JP2005290250A - Method for producing functional laminate film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a functional laminate film, which has a small economic loss by occurrence of defective products and with which a production process is rationalized. <P>SOLUTION: The method for producing a functional laminate film comprises a first process for preparing a functional film laminate (D) obtained by laminating adhesive layers (B) and separation layers (C) in this order to both sides of a first functional film layer (A) composed of at least one functional film and a functional film laminate (G) obtained by laminating a protection film (F) to one side of a second functional film layer (E) composed of at least one function film and a second process for releasing and removing one separation layer (C) from the functional film laminate (D) to give the exposed adhesive layer (B) and attaching the adhesive layer to the other side of the second functional film (E) of the functional film laminate (G) to give a functional laminate film (H). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a functional composite film. More specifically, the present invention relates to a method for producing a functional composite film excellent in economy that can efficiently bond functional films such as antireflection, neon cut, near infrared cut, and electromagnetic wave cut.

  There is known a surface protective film in which an adhesive layer is provided on one surface of a base film, and a functional film is provided on the surface opposite to the surface on which the adhesive layer of the base film is provided (Patent Document 1). This surface protective film is used with its adhesive layer adhered to the surface of a surface-polished metal product or the surface of a synthetic resin plate such as an acrylic resin plate. As a result, the surface of the metal product or the resin plate is protected.

  Such a functional composite film is produced, for example, by a method including the following steps <1> to <3>.

  <1> Functional film laminate (K) in which a protective film (F) is provided on one side of the functional film (A), and an adhesive layer (B) and a separation layer (C) are provided on the other side in this order. The process which peels and removes a protective film (F) from.

  <2> Functional film laminate (L) in which a protective film (F) is provided on one side of the functional film (E) and an adhesive layer (B) and a separation layer (C) are provided in this order on the other side A step of peeling and removing the separation layer (C).

  <3> The functional film (A) surface of the functional film laminate (K) exposed by peeling off the protective film (F) and the separation layer (C) exposed by peeling off. The process of bonding the adhesion layer (B) of a functional film laminated body (L), and obtaining a functional composite film (H).

  In the proposed method for producing a functional composite film, a functional film laminate (K) and a functional film laminate (L) used for bonding are both laminated with an adhesive layer (B).

However, when this pressure-sensitive adhesive layer (B) is laminated on the functional film (A) or the functional film (E), the pressure-sensitive adhesive layer (B) cannot be applied uniformly, or the pressure-sensitive adhesive layer (B) has a foreign object. Defective products are generated at a rate that cannot be ignored due to adhesion. Moreover, when manufacturing a functional composite film using the functional film laminated body (K) and functional film laminated body (L) of the sheet | seat cut | disconnected in the sheet form, when cutting a laminated body into a sheet form In addition, defective products are generated due to defective cutting due to the presence of the pressure-sensitive adhesive layer (B). When the functional film used for the production of the functional composite film is expensive, the economic loss due to the generation of defective products becomes enormous.
JP-A-9-169964 (Claims)

  The subject of this invention is providing the manufacturing method of the functional composite film which can eliminate the said problem, there are few economical losses by generation | occurrence | production of inferior goods, and a manufacturing process can be rationalized.

  As a result of repeated researches to solve the above problems, the present inventor has found that the method can be solved if it is a method for producing a functional composite film using a laminate having a specific laminate structure, and has reached the present invention.

  The present invention for solving the above problems is described below.

[1] (1) Functional film obtained by laminating an adhesive layer (B) and a separation layer (C) in this order on both surfaces of a first functional film layer (A) comprising at least one functional film. A laminate (D) and a functional film laminate (G) obtained by laminating a protective film (F) on one surface of a second functional film layer (E) made of at least one functional film are prepared. First step,
(2) From the functional film laminate (D), the pressure-sensitive adhesive layer (B) exposed by peeling and removing one separation layer (C) is removed from the second functional film (G). E) a second step of obtaining the functional composite film (H) by sticking to the other surface;
A method for producing a functional composite film, comprising:

  [2] The method for producing a functional composite film according to [1], wherein the functional film laminate (D) and the functional film laminate (G) are single-wafer laminates cut into predetermined dimensions.

