JP2012163834A - Sheet roll, manufacturing method of sheet role, manufacturing method of optical sheet, and manufacturing method of display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a sheet role capable of preventing the irregularity of the surface of a protective layer from being transferred to an adhesive layer, a sheet roll, a manufacturing method of an optical sheet using the manufacturing method of the sheet role, and a manufacturing method of a display device.SOLUTION: There is provided a manufacturing method of a sheet role having: a lamination step of preparing a laminated sheet including a protective layer disposed on the outermost surface of a laminated sheet in a lamination direction and capable of being separated, a first base material layer, light transmission parts disposed side by side along the surface of the first base material layer and formed so as to be able to transmit light, an optical functional layer having a light absorption part formed between the light transmission parts so as to be able to absorb light, an adhesive layer containing an adhesive, and a second base material layer serving as a base material of the adhesive layer, in this order; and a winding step of winding the laminated sheet into a roll shape, while disposing a spacer in the vicinity of both ends of a width direction of the laminated sheet. A sheet role manufactured by this manufacturing method, a manufacturing method of an optical sheet using the manufacturing method of the sheet role and a manufacturing method of a display device are also provided.

Description

  The present invention relates to a sheet roll including a laminated sheet wound in a roll shape, a method for manufacturing the sheet roll, a method for manufacturing an optical sheet using the method for manufacturing the sheet roll, and a method for manufacturing a display device.

  For video display devices that emit images to the viewer, such as liquid crystal displays, plasma displays, rear projection displays, organic ELs, FEDs, etc., the viewer can improve the quality of the video source and the video light from the video source. And an optical sheet having layers having various functions for emitting light.

  Several techniques relating to such an optical sheet have been disclosed so far. For example, Patent Document 1 discloses a filter base, an external light shielding layer formed on one surface of the filter base, and having a transparent resin material base and a large number of wedge-shaped black stripes arranged parallel to the one surface of the base. A filter for a display device is disclosed.

  In the manufacturing process of the optical sheet, a laminated sheet including a portion used as an optical sheet is manufactured in a band shape, and the laminated sheet is once wound in a roll shape and transported and stored. When the laminated sheet provided with the pressure-sensitive adhesive layer is wound in this way, if foreign matter is adhered to the surface of the laminated sheet, the pressure-sensitive adhesive layer undergoes plastic deformation due to the pressure generated when the laminated sheet is wound, so-called There was a case where a recess called a dent was formed in the pressure-sensitive adhesive layer. When a sheet provided with a pressure-sensitive adhesive layer with a dent is used as an optical sheet in a display device, a minute distortion or the like is generated in the image due to the dent, which is a factor of deteriorating the quality of the image.

  As a technique for preventing the occurrence of the dents, Patent Document 2 discloses a transparent substrate having a hard coat layer and / or an antiglare layer formed on the first surface of the first substrate, and a transparent surface on the first surface of the second substrate. A method for producing a conductive film roll, characterized in that a transparent conductive film bonded and laminated with a conductive film formed with a conductive film is wound around a core while supplying spacers to both ends. It is disclosed.

JP 2006-189867 A Japanese Patent Laid-Open No. 2004-199643

  The optical sheet may be provided with an adhesive layer for bonding to another sheet, an image source, and the like, and a protective layer for protecting the surface of the optical sheet in the manufacturing process. The protective layer is not used as a part of the optical sheet, but is provided to protect the surface of the optical sheet during production, transportation, storage, and the like of the optical sheet. That is, the protective layer is a layer that is removed when the optical sheet is used. Thus, the protective layer is not used as a part of the optical sheet. Therefore, it is common to use a protective film of an inexpensive base material as a protective layer without considering the smoothness of the surface. When a laminated sheet comprising such a protective layer and a pressure-sensitive adhesive layer is manufactured in a strip shape and wound into a roll, the surface irregularities of the protective layer are transferred to the pressure-sensitive adhesive layer by the pressure generated when the laminated sheet is wound up. The pressure-sensitive adhesive layer is plastically deformed, and so-called “Yuzu skin” is generated.

  In the conventional techniques such as the inventions described in Patent Document 1 and Patent Document 2, the above problem is not taken into consideration, and the conventional technique cannot solve the above problem.

