JP2010194809A - Method of manufacturing front panel for display - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a front panel for display which can manufacture a front panel for display having a hard coat layer with a crack prevented from being generated though a through-hole is formed. <P>SOLUTION: The method of manufacturing a front panel 1 for display includes a process of forming a resin plate 10 formed with a first through-portion H<SB>1</SB>being a part of a through-hole H by molding a transparent thermoplastic resin, a process of punching a sheet for the formation of a hard coat laminate having a hard coat layer 21c to form a second through-portion H<SB>2</SB>being a part of the through-hole H, and forming hard coat laminates 20a and 20b, and a process of adhering the hard coat laminates 20a and 20b to at least one side of the resin plate 10 so that the first through-portion H<SB>1</SB>of the resin plate 10 is superimposed on the second through-portion H<SB>2</SB>of the hard coat laminates 20a and 20b. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a display front plate attached to the front surface of a display such as a liquid crystal display.

A liquid crystal display provided in a notebook personal computer or the like is usually provided with a front plate having a hard coat layer on the surface. Since notebook personal computers are required to be lightweight from the viewpoint of portability, resin-made front plates are often used as displays for notebook personal computers and the like.
As a method for producing a resin front plate, for example, Patent Document 1 discloses a method of forming a hard coat layer by applying a liquid hard coat material to one side of a transparent substrate.
Patent Document 2 discloses a method of manufacturing a front plate by laminating an acrylic resin hard coat layer on a polycarbonate resin sheet by coextrusion.
Patent Document 3 discloses an insert molding method for producing a resin molded product in which a hard coat film is laminated by injecting a molten transparent thermoplastic resin into a mold having a hard coat film.

JP 2008-132768 A JP 2008-49623 A JP-A-7-137210

By the way, a through hole may be provided in a display front plate of a personal computer for inserting a camera or a microphone. Further, a display front plate of a notebook personal computer may be provided with a through hole for inserting a spacer for preventing contact with the keyboard when the display is folded.
In the manufacturing method of the front plate in Patent Documents 1 and 2, a through-hole cannot be provided in the coating or co-extrusion process. Therefore, if a through-hole is required, it must be drilled later. Usually, since the front plate has a thickness, a method of drilling by drilling with a drill or the like has been adopted. However, when drilled by cutting, cracks were likely to occur in the hard coat layer.

  On the other hand, as a method of manufacturing a front plate provided with a through hole by applying the insert molding method described in Patent Document 3, a resin plate having a through hole is produced by injection molding in a mold. Thus, a method of laminating the hard coat film in which the through holes are formed is conceivable. However, as a result of investigations by the present inventors, the hard coat film is hard and has low followability to the transparent thermoplastic resin filled in the mold, so the positions of the through holes of the resin plate and the through holes of the hard coat film Matching was difficult. Therefore, it has been difficult to manufacture a front plate provided with through holes by the insert molding method described in Patent Document 3. Therefore, even with the insert molding method described in Patent Document 3, it was practically impossible to provide a through hole at the molding stage. Therefore, like the front plates of Patent Documents 1 and 2, it has to be perforated by cutting, resulting in the same problems as the front plates of Patent Documents 1 and 2.

  Accordingly, an object of the present invention is to provide a method for manufacturing a display front plate that can manufacture a display front plate having a hard coat layer in which cracks are prevented from being generated despite the formation of through holes. To do.

The present invention has the following configuration.
[1] A resin plate made of a transparent thermoplastic resin and a hard coat laminate provided on at least one side of the resin plate, wherein one or more through holes are formed in the thickness direction, and the hard coat laminate is A method for producing a display front plate having a hard coat layer,
A step of producing a resin plate on which a first through portion that becomes a part of the through hole is formed by molding a transparent thermoplastic resin;
A step of punching a sheet for preparing a hard coat laminate having a hard coat layer so as to form a second penetrating portion that becomes a part of the through hole to obtain a hard coat laminate;
A front plate for a display, comprising: a step of bonding a hard coat laminate on at least one surface of the resin plate and a second penetration portion of the hard coat laminate overlapping the first penetration portion of the resin plate. Manufacturing method.
[2] The method for producing a display front plate according to [1], wherein the molding for producing the resin plate is injection molding [3] Before punching, the sheet for producing a hard coat laminate is printed [ [1] The method for producing a display front plate according to [2].

  According to the method for manufacturing a display front plate of the present invention, it is possible to manufacture a display front plate having a hard coat layer in which cracks are prevented from being generated despite the formation of through holes.

It is a top view which shows one surface of the front plate manufactured by one Embodiment of the manufacturing method of the front plate of this invention. It is a top view which shows the other surface of the front plate manufactured by one Embodiment of the manufacturing method of the front plate of this invention. It is I-I 'sectional drawing of FIG. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention. It is a figure which shows 1 process of one Embodiment of the manufacturing method of the front plate for a display of this invention.