[3] A third step of preparing the functional composite film (H) according to [1] and an adherend (J);
4th process of sticking the adhesive layer (B) which peeled and removed the separation layer (C) from the functional composite film (H) on the surface of a to-be-adhered body (J),
The processing method of the functional composite film which has these.

  In the method for producing a functional composite film of the present invention, the pressure-sensitive adhesive layer is not laminated on one functional film to be bonded, so that there is little loss due to defective products of the functional film and the economic effect is great. In particular, when this functional film is expensive, its economic effect is high. Moreover, the separation process of the separation layer can be rationalized in the production process of the functional composite film. Furthermore, the quantity of the protective film used for manufacture can be rationalized.

  In addition, when the production of functional composite films and the production of functional films are performed in Japan and the adhesive layer is laminated on the functional film overseas, according to the present invention, the function of not laminating the adhesive layer Since the transportable film does not need to be transported overseas or imported from overseas, transportation costs can be reduced.

  Hereinafter, the present invention will be described in detail.

[Functional film]
The functional film in the present invention is a film having excellent properties in optical function, thermal function, mechanical function, physical function or chemical function.

  A film having such a function can be obtained by forming a film using the constituent polymer having the above function. Or it can obtain by adding the compounding agent which expresses said function in a polymer, and forming into a film.

  The polymer constituting the functional film is not particularly limited, but examples thereof include polyolefin resins such as vinyl chloride resin, polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, polyimide resins, norbornene, and urethane. Examples thereof include celluloses such as resins and TAC, and polycarbonate acrylic resins.

  The method for producing the functional film is not particularly limited, and examples thereof include an extrusion method such as a calendar method, a casting method, a T-die method, and an inflation method. The functional film may be formed by itself, or may be formed integrally with an adhesive layer or a protective film layer by a multilayer extrusion molding method.

  The thickness of the functional film is preferably 15 μm to 200 μm. If the thickness of the functional film is less than 15 μm, the production becomes difficult. On the other hand, if it exceeds 200 μm, the quality becomes excessive and disadvantageous economically.

  Examples of the film having excellent optical function include, for example, a polarizing film, an antiglare film, a highly transparent film, a light reflecting film, an ultraviolet blocking film, a neon cut film, an electromagnetic wave cut film, a near infrared cut film, and the like. Can do.

  Examples of the film having excellent thermal function include a heat-resistant deformable film and a heat-shrinkable film.

  Examples of the film having excellent mechanical functions include a high-rigidity film, a high-hardness film, a flexible film, and a scratch-proof film.

  Examples of the film having excellent physical functions include a gas barrier film, a porous film, a water-absorbing film, an antifouling film, a slippery film, and an antistatic film.

  Examples of the film having excellent chemical function include a chemical resistant film and a weather resistant film.

  In the method for producing a functional composite film of the present invention, the functional film layer (A) is a functional film laminate (D) in which an adhesive layer (B) and a separation layer (C) are provided in this order on both sides. Use. Moreover, a functional film layer (E) is used as a functional film laminated body (G) which laminated | stacked the protective film (F) on the single side | surface.

  For this reason, the functional film layer (E) which does not laminate | stack an adhesive layer has few generation | occurrence | production of inferior goods, when manufacturing a functional film laminated body (G) or cutting a laminated body into a sheet form. Therefore, among these functional films, LR films and AG films that are relatively low in price for the functional film layer (A), TAC films that are relatively high in price for the functional film layer (E), An electromagnetic wave cut film and a sputtered AR film can be advantageously applied.

[Adhesive layer]
In the present invention, for the production of a functional composite film, a functional film laminate (D) in which an adhesive layer (B) and a separation layer (C) are provided in this order on both sides of the functional film layer (A). ) Is used.

  One layer of this pressure-sensitive adhesive layer (B) functions to bond the functional film layer (A) and the functional film layer (E). The other layer of the pressure-sensitive adhesive layer (B) functions to bond the functional composite film (H) and the adherend (J).

  The constituent components of the pressure-sensitive adhesive layer are not particularly limited, and those usually used as pressure-sensitive adhesives can be used. As main components of these pressure-sensitive adhesives, for example, ethylene-vinyl acetate copolymer (EVA), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), ethylene-ethyl acrylate copolymer (EEA) , Ethylene-methyl methacrylate copolymer (EMMA), ethylene-α-olefin copolymer, styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer (SIS), and the like.