  Therefore, the present invention provides a sheet roll capable of preventing the surface irregularities of the protective layer from being transferred to the pressure-sensitive adhesive layer, a method for producing the sheet roll, a method for producing an optical sheet using the method for producing the sheet roll, and the It is an object to provide a method for manufacturing a display device using a method for manufacturing a sheet roll.

  The present invention will be described below. In order to facilitate understanding of the present invention, reference numerals in the accompanying drawings are appended in parentheses, but the present invention is not limited to the illustrated embodiment.

  Invention of Claim 1 is a manufacturing method of a sheet roll (1) provided with the lamination sheet (10) wound by roll shape, Comprising: A lamination sheet is arrange | positioned in the lamination | stacking direction on the outermost surface of a lamination sheet. , A peelable protective layer (19), a first base material layer (11), and a light transmission part (13) formed in parallel along the surface of the first base material layer so as to transmit light, And an optical functional layer (12) having a light absorbing portion (14) formed so as to be able to absorb light between the light transmitting portions, an adhesive layer (17) containing an adhesive, and a substrate of the adhesive layer And the second base material layer (18) to be provided in this order, a lamination step (S10) for producing a laminated sheet, and spacers (20) disposed in the vicinity of both end portions in the width direction of the laminated sheet. A sheet roll manufacturing method including a winding step (S20) of winding a laminated sheet into a roll. That.

  In the present invention, the “width direction” means a direction orthogonal to the longitudinal direction of the sheet.

  Invention of Claim 2 is a manufacturing method of the sheet roll (1) of Claim 1, WHEREIN: A lamination process (S10) is an optical function layer (one surface side of a 1st base material layer (11) ( 12) forming an optical functional layer (S11), forming a protective layer (19) on the other surface side of the first base material layer (S12), and second base material layer (18) ), A pressure-sensitive adhesive layer forming step (S13) for forming the pressure-sensitive adhesive layer (17) on one surface side, and a pressure-sensitive adhesive layer and an optical functional layer, and then bonding the pressure-sensitive adhesive layer and the optical functional layer And a combination step (S14).

  In the winding process (S20) of the manufacturing method of the sheet roll (1) according to claim 1 or 2, the invention described in claim 3 is a spacer (inside the end in the width direction of the pressure-sensitive adhesive layer (17)). 20).

  In the present invention, “inside from the end in the width direction of the pressure-sensitive adhesive layer” means that in a cross section perpendicular to the longitudinal direction of the laminated sheet, it is in contact with one end in the width direction of the pressure-sensitive adhesive layer and perpendicular to the sheet surface of the laminated sheet. It means between the line and a line that is in contact with the other end in the width direction of the pressure-sensitive adhesive layer and is perpendicular to the sheet surface of the laminated sheet.

  The invention according to claim 4 is characterized in that, in the method for producing a sheet roll (1) according to any one of claims 1 to 3, a spacer (20) having a width of 5 mm or more and 50 mm or less is used.

  The invention according to claim 5 is characterized in that, in the method for producing a sheet roll (1) according to any one of claims 1 to 4, a spacer (20) having a thickness of 6 μm or more and 50 μm or less is used.

  Invention of Claim 6 is a sheet roll (1) provided with the lamination sheet (10) wound by roll shape, Comprising: A lamination sheet is arrange | positioned on the outermost surface of a lamination sheet in the lamination direction, and it can peel. Protective layer (19), first base material layer (11), light transmission part (13) formed in parallel along the surface of the first base material layer so as to transmit light, and the light An optical functional layer (12) having a light absorption part (14) formed so as to be able to absorb light between the transmission parts, an adhesive layer (17) containing an adhesive, and a base material for the adhesive layer 2 base material layers (18) in that order, a sheet roll in which spacers (20) are arranged in the vicinity of both ends in the width direction of the laminated sheet, and the laminated sheet is wound through the spacer It is.

  Invention of Claim 7 is a manufacturing method of the optical sheet which is arrange | positioned at the observer side from an image source, controls the light which injected from this image source side, and radiate | emits it to an observer side, Comprising: 6. A method for producing an optical sheet, comprising a step of producing a sheet roll by the method for producing a sheet roll according to any one of 5 and a step of unwinding the sheet roll and cutting out a sheet having a predetermined size.