An embodiment of a method for producing a display front plate (hereinafter abbreviated as a front plate) according to the present invention will be described.
<Front plate>
1, 2 and 3 show a front plate manufactured by the manufacturing method of the present embodiment. The front plate 1 has a resin plate 10 and hard coat laminates 20a and 20b provided on both surfaces of the resin plate 10, and through holes H are formed in the thickness direction.

The resin plate 10 is made of a transparent thermoplastic resin.
Examples of the transparent thermoplastic resin include polystyrene (PS), polymethyl methacrylate (PMMA), styrene-methyl methacrylate copolymer (MS), polycarbonate (PC), cycloolefin polymer (COP), polypropylene (PP), and polyethylene. Terephthalate (PET), PET-G, polyethersulfone (PES), acrylonitrile-styrene copolymer (AS), methyl methacrylate-butadiene-styrene copolymer (MBS), acrylonitrile-butadiene-styrene copolymer (ABS) ) And polyvinyl chloride (PVC). Among these, acrylic resins are preferable in terms of transparency, and polystyrene and styrene-acrylic copolymers are preferable in terms of water resistance.
Further, the resin plate 10 is formed with a _first through portion H ₁ that becomes a part of the through hole H.

  The thickness of the resin plate 10 is preferably 0.5 to 3.0 mm. If the thickness of the resin plate 10 is 0.5 mm or more, sufficient strength can be ensured, and if it is 3.0 mm or less, the size and weight can be reduced.

(Hard coat laminate)
Each of the hard coat laminates 20a and 20b includes a hard coat film 21 and an adhesive layer 22a provided on the surface of the hard coat film 21 on the resin plate 10 side. Moreover, as for one hard coat laminated body 20b, the printing layer 23 is provided in the peripheral part of the surface on the opposite side to the adhesive layer 22a of the hard coat film 21. FIG. Hereinafter, the hard coat laminate 20a without the print layer 23 is referred to as a first hard coat laminate 20a, and the hard coat laminate 20b with the print layer 23 is referred to as a second hard coat laminate 20b. .

The hard coat film 21 includes a base material 21a disposed on the pressure-sensitive adhesive layer 22a side, an adhesive layer 21b provided on the surface of the base material 21a opposite to the pressure-sensitive adhesive layer 22a, and a base material 21a of the adhesive layer 21b. And a hard coat layer 21c provided on the opposite surface.
Further, the hard coat laminate 20a, the 20b, respectively, the second through portions H ₂ which become part of the through-hole H is formed.

[Base material]
As the base material 21a, polyethylene terephthalate film, polyethylene naphthalate film, polypropylene terephthalate film, polybutylene terephthalate film, polypropylene naphthalate film, polyethylene film, polypropylene film, cellophane, diacetyl cellulose film, triacetyl cellulose film, acetyl cellulose butyrate Film, polyvinyl chloride film, polyvinylidene chloride film, polyvinyl alcohol film, ethylene-vinyl acetate copolymer film, polystyrene film, polycarbonate film, polymethylpentene film, polysulfone film, polyether ether ketone film, polyether sulfone film, Polyetherimide fill , A polyimide film, a fluororesin film, a polyamide film, and acrylic resin film.
Various additives may be contained in the base material 21a. Examples of the additive include antioxidants, heat stabilizers, ultraviolet absorbers, organic particles, inorganic particles, pigments, dyes, antistatic agents, nucleating agents, and coupling agents.

  The surface of the substrate 21a may be subjected to a surface treatment in order to improve the adhesion with the adhesive layer 21b. Examples of the surface treatment include surface roughening treatment such as sandblast treatment and solvent treatment, corona discharge treatment, chromic acid treatment, flame treatment, hot air treatment, ozone / ultraviolet irradiation treatment, and the like.

  The thickness of the base material 21a is preferably 10 to 500 μm, and more preferably 20 to 300 μm. If the thickness of the base material 21a is 10 μm or more, it is difficult to break, and if it is 500 μm or less, the transparency and handleability are excellent.

[Adhesive layer]
The adhesive layer 21b is a layer for improving the adhesion between the base material 21a and the hard coat layer 21c.
Examples of the adhesive constituting the adhesive layer 21b include polyester, acrylic resin, urethane resin, ethylene-acrylic copolymer, and ethylene-vinyl acetate copolymer.

[Hard coat layer]
The hard coat layer 21c is a layer containing a cured product obtained by curing a curable component.
Examples of the curable component include a thermosetting resin, an active energy ray curable oligomer, and an active energy ray curable monomer.

  Examples of the thermosetting resin include phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, urethane resin, epoxy resin, aminoalkyd resin, melamine-urea cocondensation resin, siloxane resin, and the like. Is mentioned.