  The means for laminating the pressure-sensitive adhesive layer on the functional film is not particularly limited. For example, a method of applying an organic solvent solution of the pressure-sensitive adhesive composition on the functional film or extrusion lamination of the pressure-sensitive adhesive composition. Depending on the method used. Alternatively, a multilayer molding method using an adhesive and a functional polymer by a T-die method, an inflation method, or the like may be used.

  The thickness of the pressure-sensitive adhesive layer (B) is preferably 10 μm to 50 μm. When the thickness is less than 10 μm, it is economically advantageous, but it is not preferable because the film formation is difficult and the adhesive effect becomes dilute. On the other hand, if it exceeds 50 μm, the quality may be excessive, which may be disadvantageous economically.

[Separation layer]
In the present invention, for the production of a functional composite film, a functional film laminate (D) in which an adhesive layer (B) and a separation layer (C) are provided in this order on both sides of the functional film layer (A). ) Is used. This separation layer (C) functions as a protective film for the pressure-sensitive adhesive layer (B) of the functional film laminate (D). The constituent component of the separation layer can be selected from those usually used in consideration of separability from the pressure-sensitive adhesive layer.

  Examples of the polymer used for the separation layer (C) include olefin polymers such as high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and polypropylene (PP).

  The thickness of the separation layer (C) is preferably 25 μm to 75 μm. When the thickness is less than 25 μm, it is economically advantageous, but it is not preferable because the flatness of the adhesive coated surface becomes poor. On the other hand, if it exceeds 75 μm, the quality becomes excessive, which may be disadvantageous economically.

[Protective film]
In this invention, the laminated body which provided the protective film (F) on the single side | surface of a functional film layer (E) is used for manufacture of a functional composite film. This protective film (F) functions as a protective film for the functional film layer (E) up to the bonding step, and after bonding, the functional film layer (E) in the functional composite film (H). Functions as a protective film. Examples of the polymer used for the protective film (F) include olefin polymers such as high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and polypropylene (PP). Can do.

  The thickness of the protective film (F) is preferably 40 μm to 80 μm. If this thickness is less than 40 μm, the performance of protecting the functional film (E) becomes unsatisfactory. On the other hand, if the thickness exceeds 80 μm, the quality may be excessive, which may be disadvantageous economically.

[Layered product]
In the present invention, the functional film laminate (D) and the functional film laminate (G) used for the production of the functional composite film may be, for example, a laminate unwound from a roll. It is preferable that the laminate is a cut sheet (sheet-like). When the functional film laminate (D) is a roll (continuous state), if there is a defective portion in the middle of the roll of (D), even if the functional film laminate (G) is good (D ) And the functional composite film (H) must all be defective. However, when the functional film laminate (D) is a sheet, even if there is a defective sheet in (D), only the defective portion can be removed and bonded to the functional film (G). The occurrence of defective products can be minimized.

[Method for producing functional composite film]
In the present invention, the pressure-sensitive adhesive layer (B) exposed by peeling off the separation layer (C) from the functional film laminate (D) prepared in the first step is used as the functional film laminate in the second step. It sticks on the other surface of the 2nd functional film layer (E) of (G). For the separation and removal of the separation layer (C), a conventional separation method can be used. Moreover, the said bonding can use the bonding method currently implemented normally.

[Processing method of functional composite film]
In the present invention, as a processing method of the functional composite film, a third step of separating the separation layer (C) from the functional composite film (H), and a function exposed by peeling off the separation layer (C). A processing method having a fourth step of bonding the pressure-sensitive adhesive layer (B) of the adhesive composite film (H) and the adherend (J) can be given as a preferred example.

  The present invention will be further described with reference to the drawings.

  A schematic configuration of the functional composite film (H) of the present invention is shown in FIG. Moreover, schematic structure of the functional film laminated body (D) and functional film laminated body (G) used for manufacturing a functional composite film (H) is shown in FIG.2 and FIG.3.

  1-3, A is a functional film layer (A), B is an adhesive layer (B), C is a separation layer (C), D is a functional film laminate (D), E is a functional film layer (E) and F are protective films (F), G is a functional film laminate (G), and H is a functional composite film (H).