  The invention according to claim 8 is a method of manufacturing a display device having an image source and an optical sheet disposed on an observer side of the image source, and the method of manufacturing an optical sheet according to claim 7. The manufacturing method of a display apparatus including the process of manufacturing an optical sheet by this, and the process of arrange | positioning an optical sheet in the observer side of an image source.

  According to the present invention, a sheet roll capable of preventing the surface irregularities of the protective layer from being transferred to the pressure-sensitive adhesive layer, a method for producing the sheet roll, a method for producing an optical sheet using the method for producing the sheet roll, and A method for manufacturing a display device using the method for manufacturing the sheet roll can be provided.

It is sectional drawing which shows roughly a part of sheet roll of this invention which concerns on one embodiment. It is a figure which shows roughly about the cross section before winding the lamination sheet with which the sheet | seat roll shown in FIG. 1 is equipped. FIG. 3 is a cross-sectional view schematically showing a part of the optical functional layer shown in FIGS. 1 and 2. It is a figure which shows the process included in the manufacturing method of the optical sheet roll of this invention. FIG. 5A is a cross-sectional view illustrating an example of a process for forming a light transmission portion. FIG.5 (b) is a figure which shows schematically a part of cross section of the sheet | seat obtained through the process shown to Fig.5 (a). FIG. 6A is a cross-sectional view illustrating an example of a process for forming a light absorbing portion. FIG. 6B is a diagram schematically showing a part of a cross section of the sheet obtained through the process shown in FIG. FIG. 7A is a cross-sectional view illustrating an example of the protective layer forming step. FIG.7 (b) is sectional drawing explaining an adhesive layer formation process. It is a perspective view explaining an example of a winding process. It is the disassembled perspective view which showed typically the plasma television manufactured by the manufacturing method of the display apparatus of this invention which concerns on one embodiment. FIG. 10 is a diagram schematically showing a part of a cross section of a plasma display panel unit provided in the plasma television shown in FIG. 9.

  The above-described operation and gain of the present invention will be clarified from embodiments for carrying out the invention described below. Hereinafter, the present invention will be described based on embodiments shown in the drawings. However, the present invention is not limited to these embodiments. In the drawings, for convenience of illustration and easy understanding, the scale and vertical / horizontal dimensional ratios are appropriately changed from those of the actual ones and exaggerated. Moreover, in each drawing, the code | symbol which becomes repeated may be abbreviate | omitted for visibility.

1. Sheet roll 1.1. Configuration of Sheet Roll The sheet roll of the present invention includes a laminated sheet wound in a roll shape. As will be described later, the sheet cut out from the sheet roll of the present invention is arranged on the viewer side from the image source except for a part, and the light incident from the image source side is controlled and emitted to the viewer side. It can be used as a possible optical sheet.

  FIG. 1 is a cross-sectional view schematically showing a part of a sheet roll 1 of the present invention according to one embodiment. In FIG. 1, the horizontal direction is the width direction of the laminated sheet 10, and the vertical direction is the thickness direction of the laminated sheet 10. FIG. 2 is a view schematically showing a cross section before the laminated sheet 10 provided in the sheet roll 1 is wound. In FIG. 2, the horizontal direction is the width direction of the laminated sheet 10, the vertical direction is the thickness direction of the laminated sheet 10, and the back / front direction is the longitudinal direction of the laminated sheet 10. As shown in FIG. 1, the sheet roll 1 includes a laminated sheet 10 and a spacer 20. Moreover, as shown in FIG.1 and FIG.2, the lamination sheet 10 has the protective layer 19, the 1st base material layer 11, the optical function layer 12, the adhesive layer 17, and the 2nd base material layer 18 in the lamination direction. It is provided in this order. These layers maintain the cross section shown in FIG. 2 and extend in the back / front direction. The spacer 20 is disposed in the vicinity of both end portions in the width direction of the laminated sheet 10, and the laminated sheet 10 is wound via the spacer 20 as shown in FIG. 1. These elements are described below.

(First base material layer 11)
The 1st base material layer 11 is a layer used as the base material for forming the optical function layer 12 demonstrated in detail later. The first base material layer 11 is preferably made of a material mainly composed of polyethylene terephthalate (PET) from the viewpoint of mass productivity, price, availability, etc. in addition to performance. Here, “main component” means that the PET is contained in an amount of 50% by mass or more with respect to the entire material forming the base material layer (hereinafter the same). Moreover, the 1st base material layer 11 has PET as a main component, and may contain other resin. Furthermore, various additives may be appropriately added to the first base material layer 11. Examples of general additives include phenol-based antioxidants, lactone-based stabilizers, and the like.

