface of the polarizing plate, a material excellent in transparency, mechanical strength, and thermal stability, such as a cellulose-based resin, a cyclic polyolefin-based resin, an acrylic resin, a phenylmaleimide-based resin, or a polycarbonate-based resin, is preferably used. As the transparent protective film of the polarizing plate, an optically anisotropic film such as a retardation plate may be used.

The optical film 1 may be formed by laminating a plurality of films with an appropriate adhesive or bonding agent. Examples of optical films other than polarizing plates include films used for forming image display devices, such as retardation films, viewing angle expanding films, viewing angle restricting (privacy) films, and light-intensifying films. A touch sensor or the like may be provided on the optical film. The surface of the optical film may be provided with a hard coat layer, an antireflection layer, an antiglare layer, an antiblocking layer, or the like, or may be subjected to surface treatment for the purpose of improving adhesiveness or the like.

The area of the optical film 1 is not particularly limited, but is usually 5cm ² ～25000cm ² Left and right. When the optical film 1 is rectangular, the length of the diagonal line is about 3cm to 250 cm. When the optical film 1 is rectangular, it may be rectangular having long sides and short sides, or may be square having 4 sides and equal lengths. The length of the long side of the rectangle is usually 10 times or less, but may be 5 times or less, 3 times or less, or twice or less the length of the short side. When the optical film is an optically anisotropic film such as a polarizing plate or a retardation film, the direction of the optical axis such as the absorption axis or the slow axis may be parallel to or perpendicular to the extending direction of the sides of the rectangle, or may be at a predetermined angle to the extending direction of the sides of the rectangle. When the optical film is a laminate of a plurality of films, the arrangement of the optical axes of the respective films is not particularly limited, and may be parallel or orthogonal to each other, or may be at a predetermined angle. For example, in a circularly polarizing plate, a polarizer and a 1/4 wavelength plate are laminated so that an angle formed by the absorption axis direction of the polarizer and the slow axis direction of the 1/4 wavelength plate is 45 °.

(adhesive sheet)

The adhesive sheet 21 provided on the first main surface of the optical film 1 is preferably formed of an optically transparent adhesive. The adhesive sheet 21 is used for bonding between the optical film 1 and an image display unit, bonding between the optical film 1 and a front surface transparent member (a transparent plate such as a cover glass, a touch sensor, or the like), and the like.

As the adhesive constituting the adhesive sheet, adhesives based on rubber-based polymers such as acrylic polymers, silicone polymers, polyesters, polyurethanes, polyamides, polyvinyl ethers, vinyl acetate/vinyl chloride polymers, modified polyolefins, epoxy-based, fluorine-based, natural rubber, and synthetic rubber can be selected and used as appropriate. In particular, an acrylic pressure-sensitive adhesive is preferably used because it is excellent in optical transparency, exhibits appropriate adhesive properties such as wettability, aggregability and adhesiveness, and is also excellent in weather resistance, heat resistance and the like. The pressure-sensitive adhesive sheet may be formed by laminating a plurality of pressure-sensitive adhesive layers.

The adhesive constituting the adhesive sheet may be a photocurable adhesive which can be cured by light irradiation after bonding. For example, when a photocurable adhesive is used for bonding to a front surface transparent member having a raised portion in decoration printing or the like, the adhesive before photocuring is bonded in a soft state, and thus has a step-absorbing property and can suppress the mixing of bubbles into the vicinity of the raised portion. After bonding, the adhesive is photo-cured by irradiation with UV or the like, whereby the bonding reliability can be improved. The photocurable pressure-sensitive adhesive preferably contains, for example, a polymer, a monomer or oligomer having a photopolymerizable functional group, and a photopolymerization initiator. As the monomer or oligomer having a photopolymerizable functional group, a crosslinking monomer having two or more polymerizable functional groups in one molecule may also be used.

The thickness of the pressure-sensitive adhesive sheet is not particularly limited, but is usually about 5 μm to 500. Mu.m. The thickness of the pressure-sensitive adhesive sheet used for bonding the optical film 1 and the image display unit is preferably about 5 μm to 50 μm. The thickness of the pressure-sensitive adhesive sheet used for bonding the optical film and the front transparent member may be appropriately set depending on the structure of the front transparent member and the like. For example, when the front surface transparent member has a raised portion due to decorative printing or the like, it is preferable to provide the adhesive sheet with a thickness of 50 μm or more so as to have step absorbability in order to prevent bubbles from being mixed into the periphery of the raised portion.

(non-adhesive region)

In the adhesive-attached optical film 51 shown in FIG. 1, 3 sides 1a among 4 sides of the optical film 1 are followed ₂ 、1a ₃ 、1a ₄ The peripheral edge is an adhesive region to which the adhesive sheet 21 is attached. At the side 1a extending along the y direction ₁ At the periphery formed, the adhesive sheet 21 is not provided on the optical film 1. In the non-adhesive region 2x, the main surface of the optical film 1 is exposed, and a void exists in the optical film 1.

At the edge 1a ₂ 、1a ₃ 、1a ₄ At the periphery formed, the end face of the optical film 1 and the end face of the adhesive sheet 21 are aligned in position. At the edge 1a ₁ In the extended non-adhesive region 2x, the end face 21e of the adhesive sheet 21 is located inward of the end face 1e of the optical film 1. These end faces 1e, 21e are along the side 1a ₁ Extending parallel to the y-direction.

Width W of non-bonded region 2x ₁ That is, the distance (offset) from the end face 1e of the optical film 1 to the end face 21e of the adhesive sheet 21 may be set as appropriate. For example, when the non-bonded region 2x is provided for the purpose of preventing the adhesive from overflowing from the end face, W ₁ It is only necessary to set the thickness to about 5 to 3000 μm. In the case where the non-adhesive region 2x is provided for the purpose of preventing physical interference between the adhesive sheet and the constituent members of the image display device in forming the image display device, W may be set according to the shape, size, and the like of the member provided in the non-adhesive region ₁ And (4) finishing. W ₁ For example, 10 μm or more, and can be 30 μm or more. W ₁ The length of the diagonal line of the optical film is usually set to 10% or less.