Examples of the active energy ray-curable oligomer include polyester acrylate, epoxy acrylate, urethane acrylate, polyol acrylate, and the like.
The polyester acrylate can be obtained, for example, by esterifying the hydroxyl group of a polyester oligomer having hydroxyl groups at both ends obtained by condensation of a polyvalent carboxylic acid and a polyhydric alcohol with (meth) acrylic acid. It can also be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide to a polyvalent carboxylic acid with (meth) acrylic acid.
The epoxy acrylate can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it.
The urethane acrylate-based prepolymer can be obtained, for example, by esterifying a polyurethane oligomer obtained by reaction of polyether polyol or polyester polyol with polyisocyanate with (meth) acrylic acid.
The polyol acrylate-based prepolymer is obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.
One of these active energy ray-curable oligomers may be used alone, or two or more thereof may be used in combination.

  Examples of the active energy ray-curable monomer include 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, and polyethylene glycol di (meth). Acrylate, neopentyl glycol adipate di (meth) acrylate, hydroxypivalic acid neopentyl glycol di (meth) acrylate, dicyclopentanyl di (meth) acrylate, caprolactone modified dicyclopentenyl di (meth) acrylate, EO modified diphosphate (Meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropane tri (meth) acrylate, diventaerythritol tri (meth) acrylate Rate, propionic acid modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, PO modified trimethylolpropane tri (meth) acrylate, tris (acryloxyethyl) isocyanurate, propionic acid modified dipentaerythritol penta ( And (meth) acrylate, dipentaerythritol hexa (meth) acrylate, caprolactone-modified dipentaerythritol hexa (meth) acrylate, and the like. One of these active energy ray-curable monomers may be used alone, or two or more thereof may be used in combination.

  When an active energy ray-curable oligomer or monomer is used as the curable component, a vinyl monomer other than the active energy ray-curable monomer may be used in combination. Examples of the vinyl monomer include ethyl (meth) acrylate, ethylhexyl (meth) acrylate, styrene, methylstyrene, N-vinylpyrrolidone and the like.

The hard coat layer 21c may be subjected to an antiglare treatment in order to improve the visibility of the display.
The antiglare treatment is a treatment for forming irregularities on the surface of the hard coat layer 21c. As a method for forming irregularities, in the manufacturing method described later, after coating and drying a coating liquid for forming a hard coat layer, contacting with an embossing roll and then curing, inorganic particles such as silica, polystyrene or acrylic resin Examples thereof include a method of containing inorganic particles or organic particles in the hard coat layer 21c using a coating liquid for forming a hard coat layer containing organic particles.
Preferable curable resins used in the antiglare treatment include polyester resins, urethane resins, acrylic resins, melamine resins, epoxy resins, silicone resins, polyimide resins, and the like. These resins may be used alone or in combination of two or more.

An antireflection layer may be provided on the surface of the hard coat layer 21c opposite to the adhesive layer 21b in order to improve the transmittance of visible light when used as a display.
The antireflection layer is preferably a layer containing a material having a refractive index smaller than that of the hard coat layer 21c. In addition, it is preferable to provide two or more antireflection layers so that the refractive index sequentially decreases from the hard coat layer 21c as the distance from the hard coat layer 21c increases. Further, it is preferably formed from two or more kinds of materials.
As a material having a refractive index less than the refractive index of the hard coat layer 21c, for _{example, CaF 2, MgF 2, NaAiF} 4, SiO 2, ThF 4, ZrO 2, Nd 2 O 3, SnO 2, TiO 2, CeO ₂ , ZnS, In ₂ O _{3 and the} like.
The antireflection layer can be formed by a dry method such as a vacuum deposition method, a sputtering method, a CVD method, or an ion plating method, or a wet method such as a gravure method, a reverse method, or a die method.
The thickness d (μm) of the antireflection layer increases the antireflection property. Therefore, the refractive index of the material constituting the antireflection layer is n, and the center wavelength of light incident on the antireflection layer is λ (nm). In this case, it is preferable to set the thickness to satisfy the relationship of n · d = λ / 4.
An antifouling layer having a thickness (about 3 nm) that does not affect the antireflection property may be provided on the surface of the antireflection layer.

  The thickness of the hard coat layer 21c is preferably 3 to 10 μm. If the thickness of the hard coat layer 21c is 3 μm or more, the surface hardness of the hard coat film 21 can be sufficiently increased, and if it is 10 μm or less, the hard coat layer 21c can be easily formed and punched to form a through hole. The generation of cracks during processing can be further prevented.

[Print layer]
The print layer 23 in the present embodiment is formed by printing so as to border the hard coat layer 21c of the second hard coat laminate 20b.
The printing layer 23 contains a coloring component and a binder component.
Examples of coloring components include nitroso pigments, nitro pigments, azo pigments, dyed lake pigments, phthalocyanine pigments, condensed polycyclic pigments and other organic pigments, titanium oxide, molybdenum, alumina white, calcium carbonate, barium sulfate, aluminum powder, Examples thereof include inorganic pigments such as zinc powder and carbon black, dyes such as azo dyes and anthraquinone dyes.
Examples of the binder component include thermoplastic resins such as polyvinyl chloride, acrylic resin, polycarbonate, polyester, ABS resin, polystyrene, polyurethane, and polyolefin, thermosetting resins such as epoxy resin and alkyd resin, paraffin wax, and carnauba wax. And waxes such as ester wax.
In addition, as the auxiliary agent, a leveling auxiliary agent, a drying inhibitor, a surfactant and the like can be used.