  However, the main component of the material constituting the first base material layer 11 is not necessarily PET, and may be other materials. Examples thereof include polybutylene terephthalate, polyethylene naphthalate, terephthalic acid-isophthalic acid-ethylene glycol copolymer, polyester resins such as terephthalic acid-cyclohexanedimethanol-ethylene glycol copolymer, and polyamide resins such as nylon 6. , Polyolefin resins such as polypropylene and polymethylpentene, acrylic resins such as polymethyl methacrylate, styrene resins such as polystyrene and styrene-acrylonitrile copolymer, cellulose resins such as triacetyl cellulose, imide resins and polycarbonate resins Etc. Moreover, you may add additives, such as a ultraviolet absorber, a filler, a plasticizer, an antistatic agent, in these resins suitably as needed.

(Optical function layer 12)
Next, the optical function layer 12 will be described. The optical functional layer 12 is a layer that has a function of appropriately absorbing stray light and external light while controlling the optical path of the image light incident from the image source side. FIG. 3 is an enlarged view showing a part of the optical functional layer 12 shown in FIGS. 1 and 2. The optical functional layer 12 will be further described with reference to FIGS.

  The optical functional layer 12 includes light transmitting parts 13, 13,... Arranged in parallel along the layer surface so that light can be transmitted, and a light absorbing part 14 arranged in parallel so as to absorb light between the light transmitting parts 13, 13,. , 14,... The optical functional layer 12 includes the light transmitting portions 13, 13,... And the light absorbing portions 14, 14, so that the optical path of the image light incident from the image source side when provided in the display device. It is possible to have a function of appropriately absorbing stray light and external light.

  The light transmission portions 13, 13,... Are elements having a function of transmitting image light, and are elements having a substantially trapezoidal cross section in the cross section shown in FIGS. An upper base and a lower base longer than the upper base in the substantially trapezoidal cross section are arranged in a direction along the layer surface of the optical functional layer 12. Further, the light transmitting portions 13, 13,... Have a refractive index of Np and have light transmittance. Such a light transmission part 13,13, ... can be comprised by hardening the light transmission part structure composition demonstrated below. The value of the refractive index Np is not particularly limited, but is preferably 1.49 to 1.56 from the viewpoint of the availability of the applied material.

  The light transmissive part constituting composition is preferably one that can be cured by light such as ultraviolet rays. For example, the following photocurable prepolymer (P1), reactive diluent monomer (M1), and photopolymerization initiator (S1) A photocurable resin composition containing the above is preferably used.

  Examples of the photocurable prepolymer (P1) include epoxy acrylate-based, urethane acrylate-based, polyether acrylate-based, polyester acrylate-based, and polythiol-based prepolymers.

  Examples of the reactive dilution monomer (M1) include vinyl pyrrolidone, 2-ethylhexyl acrylate, β-hydroxy acrylate, and tetrahydrofurfuryl acrylate.

  Examples of the photopolymerization initiator (S1) include hydroxybenzoyl compounds (2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, benzoin alkyl ether, etc.), benzoyl Formate compounds (such as methylbenzoylformate), thioxanthone compounds (such as isopropylthioxanthone), benzophenones (such as benzophenone), phosphate compounds (1,3,5-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-) Trimethylbenzoyl) -phenylphosphine oxide and the like, and benzyldimethyl ketal and the like. Of these, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, and bis (2,4) are preferable from the viewpoint of preventing coloring of the light transmitting portions 13, 13,. , 6-trimethylbenzoyl) -phenylphosphine oxide. In addition, it is preferable that the said photoinitiator (S1) is contained 0.5 mass% or more and 5.0 mass% or less on the basis (100 mass%) of light transmission part structure composition whole quantity.

  These photocurable prepolymer (P1), reactive diluent monomer (M1) and photopolymerization initiator (S1) can be used alone or in combination of two or more. In addition, in the light transmitting part constituting composition, if necessary, silicone additives, rheology control agents, It is also possible to add a defoaming agent, a release agent, an antistatic agent, an ultraviolet absorber and the like.