  The functional composite film (H) of FIG. 1 includes an adhesive layer (B) exposed by peeling and removing the separation layer (C) on one side (upper side) of the functional film laminate (D) shown in FIG. It can obtain by bonding together the surface (functional film layer (E) surface) of the side which does not provide the protective film (F) of the functional film laminated body (G) shown in FIG.

  FIG. 4 is a side view showing a schematic configuration in which the functional composite film (H) and the adherend (J) in the present invention are bonded together. The functional composite film (H) and the adherend (J) are bonded to each other by exfoliating and removing the separation layer (C) from the functional composite film (H) shown in FIG. The adhesive layer (B) of H) and the adherend (J) can be bonded together.

  5 and 6 are diagrams showing a schematic configuration of the functional film laminate (K) and the functional film laminate (L) of the prior art. 5 and 6, A is a functional film layer (A), B is an adhesive layer (B), C is a separation layer (C), E is a functional film layer (E), and F is a protective film (F). , K is a functional film laminate (K), and L is a functional film laminate (L). The functional film laminate (K) and the functional film laminate (L) both include an adhesive layer (B). In the prior art, the functional film layer (A) surface of the functional film laminate (K) exposed by peeling off the protective film (F) and the function exposed by peeling off the separation layer (C). A functional composite film (H) is obtained by laminating the adhesive layer (B) of the functional film laminate (L). In addition, the functional composite film obtained has the same layer structure as the functional composite film (H) of the present invention shown in FIG.

  In the above example, the case where two functional films are laminated has been described. However, the present invention is not limited thereto, and three or more functional films can be laminated in any number of layers. For example, the functional film layer (A) may be a laminate of two or more functional films via an adhesive layer such as a pressure-sensitive adhesive layer. The functional film layer (E) may be a laminate of two or more functional films without using an adhesive layer.

  EXAMPLES Next, the present invention will be described more specifically with reference to examples, but the present invention is not limited thereto.

[Example 1]
<First step>
On both sides of the functional film layer (A1: biaxially oriented polyester film, thickness 105 μm), an adhesive layer (B1: acrylate copolymer, thickness 20 μm), and further a separation layer (C1: biaxially oriented polyester film, thickness) The functional film laminated body (D1) which laminated | stacked 75 micrometers) was prepared.

  Moreover, the functional film laminated body (G1) which laminated | stacked the protective film (F1: polypropylene, thickness 40micrometer) on the single side | surface of a functional film layer (E1: biaxially-oriented polyester film, thickness 75micrometer) was prepared.

  Next, the functional film laminate (D1) and the functional film laminate (G1) were each cut to produce a plurality of sheets having dimensions of 1000 mm in the vertical direction and 1500 mm in the horizontal direction. As a result of evaluating the quality of the obtained sheet and removing defective products, to obtain 100 non-defective sheets, 111 functional film laminate (D1) sheets (10% defective product rate), functional film laminate (G1) The number of sheets was 100 (defective product rate 0%).

<Second step>
The separation layer (C1) on one side was peeled and removed from the functional film laminate (D1) sheet produced as described above, and the exposed adhesive layer (B1) and protective film (F1) for the functional film (E1) sheet. ) Were bonded together to obtain a functional composite film (H1) 100 sheets. The separation layer was peeled and removed by a method in which an operator peeled it by hand. In addition, the functional film laminate (D1) sheet and the functional film (E1) sheet are laminated by adhering each film to a machine provided with two suction cups, and then attaching the adhesive layer of the film on one side. The protective film was peeled off and the suction cups were pressure-bonded.

The obtained functional composite film (H1) had excellent properties as an optical film for PDP. In addition, the amount of process waste generated when 100 sheets of the functional composite film (H1) are obtained is the functional film layer (A1) (1.5 m ² × 11 sheets) and the pressure-sensitive adhesive layer (B1) (1.5 m). ² × 11 sheets) and a separation layer (C1) (1.5 m ² × 111 sheets).

[Comparative Example 1]
<First step>
On one side of the functional film layer (A1: biaxially oriented polyester film, thickness 105 μm), an adhesive layer (B1: acrylate copolymer, thickness 20 μm), and further a separation layer (C1: biaxially oriented polyester film, thickness) The functional film laminate (K1) was prepared by laminating a protective film (F1: polypropylene, thickness 40 μm) on the other surface.