[Adhesive layer]
The pressure-sensitive adhesive layer 22 a is a layer for adhering the hard coat film 21 to the resin plate 10.
As the adhesive constituting the adhesive layer 22a, for example, a natural rubber adhesive, a synthetic rubber adhesive, an acrylic adhesive, a urethane adhesive, a silicone adhesive, or the like is used. Moreover, any of solvent system, emulsion system, and water system may be sufficient.
Other auxiliary agents may be added to the adhesive as necessary. Other auxiliary agents include thickeners, pH adjusters, tackifiers, binders, crosslinking agents, adhesive fine particles, antifoaming agents, antiseptic / antifungal agents, pigments, inorganic fillers, stabilizers, wetting agents, wetting agents. Etc.

(Through hole)
Through hole H has a first penetration portion H ₁ of the resin plate 10, the second through portions H ₂ of the hard coat laminate 20a, the second through portions H ₂ and may overlap the hard coat laminate 20b Is formed by.
In the front plate 1 of the present embodiment, through holes H are provided at each of the four corners of the front plate 1. Further, the through hole H in the present embodiment has a perfect circular cross section when the front plate 1 is cut perpendicular to the thickness direction.

<Method for manufacturing front plate>
Next, a method for manufacturing the front plate 1 will be described.
The manufacturing method of the front plate 1 in the present embodiment includes a step of manufacturing the resin plate 10 (hereinafter referred to as a first step) and a step of manufacturing a hard coat laminate manufacturing sheet (hereinafter referred to as a second step). .), A step of punching the sheet for preparing the hard coat laminate to obtain a sheet for preparing the first hard coat laminate 20a (hereinafter referred to as the third step), and for preparing the hard coat laminate After the sheet is printed, a punching process is performed to obtain a sheet for producing the second hard coat laminate 20b (hereinafter referred to as a fourth step), and the first hard coat laminate 20a is formed on the resin plate 10. And a step of bonding the second hard coat laminate 20b (hereinafter referred to as a fifth step).

(First step)
In the first step, a transparent thermoplastic resin heated and melted is injected and filled into a mold having a cavity having the same shape as the resin plate 10 on which the _first through-hole H1 is formed, and then cooled. Thus, the resin plate 10 on which the _first penetrating portion H1 is formed is produced.
What is necessary is just to set shaping | molding temperature suitably according to the shape of the resin board 10, the kind of transparent thermoplastic resin, etc.

(Second step)
The second step includes a step of producing a hard coat film 21, a step of producing an adhesive film, and a step of producing a sheet for producing a hard coat laminate.

[Process for producing hard coat film]
In the step of producing the hard coat film 21, as shown in FIG. 4, first, the coating liquid for forming the adhesive layer is applied to one side of the base material 21 a drawn out from the winding A by the coater 51, and the dryer 52 is used. Dry to form the adhesive layer 21b.
Here, the coating liquid for forming an adhesive layer contains an adhesive and a solvent. Examples of the solvent include alcohol (for example, methanol, ethanol, propanol, etc.), ketone (for example, acetone, methyl ethyl ketone, etc.), ether (for example, diethyl ether, methyl cellosolve, ethyl cellosolve, etc.) and the like.
Examples of the coater 51 for applying the coating liquid for forming an adhesive layer include a blade coater, an air knife coater, a roll coater, a bar coater, a gravure coater, a rod blade coater, a lip coater, a die coater, and a curtain coater.
Examples of the dryer 52 include a heat dryer and a vacuum dryer.

  Next, a coating liquid for forming a hard coat layer is applied to the surface of the adhesive layer 21 b by the coater 53, and a thermal energy ray or an active energy ray is irradiated from the energy irradiator 54. Thereby, the applied coating liquid for forming a hard coat layer is cured to form the hard coat layer 21c, whereby the hard coat film 21 is obtained.

The coating liquid for forming a hard coat layer contains a curable component.
The curable component contained in the hard coat layer forming coating solution may be only an active energy ray-curable oligomer and / or an active energy ray-curable monomer, or may be only a thermosetting resin. The active energy ray-curable oligomer and / or the active energy ray-curable monomer and the thermosetting resin may be used.
Moreover, since high active energy ray sclerosis | hardenability and coating property are obtained, it is preferable that a sclerosing | hardenable component contains both an active energy ray curable oligomer and an active energy ray curable monomer.
When both the active energy ray-curable oligomer and the active energy ray-curable monomer are contained, the amount of the active energy ray-curable monomer is 1 to 40 parts by mass with respect to 100 parts by mass of the active energy ray-curable oligomer. It is preferably 4 to 20 parts by mass. If the amount of the active energy ray-curable monomer is 1% by mass or more, the viscosity of the coating liquid for forming a hard coat layer can be reduced to improve the coating property, and if it is 40% by mass or less, Sufficient active energy ray curability can be secured.