  Next, the light absorbers 14, 14,... Will be described. The light absorbing portions 14, 14,... Are elements disposed between the light transmitting portions 13, 13,... And having a substantially trapezoidal surface in the cross section shown in FIGS. In the substantially trapezoidal cross section of the light absorbing portions 14, 14,..., An upper base and a lower base longer than the upper base are arranged in a direction along the layer surface of the optical function layer 12. In addition, a surface corresponding to the lower base of the substantially trapezoidal cross section of the light absorbing portions 14, 14,... Is juxtaposed between the upper bases of the light transmitting portions 13, 13,. And one surface of the optical functional layer 12 is formed by the lower base of the light absorption parts 14, 14,... And the upper base of the light transmission parts 13, 13,. It is preferable that the hypotenuse in the substantially trapezoidal cross section of the light absorbing parts 14, 14,... When the angle of the hypotenuse is close to 0 degrees, the cross sections of the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,. Further, the inclination of the oblique sides of the light absorbing portions 14, 14,... Is not necessarily constant, and may be a polygonal line or a curved line. Furthermore, the light absorbing portions 13, 13,... May have a substantially triangular cross section.

  Further, the light absorbing portions 14, 14,... Are made of a predetermined material having a refractive index Nb smaller than the refractive index Np of the light transmitting portions 13, 13,. As described above, the refractive index Np of the light transmitting portions 13, 13... And the refractive index Nb of the light absorbing portions 14, 14,... Satisfy Np> Nb, so that the image source incident on the light transmitting portions 13, 13,. Can be totally reflected by Snell's law at the interface between the light absorbing parts 14, 14,... And the light transmitting parts 13, 13,. The difference in refractive index between Np and Nb is not particularly limited, but is preferably greater than 0 and 0.06 or less.

  Further, in the present embodiment, the relationship of Np> Nb is preferable as described above, but is not necessarily limited to this, and the refractive index of the light transmission part and the refractive index of the light absorption part may be the same. It is also possible to make the refractive index of the light transmission part smaller than the refractive index of the light absorption part.

  In addition, the light-absorbing part 14, 14,... In the present embodiment is a light-absorbing part-constituting composition comprising the light-absorbing particles 16, 16,... And the binder 15 in which the light-absorbing particles 16, 16,. It is configured by filling a groove between the light transmitting portions 13, 13,. As a result, the stray light incident on the inside of the light absorbing portions 14, 14,... Without being reflected by Snell's law at the interface between the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,. 16, 16, ... can be absorbed. Furthermore, the external light from the observer side incident at a predetermined angle can be appropriately absorbed by the light absorbing particles 16, 16,..., And the contrast of the image can be improved.

  It should be noted that configuring the light absorbing portions 14, 14,... By a predetermined material having a refractive index Nb means that the binder 15 is configured by a material having a refractive index Nb, for example. Although what is used as the said binder 15 is not specifically limited, What is hardened | cured by light, such as an ultraviolet-ray, is preferable, for example, a reactive dilution monomer (M2) and photopolymerization to a photocurable prepolymer (P2). A photocurable resin composition containing an initiator (S2) is preferably used.

  Examples of the photocurable prepolymer (P2) include urethane (meth) acrylate, polyester (meth) acrylate, epoxy (meth) acrylate, and butadiene (meth) acrylate.

  Examples of the reactive dilution monomer (M2) include monofunctional monomers such as N-vinyl pyrrolidone, N-vinyl caprolactone, vinyl imidazole, vinyl pyridine, styrene, and other vinyl monomers, lauryl (meth) acrylate, stearyl ( (Meth) acrylate, butoxyethyl (meth) acrylate, ethoxydiethylene glycol (meth) acrylate, methoxytriethylene glycol (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, methoxydipropylene glycol (meth) acrylate, paracumylphenoxyethyl (meth) ) Acrylate, nonylphenoxy polyethylene glycol (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, isobornyl (meth) a (Meth) acrylic acid ester monomers such as relate, cyclohexyl (meth) acrylate, benzyl methacrylate, N, N-dimethyl (meth) acrylamide, N, N-dimethylaminopropyl (meth) acrylate, acryloylmorpholine, A (meth) acrylamide derivative is mentioned. Polyfunctional monomers include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, polytetra Methylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, 3-methyl-1, 5-pentanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, dimethylol-tricyclodecane di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate Bisphenol A polypropoxydiol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) Acrylate, glyceryl tri (meth) acrylate, propoxylated glyceryl tri (meth) acrylate, tris (2-hydroxyethyl) isocyanurate triacrylate, pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate And dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and the like.