  Further, on one side of the functional film layer (E1: biaxially oriented polyester film, thickness 75 μm), an adhesive layer (B1: acrylic acid ester copolymer, thickness 20 μm), and further a separation layer (C1: biaxially oriented polyester film) , A thickness of 75 μm) was laminated, and a functional film laminate (L1) in which a protective film (F1: polypropylene, thickness of 40 μm) was laminated on the other surface was prepared.

  Subsequently, the functional film laminate (K1) and the functional film laminate (L1) were each cut to produce a plurality of sheets having the same dimensions as in Example 1. As a result of evaluating the quality of the obtained sheet and removing defective products, to obtain 100 non-defective sheets, 111 functional film laminate (K1) sheets (10% defective product rate), functional film laminate (L1) The number of sheets was 111 (defective product rate 10%).

<Second step>
The adhesive layer (B1) exposed by peeling off the separation layer (C1) on one side from the functional film laminate (K1) sheet produced as described above, and the protective film (F1) peeling of the functional film (L1) sheet The functional film layer (E1) that was removed and exposed was bonded to obtain 100 functional composite films (H1). The separation layer was peeled and removed, the protective film was peeled and removed, and the functional film laminate (K1) sheet and the functional film (L1) sheet were bonded together in the same manner as in Example 1.

Compared to Example 1, in Comparative Example 1, the separation / peeling operation for obtaining the functional composite film (H1) was increased by the removal of the protective film. In addition, the amount of process waste generated when 100 sheets of the functional composite film (H1) are obtained is the functional film layer (A1) (1.5 m ² × 11 sheets) and the pressure-sensitive adhesive layer (B1) (1.5 m). ² × 11 sheets), separation layer (C1) (1.5 m ² × 111 sheets), protective film (F1) (1.5 m ² × 111 sheets), protective film (F2) (1.5 m ² × 111 sheets) The functional film (E1) (1.5 m ² × 11 sheets) and the pressure-sensitive adhesive layer (B2) (1.5 m ² × 11 sheets).

  As is apparent from the results shown in the above examples, the production method of the present invention has a high yield rate of sheets obtained by cutting, a small amount of process waste generated when obtaining a functional composite film, and is economical. In terms of surface.

  In addition, the evaluation criteria of the sheet quality obtained by cutting were as follows.

[Evaluation of cut functional laminated sheet]
The appearance of the cut sheet was observed by transmission and reflection, and those having foreign matters, scratches, and adhesive streaks were determined to be defective, and those not having were determined to be good.

It is a side view which shows schematic structure of the functional composite film (H) of this invention. It is a side view which shows schematic structure of the functional film laminated body (D) in this invention. It is a side view which shows schematic structure of the functional film laminated body (G) in this invention. It is a side view which shows schematic structure which bonded together the functional composite film (H) and to-be-adhered body (J) in this invention. It is a side view which shows schematic structure of the functional film laminated body (K) of a prior art. It is a side view which shows schematic structure of the functional film laminated body (L) of a prior art.

Explanation of symbols

A Functional film layer (A)
B adhesive layer (B)
C Separation layer (C)
D Functional film laminate (D)
E Functional film layer (E)
F Protective film (F)
G Functional film laminate (G)
H Functional composite film (H)
J Substrate (J)
K Functional film laminate (K)
L Functional film laminate (L)

Claims (3)

(1) A functional film laminate in which an adhesive layer (B) and a separation layer (C) are laminated in this order on both surfaces of a first functional film layer (A) made of at least one functional film ( D) and a first step of preparing a functional film laminate (G) obtained by laminating a protective film (F) on one surface of a second functional film layer (E) made of at least one functional film. ,
(2) From the functional film laminate (D), the pressure-sensitive adhesive layer (B) exposed by peeling and removing one separation layer (C) is removed from the second functional film (G). E) a second step of obtaining the functional composite film (H) by sticking to the other surface;
A method for producing a functional composite film, comprising: The method for producing a functional composite film according to claim 1, wherein the functional film laminate (D) and the functional film laminate (G) are single-wafer laminates cut into predetermined dimensions. A third step of preparing the functional composite film (H) according to claim 1 and an adherend (J);
4th process of sticking the adhesive layer (B) which peeled and removed the separation layer (C) from the functional composite film (H) on the surface of a to-be-adhered body (J),
The processing method of the functional composite film which has these.

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