  In addition, in order to accelerate curing, the hard coat layer forming coating solution preferably contains a photopolymerization initiator when it contains an active energy ray-curable oligomer or monomer, and a thermosetting resin is used. When it contains, it is preferable to contain a thermal polymerization initiator.

Examples of the photopolymerization initiator include benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-butyl ether, benzoin isobutyl ether, acetophenone, dimethylaminoacetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy-2-phenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1- [4- (methylthio) phenyl]- 2-morpholino-propan-1-one, 4- (2-hydroxyethoxy) phenyl-2 (hydroxy-2-propyl) ketone, benzophenone, p-phenylbenzophenone, 4,4′-diethylaminobenzene Nzophenone, propiophenone, dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone, 2-tertiarybutylanthraquinone, 2-aminoanthraquinone, 2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone, 2,4- Examples thereof include dimethylthioxanthone, 2,4-diethylthioxanthone, benzyldimethyl ketal, acetophenone dimethyl ketal, and p-dimethylamine benzoate. These photoinitiators may be used individually by 1 type, and may be used in combination of 2 or more type.
It is preferable that the compounding quantity of a photoinitiator is 0.2-10 mass parts with respect to a total of 100 mass parts of an active energy ray hardening-type oligomer and an active energy ray hardening-type monomer. If the blending amount of the photopolymerization initiator is 0.2 parts by mass or more, curing can be further promoted. However, even if the photopolymerization initiator is blended in excess of 10 parts by mass, the promotion of curing as compared with the blending amount cannot be obtained, so only the cost is increased.
When it contains a photopolymerizable initiator, it is preferable to further contain a photosensitizer. Examples of the photosensitizer include n-butylamine, triethylamine, and tri-n-butylphosphine.

  Examples of the thermal polymerization initiator include peroxide compounds such as benzoyl peroxide and di-t-butyl peroxide.

Moreover, the coating liquid for hard-coat layer formation may contain a crosslinking agent, a solvent, etc. as needed. In particular, when a thermosetting resin is contained, it is preferable to use a crosslinking agent in combination because the curability is improved.
As a crosslinking agent, an isocyanate compound, an epoxy compound, a melamine compound, a urea compound etc. are mentioned, for example.

  Examples of the isocyanate compound include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate, hexamethylene diisocyanate, xylylene diisocyanate, isophorone diisocyanate, tetramethylxylylene diisocyanate, bis ( 4-isocyanatocyclohexyl) methane, toluene diisocyanate and the like.

Examples of the epoxy compound include polyepoxy compounds, diepoxy compounds, and monoepoxy compounds.
Examples of the polyepoxy compound include sorbitol, polyglycidyl ether, polyglycerol polyglycidyl ether, pentaerythritol polyglycidyl ether, diglycerol polyglycidyl ether, triglycidyl tris (2-hydroxyethyl) isocyanate, glycerol polyglycidyl ether, trimethylol. Examples include propane polyglycidyl ether.
Examples of the diepoxy compound include neopentyl glycol diglycidyl ether, 1,6-hexanediol diglycidyl ether, resorcin diglycidyl ether, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, propylene glycol diglycidyl ether, and polypropylene glycol diester. Examples thereof include glycidyl ether and polytetramethylene glycol diglycidyl ether.
Examples of the monoepoxy compound include allyl glycidyl ether, 2-ethylhexyl glycidyl ether, and phenyl glycidyl ether.

  Examples of the melamine compound include compounds obtained by reacting a methylol melamine derivative obtained by condensing melamine and formaldehyde with a lower alcohol (methanol, ethanol, propanol, etc.) and etherified, and a mixture thereof. Examples of the methylol meamine derivative include monomethylol melamine, dimethylol melamine, trimethylol melamine, tetramethylol melamine, pentamethylol melamine, hexamethylol melamine and the like.

  Examples of the urea compound include dimethylol urea, dimethylol ethylene urea, dimethylol propylene urea, tetramethylol acetylene urea, 4-methoxy-5-dimethylpropylene urea dimethylol and the like.

  As the solvent, for example, methanol, ethanol, isopropanol, acetone, methyl ethyl ketone, N-methyl-2-pyrrolidone and the like are used.

  For the hard coat layer forming coating liquid, an organic solvent, a photosensitizer, a light stabilizer, an ultraviolet absorber, a catalyst, a colorant, an antistatic agent, a lubricant, an antifoaming agent, and a polymerization accelerator are used as necessary. , Antioxidants, flame retardants, infrared absorbers, surfactants, surface modifiers, thixotropic agents, colloidal silica, organic fine particles, inorganic fillers, hydrolysates of (meth) acrylates containing silicon atoms, etc. Also good.