  Examples of the photopolymerization initiator (S2) include 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2,2-dimethoxy-1,2-diphenylethane- Examples include 1-one, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, and bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide. Among these, the irradiation device for curing the photocurable resin composition and the curability of the photocurable resin composition can be arbitrarily selected. In the present invention, the amount of the photopolymerization initiator (S2) contained in the photocurable resin composition is based on the total amount of the photocurable resin composition from the viewpoint of curability and cost of the photocurable resin composition (100 mass). %) Is preferably included in an amount of 0.5% by mass or more and 10.0% by mass or less.

  These photocurable prepolymer (P2), reactive diluent monomer (M2) and photopolymerization initiator (S2) can be used alone or in combination of two or more. Specifically, refraction of polymerizable components (specifically, photocurable prepolymer (P2) and reactive dilution monomer (M2)) composed of urethane acrylate, epoxy acrylate, tripropylene glycol diacrylate and methoxytriethylene glycol acrylate. The ratio, viscosity, or influence on the performance of the optical functional layer 12 can be taken into consideration and used.

  Moreover, you may add silicone, an antifoamer, a leveling agent, a solvent, etc. to a light absorption part structure composition as an additive as needed.

  The light absorbing particles 16, 16,... Are included in the light absorbing portion constituting composition, and act to absorb stray light and external light when the light absorbing portions 14, 14,.

  As the light-absorbing particles 16, 16,..., Light-absorbing colored particles such as carbon black are preferably used. However, the present invention is not limited to these, and a specific wavelength is selectively selected according to the characteristics of the image light. Absorbing colored particles may be used. Specifically, organic fine particles colored with metal salts such as carbon black, graphite, black iron oxide, dyes, pigments, colored glass beads, and the like can be used as the light absorbing particles 16, 16,. In particular, colored organic fine particles are preferably used from the viewpoints of cost, quality, availability, and the like. More specifically, acrylic cross-linked fine particles containing carbon black, urethane cross-linked fine particles containing carbon black, and the like are preferably used. These light absorbing particles 16, 16,... Are usually contained in the light absorbing part constituting composition in a range of 3% by mass to 30% by mass. The average particle diameter of the light absorbing particles 16, 16,... Is preferably 1.0 μm or more and 20 μm or less. As described later (see FIG. 6A), in the method of manufacturing the light absorbing portions 14, 14,..., The light absorbing portion constituting composition 46 containing the light absorbing particles 16, 16,. A step of scraping off an excess of the light absorbing portion constituent composition 46 using the doctor blade 47 while filling the grooves 13a, 13a,. At this time, by using the light absorbing particles 16, 16,... Having an average particle diameter of 1.0 μm or more, the light absorbing particles 16, 16,... Are disposed between the doctor blade 47 and the light transmitting portions 13, 13,. It is possible to prevent the light absorption particles 16, 16,... From remaining on the light transmitting portions 13, 13,.

  In addition, depending on the material constituting the light transmitting portions 13, 13,..., The surfaces of the light absorbing portions 14, 14,... Are filled on the same plane (smooth) with respect to the surfaces of the light transmitting portions 13, 13,. In some cases, a concave portion may be formed on the light absorbing portions 14, 14,. The concave portion is used when the light absorbing portion constituting composition 46 is scraped off using the doctor blade 47 as described later (see FIG. 6A), when the light absorbing portion constituting composition 46 is cured, or the like. Formed.

  Note that the means for absorbing light by the light absorbing portion is not limited to the method using the light absorbing particles as in the present embodiment. For example, the whole light absorption part can also be colored using the light absorption part structural composition colored with the pigment or dye.