(protective sheet)

The protective sheet 41 is bonded to the pressure-sensitive adhesive sheet 21 with the pressure-sensitive adhesive optical film 51 in a detachable manner. When the protective sheet is temporarily bonded to the pressure-sensitive adhesive sheet, the exposed surface of the pressure-sensitive adhesive sheet 21 can be protected until the optical film 1 is bonded to the adherend.

As a material constituting the protective sheet 41, a plastic film such as polyethylene, polypropylene, polyethylene terephthalate, or polyester film is preferable. The thickness of the protective sheet 41 is usually 5 μm to 200 μm, preferably about 10 μm to 150 μm. The surface of the protective sheet 41 to be bonded to the adhesive sheet 21 may be subjected to a peeling treatment using a silicone release agent or the like.

(method for producing optical film with adhesive)

An adhesive-equipped optical film having a patterned adhesive sheet on an optical film is produced by bonding an optical film and a laminate having a patterned adhesive sheet on a longitudinal carrier base material by a roll-to-roll process to produce a mother substrate, and cutting out individual sheets from the mother substrate. In this method, the position of the end face of the adhesive sheet and the position of the end face of the optical film can be independently set. Since it is not necessary to bond a single optical film and a single adhesive sheet and to align them at the time of bonding them, a single adhesive-equipped optical film having a non-adhesive region can be efficiently obtained.

Examples of the method for producing a patterned adhesive sheet include a method of patterning when forming an adhesive sheet on a substrate, and a method of cutting and patterning an adhesive sheet formed on the entire surface of a substrate except for an edge portion. Patterning by cutting is preferable because an accurate pattern can be formed and the position, shape, size, and the like of the non-bonded region can be easily controlled.

Hereinafter, a method of manufacturing a single adhesive-attached optical film by bonding an optical film and an adhesive sheet patterned by cutting on a carrier base material to manufacture a mother substrate and cutting the mother substrate will be described. Fig. 2 is a schematic process diagram showing an example of a process for producing a single adhesive-attached optical film having a non-adhesive region. Fig. 3A to 3G are cross-sectional views showing the structure of the laminate at reference numerals a to G in fig. 2.

A roll of slide 4 is positioned on the take-up roll 104. In the present embodiment, the carrier sheet 4 is used as a carrier base material, and the pressure-sensitive adhesive sheet or the optical film is cut on the carrier sheet.

A roll of the laminated adhesive sheet 2 is set on the take-up roll 102. The laminated adhesive sheet 2 has

protective sheets

40 and 41 on both sides of the adhesive sheet 21. In the adhesive-attached optical film 51 cut into individual pieces, the protective sheet 41 is also directly attached as a protective sheet of the adhesive sheet 21 (see fig. 1B). The protective sheet 40 is temporarily bonded to the pressure-sensitive adhesive sheet 21 in order to protect the surface of the pressure-sensitive adhesive sheet 21 until the optical film 1 is bonded to the pressure-sensitive adhesive sheet 21.

It is preferable to suppress peeling at the interface between the protective sheet 41 and the adhesive sheet 21 when peeling from the surface of the adhesive sheet 21 and removing the protective sheet 40. Therefore, the adhesion force between the adhesive sheet 21 and the protective sheet 40 is preferably smaller than the adhesion force between the adhesive sheet 21 and the protective sheet 41. That is, it is preferable that the protective sheet 40 is a light-weight release sheet having a relatively small peeling force from the adhesive sheet, and the protective sheet 41 attached to the carrier sheet 4 is a heavy-weight release sheet having a relatively large peeling force from the adhesive sheet. The peelability of the protective sheet can be adjusted according to, for example, the type of release agent on the sheet surface, the coating thickness, and the like.

In the embodiment shown in fig. 2, the pressure-sensitive adhesive sheet 21 is cut by the first cutting means 131 and the optical film 1 and the pressure-sensitive adhesive sheet 21 are cut by the second cutting means 132 in a state where the carrier sheet 4 is bonded to the back surface of the protective sheet 41 (the surface of the protective sheet 41 opposite to the surface to which the pressure-sensitive adhesive sheet 21 is attached). Since the carrier sheet 4 is not cut after the adhesive sheet 21 and the optical film 1 are cut, the laminate can be stably transported by a roll-to-roll process.

As the material constituting the carrier sheet 4, a plastic film is preferable, similarly to the protective sheet 41. Preferably, the slide 4 has a small dimensional change under the conveying tension during roll-to-roll conveyance. In addition, when the cutting means 131 and 132 cuts (half-cuts) the slide sheet 4 so as to reach the front surface of the slide sheet 4 (the interface between the slide sheet 4 and the protective sheet 41), it is necessary to prevent the cutting blade from reaching the back surface of the slide sheet 4. Therefore, the thickness of the carrier sheet 4 is preferably 10 μm or more, and more preferably 20 μm or more.

Preferably, an adhesive layer (not shown) for fixing the protective sheet 41 is provided on the surface of the carrier sheet 4. As the carrier sheet 4, a self-adhesive film in which an adhesive layer is integrally formed on the surface of a base film may be used. It is preferable to suppress peeling at the interface between the carrier sheet 4 and the protective sheet 41 when peeling from the surface of the adhesive sheet 21 and removing the protective sheet 40. It is preferable that peeling at the interface between the protective sheet 41 and the adhesive sheet 21 is suppressed when the protective sheet 41 is peeled from the carrier sheet 4. Therefore, it is preferable that the adhesive force between the back surface of the protective sheet 41 (heavy release sheet) and the carrier sheet 4 is larger than the adhesive force between the adhesive sheet 21 and the protective sheet 40 (light release sheet) and smaller than the adhesive force between the adhesive sheet 21 and the protective sheet 41.

The laminated adhesive sheet 2 wound out from the winding-out roller 102 and the carrier sheet 4 wound out from the winding-out roller 104 are bonded by the pinch roller 141 to form a laminated body 151 (fig. 3A). The carrier sheet 4 and the laminated body 151 in which the adhesive sheet 2 is laminated move to the downstream side in the conveying direction (y direction) and reach the first cutting unit 131.