When the second hard coat laminate 20b is formed on the base material 21a by coating and the wettability on the surface of the base material 21a is low, or when the surface property of the layer to be formed is low In order to improve them, it is preferable to add a leveling agent (also referred to as a surface conditioner).
Examples of the leveling agent include compounds such as silicone, fluorine, polyether, acrylic copolymer, and titanate. Among these, in order to improve the ink adhesion after printing, the acrylic acid copolymer is preferably 0.05 to 3.0% by mass, more preferably 0.1 to 1.0% by mass in the coating liquid. % Content is preferable. If the amount of leveling agent added is 0.05% by mass or more, a sufficient leveling effect can be obtained, and if it is 3% by mass or less, a decrease in ink adhesion can be prevented. The acrylic acid copolymer may be added as a solution.
When using a silicone-based or fluorine-based leveling agent instead of or in combination with the acrylic acid copolymer, the leveling agent addition amount is preferably 0 to 0.05% by mass. If the leveling agent amount is 0.05% by mass or less, a decrease in ink adhesion can be prevented.

  Examples of the coater 53 for coating the hard coat layer forming coating solution include a blade coater, an air knife coater, a roll coater, a bar coater, a gravure coater, a rod blade coater, a lip coater, a die coater, and a curtain coater. .

In the case where a thermosetting resin is contained as the curable component, the hard coat layer forming coating solution is applied and then heated and cured by using a heating furnace or an infrared lamp as the energy irradiator 54.
When an active energy ray-curable oligomer or monomer is contained as the curable component, it is cured by irradiation with active energy rays.
Examples of the active energy rays include ultraviolet rays and electron beams. Among them, ultraviolet rays are preferable from the viewpoint of versatility. When ultraviolet rays are used as the active energy rays, an ultraviolet light source is used as the energy irradiator 54. As the ultraviolet light source, for example, a high pressure mercury lamp, a low pressure mercury lamp, an ultrahigh pressure mercury lamp, a metal halide lamp, a carbon arc, a xenon arc, or the like can be used.
When an electron beam is used as the active energy beam, an electron beam generator is used as the energy irradiator 54. Examples of the electron beam generator include a Cockloftwald type, a bandecraft type, a resonant transformation type, an insulating core transformer type, a linear type, a dynamitron type, and a high frequency type.
Curing by irradiation with active energy rays is preferably performed in the presence of an inert gas such as nitrogen.

[Process for producing adhesive film]
In the step of producing the adhesive film, as shown in FIG. 5, the adhesive layer forming coating liquid is applied to the release surface of the release sheet 22 b drawn from the winding B by the coater 61 and dried by the dryer 62. Thus, the pressure-sensitive adhesive film 22 having the pressure-sensitive adhesive layer 22a is obtained.
Here, the coating solution for forming an adhesive layer contains an adhesive and a solvent.
As the solvent, the coating method, and the drying method of the adhesive layer forming coating solution, the same methods as the solvent, the coating method, and the drying method of the adhesive layer forming coating solution can be applied.

As release sheet 22b, what has the base material for release sheets and the release agent layer provided in the adhesive layer 22a side of the base material for release sheets is mentioned, for example.
Examples of the release sheet substrate include paper such as high-quality paper and glassine paper, and plastic films such as polyethylene terephthalate film and polypropylene film.
As the release agent constituting the release agent layer, for example, a general-purpose addition type or condensation type silicone release agent or a long-chain alkyl group-containing compound is used. In particular, an addition type silicone release agent having high reactivity is preferably used.
Specific examples of silicone release agents include BY24-4527 and SD-7220 manufactured by Toray Dow Corning, and KS-3600, KS-774, and X62-2600 manufactured by Shin-Etsu Chemical Co., Ltd. Can be mentioned. Further, the silicone-based release agent may contain a silicone resin that is an organosilicon compound having a SiO ₂ unit and (CH ₃ ) ₃ SiO _1/2 unit or CH ₂ ═CH (CH ₃ ) SiO _1/2 unit. preferable. Specific examples of the silicone resin include BY24-843, SD-7292, SHR-1404 and the like manufactured by Toray Dow Corning, and KS-3800 and X92-183 manufactured by Shin-Etsu Chemical Co., Ltd.

[Process for producing a sheet for producing a hard coat laminate]
In the step of producing the hard coat laminate production sheet, as shown in FIG. 6, a protective film 31 is laminated on the surface of the hard coat film 21 on the hard coat layer 21 c side, and the hard coat film 21 on the base 21 a side. The adhesive film 22 is bonded to the surface by the adhesive layer 22a. Thereby, the sheet | seat 30 for hard-coat laminated body preparation is obtained.

  Here, the protective film 31 is a film for protecting the hard coat layer 21c. As the protective film 31, for example, a polyethylene film, a polypropylene film, a polyethylene terephthalate film, a polyvinyl chloride film, a polyurethane film, or the like is used.

(Third step)
In the third step, as shown in FIG. 7, the hard coat laminate production sheet 30 obtained in the second step is punched and further cut into a single sheet to form a surface on the pressure-sensitive adhesive layer 22a side. A sheet-like first hard coat laminate 20a in which a release sheet 22b is laminated and a protective film is laminated on the surface of the hard coat layer 21c is obtained.