(Adhesive layer 17)
Next, the adhesive layer 17 will be described. The pressure-sensitive adhesive layer 17 is a layer composed of a pressure-sensitive adhesive composition containing a pressure-sensitive adhesive. The pressure-sensitive adhesive refers to one type of adhesive. When bonding, it is performed at room temperature (for example, 15 to 40 ° C.), and the surface is only sticky by pressing moderately, usually lightly by hand. It means that it can be bonded only by its properties. The material of the pressure-sensitive adhesive composition is not particularly limited as long as it transmits light and has appropriate adhesiveness. The adhesive strength of the adhesive layer 17 can be set to, for example, about several N / 25 mm to 20 N / 25 mm.

  The pressure-sensitive adhesive that can be used for the pressure-sensitive adhesive layer 17 is not particularly limited as long as it achieves necessary film forming properties, light transmittance, pressure-sensitive adhesiveness, and weather resistance, and various conventionally known pressure-sensitive adhesives can be used. It can be appropriately selected and used. The higher the transparency of the pressure-sensitive adhesive layer 17 is, the better, but the light transmittance is preferably such that the wavelength average light transmittance in the visible light region of 380 to 780 nm is 70% or more, more preferably 80% or more.

  Examples of the constituent material of the pressure-sensitive adhesive include natural rubber, synthetic rubber, acrylic resin (hereinafter referred to as “acrylic”), silicone resin, and polyester resin. Specific examples of synthetic rubbers include styrene-butadiene rubber, acrylonitrile-butadiene rubber, and polyisobutylene rubber. These pressure-sensitive adhesives can be used alone or in combination of two or more.

  An acrylic adhesive is mentioned as an adhesive suitably used. The acrylic pressure-sensitive adhesive is a polymer containing at least a (meth) acrylic acid alkyl ester monomer. A copolymer of a (meth) acrylic acid alkyl ester monomer having an alkyl group having about 1 to 18 carbon atoms and a monomer having a carboxyl group, or (meth) acrylic acid having an alkyl group having about 1 to 18 carbon atoms A copolymer using two or more kinds of alkyl ester monomers is generally used. In the present invention, (meth) acrylic acid means acrylic acid and / or methacrylic acid.

  Examples of (meth) acrylic acid alkyl ester monomers used here include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, n-butyl (meth) acrylate, etc. Can be mentioned.

The pressure-sensitive adhesive composition may contain an ultraviolet absorber, a near-infrared absorber, a neon line absorber, a toning pigment, and the like as desired. Moreover, when bonding the adhesive layer 17 to the electromagnetic wave shielding layer described later, an antioxidant such as benzotriazole is included in the adhesive composition, or an acid group such as —COOH or —NH ₂ is used. It is desirable that it is not contained in the composition.

(Protective layer 19)
Next, the protective layer 19 will be described. The protective layer 19 is a layer provided on the outermost surface of the laminated sheet 10 in order to protect the surface of the laminated sheet 10 used as an optical sheet during production, transportation, storage, etc. of the sheet roll 1. is there. The protective layer 19 is a layer that is removed when a part of the laminated sheet 10 is used as an optical sheet. Therefore, the protective layer 19 is comprised by the film (henceforth "protective film") which can be peeled after once bonding. As such a protective film, a known film can be used.

  The protective film has an adhesive layer composed of an adhesive on one surface of the substrate. Examples of the base material of the protective film include polyesters such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, terephthalic acid-isophthalic acid-ethylene glycol copolymer, and terephthalic acid-cyclohexanedimethanol-ethylene glycol copolymer. Examples thereof include resins, polyamide resins such as nylon 6, polyolefin resins such as polypropylene, polymethylpentene, and cycloolefin polymers, paper such as high-quality paper, parchment paper, and sulfuric acid paper. These resins can be used alone or as a plurality of types of mixed resins (including polymer alloys). The base material of the protective film can be composed of a single layer or a laminate of two or more layers made of the above materials.

  Although the thickness of the base material of a protective film is not specifically limited, 10 micrometers or more and 100 micrometers or less are preferable. In order to improve the adhesion between the substrate and the pressure-sensitive adhesive layer, easy adhesion treatment such as corona discharge treatment, plasma treatment, primer coating, degreasing treatment, surface roughening treatment, etc. is applied to the surface of the substrate as necessary. It can also be done.

  The pressure-sensitive adhesive layer of the protective film is required to leave no pressure-sensitive adhesive on the adherend during peeling. Therefore, the adhesive strength of the adhesive needs to be in an appropriate range. Therefore, the adhesive strength of the adhesive is preferably about 1 N / 25 mm or less. Examples of such an adhesive include natural rubber, synthetic rubber, acrylic resin (hereinafter referred to as “acrylic”), silicone resin, polyester resin, and the like. Specific examples of synthetic rubbers include styrene-butadiene rubber, acrylonitrile-butadiene rubber, and polyisobutylene rubber.