At the first cutting unit 131, cutting (half-cutting) is performed from the side of the laminated adhesive sheet 2 (the side of the light peeling sheet 40) to a depth reaching the surface of the carrier sheet 4. By cutting by the first cutting means, cutting lines 31a and 31B are formed in the entire thickness direction on the protective sheet 40, the adhesive sheet 21, and the protective sheet 41 constituting the laminated adhesive sheet 2 (fig. 3B). A cut may also be made in the carrier sheet 4 to a depth that does not reach the back of the carrier sheet 4. In the half-cutting, the slide sheet 4 is cut so that at least a part thereof in the thickness direction is not cut. The depth of the cut formed in the carrier sheet 4 at the time of half-cutting is preferably 1/2 or less of the thickness of the carrier sheet, and more preferably 1/3 or less of the thickness of the carrier sheet. The method of cutting by the first cutting unit is not particularly limited as long as the

protective sheets

40 and 41 and the adhesive sheet 21 constituting the laminated adhesive sheet 2 can be cut, and an appropriate cutting method using a rotary cutter, a press-in blade (for example, thomson blade), a laser cutter, or the like can be employed.

The cutting by the first cutting unit 131 may be performed while the stacked body 151 is conveyed, or may be performed in a state where the conveyance of the stacked body is stopped. For example, when a cutting line extending in the width direction is to be formed, the laminate is preferably cut after the conveyance of the laminate is stopped.

Fig. 4 is a plan view of the laminate before and after cutting by the first cutting means. The laminated adhesive sheet 2 is cut by the first cutting unit 131 with respect to the laminated body 151 conveyed from the pinch roller 141 side in the y direction, and cut

lines

31a and 31b extending in the y direction are formed. The cutting lines 31a and 31b adjacent to each other are arranged in pairs.

The laminate 152 on which the cutting lines are formed is conveyed to the pinch roller 142, and the portion of the region 31 surrounded by the pair of cutting

lines

31a and 31b of the laminated adhesive sheet 2 is peeled from the receiving sheet 4 as a strip-shaped cut piece 161 extending in the longitudinal direction (conveying direction). At the end in the width direction, the region 37 between the cut line 31b (or 31 a) and the end face of the laminated adhesive sheet 2 may be peeled as a cut piece from the carrier sheet. The strip-shaped cut piece 161 peeled from the laminate 152 is wound and collected by a winding roller 192. In the laminated body 153 from which the cut pieces have been removed, a groove-like void 310 (fig. 3C) extending in the transport direction is formed.

Fig. 4 shows a configuration in which the cutting lines are provided in parallel so as to extend in the transport direction, and the strip-shaped region 31 surrounded by the two

cutting lines

31a and 31b is peeled and removed from the laminate as the cut piece 161, but the cutting lines are not necessarily parallel to the transport direction. The cutting line may extend in an oblique direction or in a width direction. The cutting line does not need to be linear in a plan view, and may be a curved line. The cut lines may be formed in a lattice shape. In order to continuously peel and remove the region surrounded by the cutting lines from the laminate as the cut pieces 161, the cutting lines are preferably formed so that the region surrounded by the cutting lines is continuous in the conveying direction.

The laminate 153 from which the cut pieces have been removed is conveyed to a pinch roller 144, and the light release sheet 40 temporarily bonded to the pressure-sensitive adhesive sheet 21 is peeled (fig. 3D). The light release sheet 40 peeled and removed from the laminate 153 is wound and collected by a winding roller 193. In the embodiment of fig. 2, after the cut piece 161 of the adhesive sheet is peeled off by the pinch roller 142, the light release sheet 40 is peeled off by the other pinch roller 144. In this way, by sequentially peeling the cut piece and the light-weight peel piece from the laminate, the peeling tension and the conveyance tension can be stabilized. The cut pieces and the light release pieces may be simultaneously peeled and removed from the laminated body.

The laminate 154 from which the cut pieces and the light release sheet have been removed is conveyed to a pinch roller 143, and the optical film 1 wound off from the wind-off roller 101 is laminated on the adhesive sheet 21 to form a laminate 155 (fig. 3E). The optical film 1 is bonded so as to cover the entire surface of the pressure-sensitive adhesive sheet 21 attached to the carrier sheet 4. At this time, the optical film 1 is also provided on the space 310 formed by removing the cut piece.

As described above, the adhesive sheet is cut by the first cutting unit, and the optical film 1 is bonded to the adhesive sheet 21 from which the cut pieces have been removed by a roll-to-roll process, thereby obtaining the vertically long laminate 155. The adhesive-attached optical film having a non-adhesive region is formed by cutting out individual pieces from the mother substrate using the vertically long laminated body 155 as a mother substrate. In the optical film 51 with adhesive cut into individual pieces, the portion of the mother substrate with the void 310 becomes the non-bonded region 2x.

The stacked body 155 moves to the downstream side in the transport direction, and reaches the second cutting unit 132, thereby forming a cut line in the stacked body (fig. 3F). Fig. 5 is a plan view of the laminate before and after cutting by the second cutting means. At the second cutting unit 132, a cutting line 32a extending in the conveying direction is formed ₁ 、32a ₂ And a cutting line 32a extending in the width direction (x direction) ₃ 、32a ₄ . The cutting method of the second cutting unit 132 is not particularly limited, and an appropriate cutting method can be adopted as in the cutting of the first cutting unit. The cutting by the second cutting unit 132 may be performed while conveying the stacked body 155, or may be performed in a state where the conveyance of the stacked body is stopped. Preferably, a cutting line 32a extending in the width direction is formed ₃ 、32a ₄ In this case, the laminate is cut after the conveyance is stopped.

At the second cutting unit 132, the laminate 155 is cut from the optical film 1 side. The adhesive sheet 21 is cut so as to reach the surface of the carrier sheet 4 in the region where the adhesive sheet 21 is provided, and a cutting line 32a is formed in the optical film 1, the adhesive sheet 21, and the protective sheet 41 over the entire thickness direction ₂ 、32a ₃ 、32a ₄ . A cut may also be made in the slide 4 to a depth short of the back side of the slide 4.

In the region 310 where the adhesive sheet 21 is not provided, the optical film 1 is cut to form a cut line 32a ₁ . At this time, the cutting line 32a ₁ The cutting line 32a may be provided so as to cut the entire optical film 1 in the thickness direction thereof ₁ It is not necessary to reach the slide 4. As shown in fig. 3F, the slide 4 may be cut so as to reach the surface of the slide 4, thereby forming a notch in the slide 4.