In the punching process, using a punching machine including a punching blade 71 for punching into the contour shape of the front plate 1 and a punching blade 72 for forming the _second through portion H2, the sheet 20 for producing a hard coat laminate is formed. The outer shape is the same as that of the front plate 1 and the second penetrating portion H ₂ is formed. At that time, the punching blades 71 and 72 are inserted from the protective film 31 toward the adhesive layer 22a, and the punching depth is adjusted so as not to punch the release sheet 22b. The second penetration portion H so as to be disposed at a position corresponding to the first through portions H ₁ in a first hard coat laminate 20a superposed on the resin plate 10 by a fifth step described below ₂ is formed.
As the punching machine, the punching blades 71 and 72 may rotate, or the punching blades 71 and 72 may reciprocate so as to come into contact with and separate from the hard coat laminate manufacturing sheet 30.
After the punching, the portion 30b outside the punching blade 71 and the portion 30b surrounded by the punching blade 72 of the hard coat laminate manufacturing sheet 30 are peeled from the release sheet 22b.

(Fourth process)
In a 4th process, as shown in FIG. 8, after peeling off the protective film 31 from the sheet | seat 30 for hard-coat laminated body preparation, the printing layer 23 is formed in the peripheral part of the 2nd hard-coat laminated body 20b obtained after a punching process. Is printed so that the printed laminated sheet 40a is obtained. Thereafter, as shown in FIG. 9, the protective film 31 is laminated on the printed layer 23 and the hard coat layer 21c of the printed laminated sheet 40a, and the printed laminated sheet 40b with the protective film thus obtained is punched, A sheet-like second hard coat laminate in which a release sheet 22b is laminated on the surface on the pressure-sensitive adhesive layer 22a side, and a protective film is laminated on the surface on the hard coat layer 21c and print layer 23 side. 20b is obtained.

  As a printing method in the fourth step, a known printing method such as a screen printing method, a gravure printing method, an offset printing method, a flexographic printing method, or an offset gravure printing method may be applied according to the product shape or printing application. it can. In particular, the screen printing method is preferable when it is desired to give the printing layer 23 a thickness in order to impart concealability.

In the punching process in the fourth step, as in the third step, a punching machine including a punching blade 71 for punching into the contour shape of the front plate 1 and a punching blade 72 for forming the _second through portion H ₂ is used. use, a protective film with printed laminated sheet 40b, with the same outer shape as the front plate 1 to form a second penetration portion H _2. At that time, the punching blades 71 and 72 are inserted from the protective film 31 toward the adhesive layer 22a, and the punching depth is adjusted so as not to punch the release sheet 22b. Further, when the second hard coat laminate 20b is overlaid on the resin plate 10 in the fifth step described later, the second through portion H is disposed at a position corresponding to the _first through portion H1. to form a _2.
After the punching, the portion 40c outside the punching blade 71 and the portion 40d surrounded by the punching blade 72 of the printed laminated sheet 40b are peeled from the release sheet 22b.

  The fourth step may be performed after the third step, may be performed before the third step, or may be performed simultaneously with the third step.

(Fifth step)
In the fifth step, the release sheet 22b is peeled off for each of the sheet-like first hard coat laminate 20a and the sheet-like second hard coat laminate 20b in which the release sheet and the protective film are laminated, The pressure-sensitive adhesive layer 22a is exposed to obtain the first hard coat laminate 20a and the second hard coat laminate 20b with the protective film 31. Next, the first hard coat laminate 20a with the protective film 31 is bonded to one surface of the resin plate 10 by the exposed adhesive layer 22a, and the second hard coat with the protective film 31 is bonded to the other surface. The laminated body 20b is bonded together.
At that time, the first through part H ₁ of the resin plate 10, the second is through portions of H ₂ second penetrating portions H ₂ and a second hard coat laminate 20b of the first hard coat laminate 20a The positions of the first hard coat laminate 20a and the second hard coat laminate 20b are adjusted so as to overlap.
And the protective film 31 is peeled from each of the 1st hard coat laminated body 20a and the 2nd hard coat laminated body 20b, and the front board 1 is obtained.

When attaching the first hard coat laminate 20a and the second hard coat laminate 20b is taken from above by an image pickup device such as a CCD camera, in the captured image, the first through portions H ₁ and the The first hard coat laminate 20a and the second hard coat laminate 20b may be automatically positioned so that the _two through portions H2 overlap.