The optical film 1 is cut by the second cutting means into a plurality of cutting lines 32a extending in the y direction ₁ 、32a ₂ And a cutting line 32a extending in the x direction ₃ 、32a ₄ A rectangle is formed by enclosing. Cutting line 32a ₁ With the edge 1a of the individual optical film 51 having the adhesive ₁ And correspondingly. Cutting line 32a ₂ And edge 1a ₂ Correspondingly, the cutting line 32a ₃ And edge 1a ₃ Correspondingly, the cutting line 32a ₄ And edge 1a ₄ And (4) correspondingly.

As shown in fig. 3F, a gap is present between the wall surface of the adhesive sheet 21 formed by the cut line 31b generated by the first cutting unit and the cut line 32a formed in the region 310. When the cutting lines are formed so that the regions surrounded by the cutting lines overlap the regions 310 where the adhesive sheet 21 is not provided, the adhesive-attached optical film cut into individual pieces has non-adhesive regions where no adhesive sheet is provided on the main surface of the optical film.

In the present embodiment, by cutting by the second cutting means, a cut line is formed in the region 310 where the adhesive sheet 21 is not provided, and the cut line can be obtained along the edge 1a of the optical film ₁ The adhesive-attached optical film having a non-adhesive region at the periphery is formed. By aligning the cutting line 31b produced by the first cutting unit and the cutting line 32a produced by the second cutting unit ₁ The positional relationship between the non-adhesive regions 2x is adjusted to arbitrarily set the width W of the non-adhesive region ₁ 。

As shown in fig. 5, the optical film 1 is cut into a rectangular shape surrounded by the cutting lines by the second cutting unit 132. It is difficult to feed a film or an adhesive sheet surrounded by a cut line in a roll-to-roll manner as a single body. In the laminate 156 of the present embodiment, the optical film 1, the adhesive sheet 21, and the protective sheet 41 are cut, but the carrier sheet 4 is not cut. The protective sheet 41, the adhesive sheet 21, and the optical film 1 attached to the carrier sheet are also integrated, and the laminate 156 can be roll-to-roll fed downstream.

The laminate 156 cut by the second cutting unit 132 is conveyed to the pinch roller 146, and the optical film 1, the adhesive sheet 21, and the protective sheet 41 are cut by the cutting line 32a ₁ 、32a ₂ The portion of the enclosed area 32 is peeled away from the slide 4 as a cut-off piece 162. At the end in the width direction, the cutting line 32a may be cut ₁ Or cutting line 32a ₂ The

regions

38 and 39 between the optical film 1 and the end faces of the adhesive sheet 21 are peeled from the carrier sheet as cut pieces.

By removing the cut piece 162, the adhesive-attached optical film 51 having a rectangular shape surrounded by the cut line remains on the carrier sheet 4 (fig. 3G). The laminate 157 having the adhesive-attached optical films 51 attached to the carrier sheet 4 is wound into a roll by the winding roll 150. The adhesive-attached optical film 51 shown in fig. 1 can be obtained by peeling the adhesive sheet 21 and the optical film 1 together with the protective sheet 41 from the carrier sheet 4 of the laminate 157.

The laminate 156 provided with the cut line may be directly wound into a roll without peeling the cut piece 162 from the carrier sheet 4. The adhesive-attached optical film 51 surrounded by the cutting line may be peeled from the carrier sheet 4 by leaving the cut piece 162 on the carrier sheet 4 of the laminate 156.

In the process shown in fig. 2, the following steps are carried out as a series of consecutive steps: the laminated adhesive sheet 2 is bonded to the carrier sheet 4, the adhesive sheet is cut by the first cutting unit 131, the cut piece 161 and the light release sheet 40 are peeled and removed, the optical film 1 and the patterned adhesive sheet 21 are bonded, and the optical film and the adhesive sheet are cut by the second cutting unit 132. These steps are not necessarily performed continuously.

For example, the laminate 151 obtained by laminating the adhesive sheet 2 on the carrier sheet 4 may be wound in a roll shape, the laminate 151 may be wound out from the roll, and the adhesive sheet may be cut by the first cutting unit 131. The laminate 152 obtained by cutting the adhesive sheet by the first cutting means 131 or the laminate 153 obtained by peeling and removing the cut piece 161 may be wound up in a roll shape, and then the laminate may be taken out from the roll, and the light release sheet 40 may be peeled off to bond the optical film 1 to the patterned adhesive sheet 21. Since the pressure-sensitive adhesive sheet 21 is exposed during the period from when the light release sheet 40 is peeled to when the optical film 1 is bonded, it is preferable that the peeling of the light release sheet 40 and the bonding of the optical film 1 are performed by a series of roll-to-roll processes. The laminate 155 (mother substrate) obtained by bonding the optical film 1 to the adhesive sheet 21 may be temporarily wound up.

As described above, in the present embodiment, the adhesive sheet 21 is cut on the carrier sheet 4, and after the cut piece is peeled off and removed, the optical film 1 is bonded to the adhesive sheet 21, thereby obtaining a vertically long mother substrate (laminated body 155). The mother substrate has a region where the optical film 1 is bonded to the carrier sheet 4 via the adhesive sheet 21 and a region where the adhesive sheet is not provided on the carrier sheet 4 and a gap exists between the carrier sheet 4 and the optical film 1. After the optical film 1 is cut into a predetermined shape on the mother substrate, the cut piece is peeled and removed from the carrier sheet 4 together with the adhesive sheet 21, thereby obtaining an adhesive-attached optical film 51 having a region (non-adhesive region) where no adhesive sheet is provided.

(double-sided tape adhesive optical film)

The adhesive-attached optical film shown in the cross-sectional view of fig. 6 has a first adhesive sheet 21 on one main surface of the optical film 1 and a second adhesive sheet 22 on the other main surface of the optical film 1. In the double-sided adhesive optical film 52, the first adhesive sheet 21 is patterned in the same manner as the adhesive optical film 51 of fig. 1.

The first adhesive sheet 21 is not provided on the optical film 1 at the peripheral edge formed along the 1 side extending in the y direction, and the end face 21e of the adhesive sheet 21 is located inside the end face 1e of the optical film 1. The position of the end face 41e of the first protective sheet 41 provided on the adhesive sheet 21 coincides with the position of the end face 1e of the optical film 1.

The second adhesive sheet 22 is not patterned, and the position of the end face 1e of the optical film 1 and the position of the end face 22e of the second adhesive sheet 22 coincide in all the sides. The position of the end face 42e of the protective sheet 42 provided on the second psa sheet 22 also coincides with the position of the end face 1e of the optical film 1. The double-sided adhesive optical film 52 has a non-adhesive region 2x on the first main surface of the optical film 1, and has no non-adhesive region on the second main surface of the optical film 1.

The single double-sided adhesive optical film 52 shown in fig. 6 can be manufactured by the same method as the single-sided adhesive optical film 51 shown in fig. 1. In the production of the double-sided adhesive optical film 52, the following operations are required: the laminated adhesive sheet 2 is cut, and the cut piece and the light release sheet are removed to form a laminate 154 shown in fig. 3D, and then the optical film with an adhesive on one side is bonded to the adhesive sheet 21 of the laminate 154.

Fig. 7 is a cross-sectional view showing a state in which a long pressure-sensitive adhesive-attached optical film 50 is bonded to the pressure-sensitive adhesive sheet 21 of the laminate 154. The pressure-sensitive adhesive-attached optical film 50 has a pressure-sensitive adhesive sheet 22 on the optical film 1. The protective sheet 42 is provided on the pressure-sensitive adhesive sheet 22. The optical film 1 with the adhesive optical film 50 is bonded to the patterned adhesive sheet 21 by a roll-to-roll process, thereby forming a laminate 755 (mother substrate). Instead of bonding the optical film 50 with the pressure-sensitive adhesive, the optical film 1 may be bonded to the laminate 154, and the pressure-sensitive adhesive sheet 22 having the protective sheet 42 attached to one surface thereof may be bonded to the optical film, thereby forming a laminate 755.

The stacked body 755 illustrated in fig. 7 is cut from the protective sheet 42 side by the second cutting means 132. At the second cutting unit 132, in addition to the optical film 1 being cut, the adhesive sheet 22 and the protective sheet 42 provided on the optical film 1 are also cut. Otherwise, the cutting operation by the second cutting unit 132 in the formation of the optical film with a single-sided adhesive is the same as that described above. In the area where the pressure-sensitive adhesive sheet 21 is provided, half-cutting is performed at a depth reaching the surface of the carrier sheet 4, and a cutting line 732a is formed in the entire thickness direction of the protective sheet 42, the pressure-sensitive adhesive sheet 22, the optical film 1, the pressure-sensitive adhesive sheet 21, and the protective sheet 41 ₂ . In the region 310 where the adhesive sheet 21 is not provided, the protective sheet 42, the adhesive sheet 22, and the optical film 1 are cut to form a cutCut line 732a ₁ . At the cutting line 732a, too ₁ The half-cut is also performed so as to reach the surface of the carrier sheet 4.

The pressure-sensitive adhesive sheet 21, the optical film 1, the pressure-sensitive adhesive sheet 22, and the protective sheet 42 are peeled from the carrier sheet 4 of the cut laminate together with the protective sheet 41, whereby a single double-sided pressure-sensitive adhesive optical film 52 shown in fig. 6 can be obtained.

(use of optical film with adhesive)

The adhesive-attached

optical films

51 and 52 in which the patterned adhesive sheet 21 is provided on the optical film 1 are preferably used for forming an image display device. By positioning the end face 21e of the adhesive sheet 21 inside the end face 1e of the optical film 1, contamination, shortage of adhesive, and the like due to the adhesive overflowing from the end face can be prevented. In addition, since the region 2x where the adhesive sheet 21 is not provided is present on the main surface of the optical film 1, physical interference between the adhesive sheet and the constituent members of the image display device can be prevented, and the space in the device can be effectively used.

Fig. 8 is a sectional view of an image display device 801 manufactured using the double-sided adhesive optical film 52. In the image display device 801, the optical film 1 is disposed on the image display unit 60, and the cover glass 71 with a touch sensor is provided on the visual perception side of the optical film 1. The optical film 1 and the image display unit 60 are bonded together via the second adhesive sheet 22, and the optical film 1 and the cover glass 71 are bonded together via the first adhesive sheet 21. The image display unit 60 is, for example, a liquid crystal unit, an organic EL (OLED), or a micro LED. A transparent resin plate made of a transparent resin material such as acrylic may be used instead of the cover glass 71.

A flexible printed wiring board (FPC) 91 as an electrical connection member is connected to a touch sensor (not shown) provided on a surface of the cover glass 71 facing the optical film 1 in the vicinity of an end portion of the cover glass 71. The FPC91 is bent so as to wrap around the rear surface side of the image display unit 60.

In the image display device 801, the FPC91 is disposed along the side 1a of the optical film 1 ₁ The space of the extended non-bonded area 2x,accordingly, the contact 7a between the touch sensor and the FPC91 can be provided on the end surface 1e of the optical film 1 or inside the end surface 1 e. By providing the non-adhesive region 2x in the optical film 1 and disposing an FPC or the like in the space portion of the optical film 1 in this manner, the peripheral edge of the screen and the space in the vicinity of the peripheral edge are effectively utilized, and thereby the frame of the image display device can be narrowed.

In the non-adhesive region 2x, not only the FPC but also various components of the image display device can be arranged. Examples of the member disposed in the non-adhesive region include a cover glass, a touch sensor, a housing, a conductive material, and a resin material. Fig. 8 shows a pattern of patterning the adhesive sheet 21 obtained by bonding the optical film 1 and the cover glass 71, but the adhesive sheet may be patterned on the image display unit 60 side.

(construction example of optical film with adhesive)

In FIGS. 1 and 6, the optical film is shown along 1 side 1a of a rectangular optical film ₁ The peripheral edge is formed to have the non-bonded region 2x, but the position, shape, size, and the like of the non-bonded region 2x are not particularly limited. An optical film with an adhesive can be used in which the position, shape, size, and the like of the non-bonded region are adjusted in accordance with the shape, size, and the like of a member to avoid physical interference with the adhesive.