(Function and effect)
In the punching of the hard coat laminate preparation sheet 20 and the printed laminate sheet 40b with a protective film, the hard coat laminate preparation sheet 20 and the print laminate sheet 40b that are thinner than the resin plate 10 need only be punched out, so that the tip is sharp. Punching blades 71 and 72 can be used. Therefore, while preventing the cracking of the hard coat laminate hard coating layer 21c, the second penetration portion H ₂ is formed hard coat laminate 20a, it is possible to obtain 20b.
Then, in order to bond the hard coat laminates 20a and 20b to the resin plate 10 produced by injection molding, the hard coat layer 21c has a hard coat layer 21c in which cracks are prevented and a through hole H is formed in the thickness direction. The face plate 1 can be obtained.
Moreover, in the said manufacturing method which produces the resin board 10 by injection molding, since there is no need for cutting, adhesion of swarf can be prevented and the operation | work which removes swarf can be abbreviate | omitted.
Furthermore, since the manufacturing method is not a method of directly laminating the resin plate 10 and the hard coat layer 21c, it is necessary to consider the adhesion between the transparent thermoplastic resin of the resin plate 10 and the curable component of the hard coat layer 21c. There is no. Therefore, the selection range of the combination of the transparent thermoplastic resin of the resin plate 10 and the curable component of the hard coat layer 21c can be widened.

(Other embodiments)
In addition, this invention is not limited to the said embodiment. For example, the hard coat layer 21c may be provided directly on the surface of the substrate 21a without forming the adhesive layer 21b in the second step.
Further, the second step may be omitted and a commercially available hard coat film 21 may be used.
In the second step, the hard coat layer 21c of the hard coat laminate preparation sheet 20 is set in a semi-cured state, and is punched by performing the second step in the semi-cured state, and then the semi-cured hard coat The layer 21c may be completely cured. Here, the semi-cured state is a state where the gel fraction exceeds 70% by mass and is 94% by mass or less, and the fully cured state is that the gel fraction is 94% by mass or more.
In the second step and the fourth step, lamination of the protective film 31 may be omitted. However, in terms of protecting the hard coat layer 21c, the protective film 31 is preferably laminated.

The pressure-sensitive adhesive layer 22a may be formed by directly applying a pressure-sensitive adhesive layer forming coating solution to the base material 21a of the hard coat film 21.
Further, the formation of the pressure-sensitive adhesive layer 22a may be omitted. Even if the adhesive layer 22a is not formed, the hard coat film 21 can be bonded by applying an adhesive to the resin plate 10.

In the present invention, the resin plate 10 may be produced by a molding method other than injection molding, for example, extrusion molding or press molding. When extrusion molding is applied, it is necessary to perform cutting when cutting into a single wafer or when forming the _first through portion H1, so that the chips adhere to the resulting resin plate 10. Therefore, it is preferable to remove chips generated by cutting before bonding the hard coat laminates 20a and 20b.

In the present invention, the cross-sectional shape of the through hole H in the front plate 1 may be an elliptical shape, a triangular shape, a quadrangular shape, or the like.
The positions of the through holes H are not limited to the four corners of the front plate 1 and can be set to arbitrary positions according to the purpose.
Further, the printing layer 23 may be provided on the first hard coat laminate 20a similarly to the second hard coat laminate 20b, or the print layer 23 of the second hard coat laminate 20b may be omitted. . Even when the printing layer 23 is omitted, when the hard coat film 21 contains a thermal colorant, thermal printing can be performed.
Further, the hard coat laminate 20a (or the hard coat laminate 20b) may be laminated only on one surface of the resin plate 10.

The front plate manufactured by the method for manufacturing a front plate of the present invention is applied to a front plate of a desktop personal computer display, a television receiver display, a touch panel, for example, in addition to the use of a notebook personal computer display. it can.
Further, it can be applied to front plates such as a plasma display, an organic electroluminescence display, and a surface conduction electron-emitting device display.

1 Front plate 10 Resin plate 20a First hard coat laminate (hard coat laminate)
20b Second hard coat laminate (hard coat laminate)
DESCRIPTION OF SYMBOLS 21 Hard coat film 21a Base material 21b Adhesive layer 21c Hard coat layer 22 Adhesive film 22a Adhesive layer 22b Release sheet 23 Print layer 30 Hard coat laminated body preparation sheet 40a Print laminate sheet 40b Print laminate sheet with protective film 31 Protective film 51 , 53 and 61 coaters 52,62 dryer 54 energy irradiation apparatus 71, 72 punching blade H through hole H ₁ first penetrating portion H ₂ second penetrating portions

Claims (3)

A transparent thermoplastic resin plate and a hard coat laminate provided on at least one side of the resin plate, wherein one or more through holes are formed in the thickness direction, and the hard coat laminate is a hard coat layer A method of manufacturing a display front plate having:
A step of producing a resin plate on which a first through portion that becomes a part of the through hole is formed by molding a transparent thermoplastic resin;
A step of punching a sheet for preparing a hard coat laminate having a hard coat layer so as to form a second penetrating portion that becomes a part of the through hole to obtain a hard coat laminate;
A front plate for a display, comprising: a step of bonding a hard coat laminate on at least one surface of the resin plate and a second penetration portion of the hard coat laminate overlapping the first penetration portion of the resin plate. Manufacturing method.   The method for producing a display front plate according to claim 1, wherein the molding for producing the resin plate is injection molding.   The manufacturing method of the front plate for a display according to claim 1 or 2, wherein the sheet for producing a hard coat laminate is subjected to printing before punching.

Images