For example, the non-adhesive region may be provided along at least two sides of the rectangle, or may be provided along the long side of the rectangle. In the non-adhesive region, the end face of the adhesive sheet need not extend parallel to the edge of the optical film. For example, the non-bonded region may have a portion whose width decreases from the end of the side of the rectangle (the vertex of the rectangle) toward the center of the side. The non-bonded regions need not be provided along the entire length of the edges. For example, the non-bonded region may be provided only at a part of the side of the rectangle or at the vertex of the rectangle. The non-adhesive region may be provided at the center in the plane of the optical film.

By adjusting the formation position of the cut line formed on the adhesive sheet by the first cutting means before the adhesive sheet and the optical film are bonded to each other, an adhesive sheet having an arbitrary pattern shape can be produced. Further, by adjusting the position of the cutting line when cutting the mother substrate to which the adhesive sheet and the optical film are bonded by the second cutting means, the position, shape, size, and the like of the non-adhesive region can be arbitrarily adjusted.

The adhesive-attached optical film 56 shown in the plan view of fig. 9 (a) is along 1 side 1a ₁ The periphery is formed with a non-bonded area 2x ₁ At another edge 1a along ₂ The periphery is formed with a non-adhesive region 2x ₂ . Fig. 9 (B) is a cross-sectional view of the adhesive-equipped optical film 56 taken along line B1-B2. A non-bonded region 2x ₁ Width W of ₁ And another non-bonded region 2x ₂ Width W of ₂ May be the same or different. By adjusting the forming position of the cutting line of the second cutting unit, the adhesive-attached optical film having the non-adhesive region along both edges can be obtained.

For example, as shown in fig. 10, by providing 1 cutting line 32a extending in the y direction in the region 310 where the adhesive sheet 21 is not provided ₁ An adhesive-attached optical film having non-bonded regions along both edges can be obtained. As shown in fig. 11, two cutting lines 32a may be provided in the region 310 ₁ 、32a ₂ . In either mode, the width W of the non-bonded region can be adjusted by adjusting the position of the cut line in the region 310 ₁ 、W ₂ Adjusted to the desired value.

In the adhesive-attached optical film 57 shown in the plan view of fig. 12 (a), the side 1a is located along the edge ₁ 、1a ₂ The peripheral region is formed without non-adhesive region, and the non-peripheral region has a side 1a ₁ 、1a ₂ Parallel extending non-bonded regions 2x ₃ . By adjusting the forming position of the cutting line of the second cutting unit, an adhesive-attached optical film having a non-adhesive region at the center in the plane can be formed.

For example, as shown in fig. 13, the following operations may be performed: 1 cutting line 3 extending in the y direction is formed in the region where the adhesive sheet 21 is provided2a ₁ The optical film and the adhesive sheet are cut at two cutting lines 32a ₁ The portion of the enclosed area is cut into individual pieces. As shown in fig. 14, two cutting lines 32a may be provided in the region where the adhesive sheet 21 is provided ₁ 、32a ₂ . In either mode, the region 310 is a non-bonded region 2x in the cut adhesive-attached optical film 57 ₃ 。

As described in the above example, by adjusting the formation position of the cutting line formed on the long mother substrate (the laminate 156), an adhesive-attached optical film having a non-adhesive region at an arbitrary position can be obtained. Further, by adjusting the direction in which the cutting lines of the first cutting unit are formed, the interval between the pair of cutting

lines

31a and 31b, and the like, it is possible to obtain an adhesive-attached optical film having non-adhesive regions of various shapes.

In the formation of the double-sided adhesive optical film, the non-adhesive region having various shapes can be formed on the first main surface of the optical film 1 by adjusting the formation positions of the cutting lines of the first cutting means and the second cutting means. The double-sided adhesive optical film may have a non-adhesive region on both of the first main surface and the second main surface of the optical film. For example, the double-sided adhesive optical film 59 shown in the cross-sectional view of fig. 15 has a non-adhesive region 2x on the first main surface in the peripheral region formed along 1 side of the optical film 1 ₁₁ And a non-adhesive region 2x on the second main surface ₁₂ 。

A double-sided adhesive optical film having non-adhesive regions on both sides of the optical film can be produced using a mother substrate to which a patterned first adhesive sheet 21 is bonded to a first main surface of the optical film 1 and a patterned second adhesive sheet 22 is bonded to a second main surface of the optical film 1, as in a laminate 955 shown in fig. 16. The laminate 955 having the patterned adhesive sheets on both sides can be formed by: the laminate 154 shown in fig. 3D is bonded to the first main surface of the optical film 1, and the laminate 254 including the patterned adhesive sheet 22 is bonded to the second main surface of the optical film 1. Similarly to the production of the laminate 154, the laminate 254 having the protective sheet 42 provided on the patterned adhesive sheet 22 can be produced by cutting the adhesive sheet 22 and the protective sheet 42 on the carrier sheet 44 to form a pattern.

After the laminated body 955 is half-cut from the side of the carrier sheet 44 to a depth reaching the carrier sheet 4, the

carrier sheets

4 and 44 on both sides are peeled off, thereby obtaining a single double-sided adhesive optical film 59 shown in fig. 15. The stacked body 955 may be cut from the side of the carrier sheet 4 so as to reach the carrier sheet 44. The carrier sheet may be provided on only any one side. For example, the carrier sheet 44 may be peeled off from the laminated body 955 before cutting, and half-cut may be performed so as to reach the carrier sheet 4 from the protective sheet 42 side.

In this embodiment, the patterning of the first adhesive sheet 21 on the carrier sheet 4 and the patterning of the second adhesive sheet 22 on the carrier sheet 44 are performed independently of each other. Therefore, the shape, size, and position of the cut-and-removed area 310 of the first adhesive sheet 21 and the shape, size, and position of the cut-and-removed area 320 of the second adhesive sheet 22 can be set individually.

The optical film with double-sided adhesive may have a non-bonded region 2x on the first main surface thereof ₁₁ And a non-bonded area 2x on the second main surface ₁₂ Are different in shape, size and location. For example, as shown in fig. 15, the non-bonded region 2x on the first main surface may be made ₁₁ Width greater than non-bonded area 2x on second main surface ₁₂ Is measured. It is also possible to make a double-sided tape adhesive optical film having non-adhesive regions at different positions on the first major surface and the second major surface.

The shape of the adhesive-attached optical film cut by the second cutting means is not limited to a rectangular shape, and can be appropriately set in accordance with the shape and size of the screen of the image display device. For example, the planar shape of the optical film may be a polygon such as a triangle, a rhombus, a parallelogram, a trapezoid, a pentagon, or a hexagon, a circle, an ellipse, or a star.

(combination of Carrier substrate and protective sheet)

In the above embodiment, the laminated body in which the protective sheet (heavy release sheet) 41, the adhesive sheet 21, and the protective sheet 40 (light release sheet) are laminated on the carrier sheet 4 as the carrier base material is cut to pattern the adhesive sheet 21. In the embodiment using the carrier sheet, the mother substrate is cut by the second cutting means, and then the carrier sheet 4 and the protective sheet 41 are peeled off from each other at the interface therebetween, thereby obtaining a single pressure-sensitive adhesive optical film having the protective sheet 41 on the pressure-sensitive adhesive sheet 21.

Instead of the carrier sheet 4, an optical film with an adhesive may be produced by using the protective sheet 41 attached to the adhesive sheet 21 as a carrier substrate. In the cutting by the first cutting unit and the second cutting unit, the protective sheet is not cut as long as the cutting is performed at a depth reaching the surface of the protective sheet (half-cutting), and therefore the protective sheet can be used as the carrier base material.

Fig. 17 is a schematic process diagram showing an example of a manufacturing process for manufacturing a single adhesive-equipped optical film having a non-adhesive region by using a protective sheet 41 attached to an adhesive sheet 21 as a carrier base material. Fig. 18A to 18F are sectional views showing the structure of the laminate at reference numerals a to F in fig. 17. Here, an example of manufacturing the optical film with an adhesive shown in fig. 1 is described, but the present embodiment can also be applied to manufacturing the double-sided adhesive optical film described above or an optical film with an adhesive having a non-adhesive region in various regions.

In fig. 17, a roll of the laminated adhesive sheet 2 is set on a take-up roll 602. The laminated adhesive sheet 2 has

protective sheets

40 and 41 on both sides of the adhesive sheet 21. The protective sheet 41 is a heavy release sheet having higher adhesiveness to the adhesive sheet 21 than the protective sheet 40 is to the adhesive sheet 21, and the protective sheet 41 also functions as a carrier substrate when cutting and transporting the adhesive sheet and the optical film.

The laminated adhesive sheet 2 (see fig. 18A) wound out from the winding-out roller 602 is moved downstream in the transport direction by the pinch roller 641 and reaches the first cutting unit 631. In the first cutting unit 631, cutting (half cutting) is performed at a depth reaching the surface of the heavy peeling sheet 41 as the carrier base material from the light peeling sheet 40 side. By cutting the pressure-sensitive adhesive sheet so as to reach the surface of the heavy release sheet 41, cutting lines 531a and 531B are formed in the entire thickness direction of the light release sheet 40 and the pressure-sensitive adhesive sheet 21 constituting the laminated pressure-sensitive adhesive sheet 2 (fig. 18B). A notch may be formed in the heavy release sheet 41 as a carrier base material to a depth not reaching the back surface of the heavy release sheet 41. The cutting by the first cutting unit 631 is the same as the cutting by the first cutting unit in the case where the carrier sheet 4 is used as a carrier base material, except that the

cutting lines

531a and 531b are formed so as not to reach the back surface of the heavy release sheet (see fig. 4).

The laminate 652 on which the cut line is formed is conveyed to a pinch roller 642, and the portion of the psa sheet 21 and the light release sheet 40 in the region 531 surrounded by the pair of

cut lines

531a and 531b is peeled as a cut section 661 from the heavy release sheet 41 as a carrier substrate. The cut piece 661 peeled from the laminate 652 is wound and collected by a winding roller 692 (fig. 18C). After that, the light release sheet 40 temporarily adhered to the adhesive sheet 21 is peeled off (fig. 18D) and wound and recovered by a winding roller 693. The cut piece and the light release piece may be simultaneously peeled and removed from the laminate.

The laminate 654 from which the cut pieces and the light peeling pieces have been removed is conveyed to a pinch roller 643, and the optical film 1 wound out from the wind-up roller 601 is laminated on the psa sheet 21 to form a laminate 655 (fig. 18E). In this manner, the pressure-sensitive adhesive sheet is cut in half by the first cutting unit using the heavy release sheet 41 as the carrier base, and the optical film 1 is bonded to the pressure-sensitive adhesive sheet from which the cut piece has been removed by a roll-to-roll process, thereby obtaining the vertically long laminate 655.

The stacked body 655 moves to the downstream side in the transport direction and is cut by the second cutting unit 632 (fig. 18F). In the region where the adhesive sheet 21 is provided, half-cutting is performed so as to reach the surface of the heavy release sheet 41 as a carrier substrate, and cut lines 532a are formed in the entire thickness direction of the optical film 1 and the adhesive sheet 21 ₂ 、532a ₃ 、532a ₄ . The heavy peeling sheet 41 may be provided with a notch at a depth not reaching the back surface of the heavy peeling sheet 41. In the region 310 where the adhesive sheet 21 is not provided, the optical film 1 is cut to form a cutting line 532a ₁ . At this time, the cutting line532a ₁ The optical thin film 1 may be provided so as to be cut entirely in the thickness direction. The heavy release sheet 41 may be cut so as to reach the surface of the heavy release sheet 41, and a notch may be formed in the heavy release sheet 41.

After forming the cutting line 532a ₁ 、532a ₂ 、532a ₃ 、532a ₄ The cutting by the second cutting unit 632 is the same as the cutting by the second cutting unit in the case where the carrier sheet 4 is used as the carrier base material, except that the cutting is performed so as not to reach the back surface of the heavy peeling sheet 41 (see fig. 5). After the optical film 1 and the adhesive sheet 21 are cut by the cutting by the second cutting means, the optical film 1 is fixed to the heavy release sheet 41 as the carrier substrate via the adhesive sheet 21 in the laminate 656, and the heavy release sheet 41 is not cut. Therefore, the pressure-sensitive adhesive sheet 21 that is in contact with and laminated on the heavy release sheet 41 as the carrier substrate and the optical film 1 bonded to the pressure-sensitive adhesive sheet 21 are also integrated, and the laminated body 656 can be roll-to-roll transported downstream.

The stacked body 656 cut by the second cutting unit 632 is conveyed to the pinch roller 646, and wound into a roll by the winding roller 694 to be collected. The laminate thus obtained has a laminate of the optical film 1 and the adhesive sheet 21 cut into a rectangular shape on the protective sheet 41 that is long. By peeling this laminate at the interface between the protective sheet 41 and the pressure-sensitive adhesive sheet 21, the peeled laminate of the optical film 1 and the pressure-sensitive adhesive sheet 21 can be used as a single pressure-sensitive adhesive-attached optical film.

A separate protective sheet may be bonded to the pressure-sensitive adhesive sheet with the pressure-sensitive adhesive optical film after being peeled from the protective sheet 41. When the adhesive-attached optical film is peeled off from the protective sheet 41 immediately before being bonded to the image display unit, the front surface transparent member, or the like, it is not necessary to provide a separate protective sheet on the adhesive sheet 21.

In the method of using the protective sheet 41 attached to the psa sheet 21 as a carrier substrate, the adhesive-attached optical film having non-adhesive regions of various shapes can be produced by adjusting the positions of the cut lines formed by the first cutting means and the second cutting means. Further, a double-sided pressure-sensitive adhesive optical film can be produced by using the protective sheet 41 as a carrier base material. As shown in fig. 15, in the case of manufacturing a double-sided pressure-sensitive adhesive optical film having non-adhesive regions on both sides of the optical film 1, patterning of the first pressure-sensitive adhesive sheet 21 and the protective sheet 41 may be performed on the carrier sheet 4, and patterning of the second pressure-sensitive adhesive sheet 22 may be performed using the protective sheet 42 as a carrier substrate.

In each of the above embodiments, the carrier base material is half-cut so as not to be cut when the cutting is performed by the second cutting means, but the carrier base material may be fully cut by cutting the optical film 1 and the adhesive sheet 21 together at the second cutting means. The fully cut laminate may be placed on a suitable conveying member such as a belt conveyor and conveyed to the downstream side, and the adhesive-attached optical film cut into individual pieces may be collected.

At the second cutting unit, full cutting and half cutting may also be used in combination. For example, the cutting line 532a extending in the conveying direction is formed by full cutting ₁ 、532a ₂ A cutting line 532a extending in the width direction is formed by half cutting ₃ 、532a ₄ . By half-cutting in the width direction, the protective sheet 41 serving as a carrier base material maintains continuity in the transport direction, and therefore, the stacked body can be transported by a roll-to-roll process. By forming the cutting lines by full cutting in the transport direction, a long laminate corresponding to the dimension in the width direction of the adhesive-attached optical film as a final product can be obtained. In this vertically long laminate, a plurality of individual adhesive-carrying optical films are bonded to the protective sheet 41 serving as a carrier base material along the conveyance direction. The laminate can also be applied to bonding to a workpiece such as an image display unit by a roll-to-roll method (for example, japanese patent No. 4503689).

The cutting by the second cutting means (cutting the optical film into individual sheets) may be performed in a plurality of steps. For example, after forming a cutting line extending in a direction parallel to the conveyance direction, a cutting line extending in the width direction may be formed, and the adhesive-attached optical film may be cut into individual pieces. The cutting lines extending in the conveying direction may be formed by full cutting and divided into a plurality of strip-shaped pieces, and the cutting lines extending in the width direction may be formed on the divided mother substrates. The mother substrate on which the cutting lines extending in parallel to the transport direction are formed may be temporarily wound, and then the cutting lines extending in the width direction may be formed in a different step.

Claims

1. A method for producing an adhesive-equipped optical film having a first adhesive sheet on a first main surface of an optical film having a first main surface and a second main surface, and having a non-adhesive region where the first adhesive sheet is not provided in a part on the first main surface of the optical film, wherein,

in the method for manufacturing an optical film with an adhesive,

a laminated adhesive sheet having a protective sheet and an unpatterned first adhesive sheet on a carrier sheet is prepared,

the following laminate was produced by cutting the first adhesive sheet on the carrier sheet, and peeling off and removing a portion of the first adhesive sheet in a region surrounded by the cutting line from the carrier sheet: a protective sheet is bonded to a vertically long carrier base material, a first pressure-sensitive adhesive sheet is provided on the protective sheet, the first pressure-sensitive adhesive sheet is patterned into a region provided with an adhesive and a region not provided with an adhesive,

a long mother substrate having a protective sheet, an optical film, and a patterned first adhesive sheet on a carrier base material is manufactured by bonding the laminate and the optical film by a roll-to-roll process such that the first adhesive sheet of the laminate and the first main surface of the optical film face each other,

cutting the optical film and the first adhesive sheet from the mother substrate into individual sheets of a predetermined shape including a region where the first adhesive sheet is not provided.

2. The method of manufacturing an adhesive-equipped optical film according to claim 1,

a light release sheet is temporarily adhered to the first adhesive sheet before the patterning,

cutting the light release sheet and the first adhesive sheet on the carrier sheet,

the laminate having the protective sheet and the patterned first adhesive sheet on the carrier base material is produced by removing the light release sheet and a portion of the first adhesive sheet in the region surrounded by the cutting line from the carrier sheet.

3. The method of manufacturing an adhesive-attached optical film according to claim 2,

the peel force of the interface between the protective sheet and the first adhesive sheet is greater than the peel force of the interface between the first adhesive sheet and the light-peeling sheet.

4. The method of manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

the peel force of the interface between the protective sheet and the first adhesive sheet is greater than the peel force of the interface between the protective sheet and the carrier substrate.

5. The method for manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

the first adhesive sheet of the laminate is patterned into a strip-like shape extending in the longitudinal direction in a region where the adhesive is not provided.

6. The method for manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

a non-adhesive region is provided at the peripheral edge of each of the optical films by forming a cut line in a portion of the optical film which is laminated on a region of the mother substrate where the first adhesive sheet is not provided.

7. The method for manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

disposing a second adhesive sheet on the second major surface of the optical film before cutting the optical film and the first adhesive sheet into individual pieces,

and cutting the optical film, the first adhesive sheet and the second adhesive sheet into individual sheets of a predetermined shape surrounded by a cutting line.

8. The method of manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

cutting the optical film from the mother substrate into a rectangle.

9. The method for manufacturing an adhesive-attached optical film according to any one of claims 1 to 3,

the optical film includes a polarizing plate.