(Second base material layer 18)
Next, the second base material layer 18 will be described. The second base material layer 18 is a layer that becomes a base material of the pressure-sensitive adhesive layer 17. The second base material layer 18 can be composed of a release film similar to the protective layer 19. When the second base material layer 18 is composed of a release film, it prevents foreign matter from adhering to the portion of the pressure-sensitive adhesive layer 17 that is used as an optical sheet, and prevents the pressure-sensitive adhesive layer 17 from coming into contact with others. can do. When the 2nd base material layer 18 is comprised with a release film, when using a part of lamination sheet 10 as an optical sheet, it is removed.

  Moreover, the layer with which an optical sheet is equipped can also be used for the 2nd base material layer 18. FIG. Examples thereof include an electromagnetic wave shielding layer, an antiglare layer, an antireflection layer, a hard coat layer, and a wavelength filter layer described below.

(Other layers)
In the description of the present invention so far, the laminated sheet 10 has been described with respect to the form in which the protective layer 19, the first base material layer 11, the optical function layer 12, the adhesive layer 17, and the second base material layer 18 are provided. The sheet 10 may be provided with a layer having other functions depending on the application. As other layers that can be provided in the laminated sheet 10, those used in the conventional optical sheet can be used without any particular limitation. Specific examples include an electromagnetic wave shielding layer, an antiglare layer, an antireflection layer, a hard coat layer, a wavelength filter layer, and an impact absorption layer. These layers can be used as the second base material layer 18 as described above, and can be bonded to other layers using an adhesive layer. As the pressure-sensitive adhesive layer, a known pressure-sensitive adhesive can be used in the same manner as the pressure-sensitive adhesive layer 17, and similarly to the pressure-sensitive adhesive layer 17, an ultraviolet absorber, a near-infrared absorber, a neon line absorber, and a preparation are used. It is also possible to include color pigments. The stacking order and the number of stacking of these layers are appropriately determined according to the use of the optical sheet cut out from the stacking sheet 10. The functions of these layers will be described below.

  As the name indicates, the electromagnetic wave shielding layer is a layer having a function of shielding electromagnetic waves. As long as the layer has the function, a means for blocking electromagnetic waves is not particularly limited. For example, a metal (copper etc.) mesh can be mentioned. As a method for obtaining the metal mesh, it is effective to form a fine metal mesh pattern by etching, vapor deposition or the like. The pitch of the metal mesh is appropriately designed depending on the electromagnetic wave to be blocked, the required transmittance, and the state of occurrence of moire, and examples thereof include a pitch of about 300 μm and a line width of 12 μm.

  The antiglare layer is a layer having a function of suppressing so-called glare and is sometimes called an antiglare layer or an AG layer. Such an antiglare layer can be constituted by using a commercially available film.

  The antireflection layer is a layer having a function of preventing reflection of external light. According to this, it can suppress that external light reflects on the observer side surface of an optical sheet, returns to the observer side, and what is called a reflection is produced on a display surface, and an image becomes difficult to see. Such an antireflection layer can be constituted by using a commercially available antireflection film.

  The hard coat layer is sometimes called an HC layer. This is a layer in which a film having a function capable of imparting scratch resistance is provided in order to prevent the display surface from being scratched.

  The wavelength filter layer is a layer having a function of suppressing transmission of light having a predetermined wavelength. The wavelength whose transmission should be suppressed can be appropriately selected as necessary. Specific examples of the wavelength filter layer include a layer that absorbs neon rays emitted from the PDP, an infrared ray, a near infrared ray, and an ultraviolet ray, a layer that adjusts color tone, and the like. The wavelength filter layer can also be combined with other functional layers such as an adhesive layer.

  The shock absorbing layer is a layer for protecting the PDP panel (glass) from an external shock. Usually, a resin material having a thickness of about 200 μm to 1000 μm and absorbing an impact is used.

(Spacer 20)
Next, the spacer 20 will be described. By providing the sheet roll 1 with the spacer 20, the pressure applied to the laminated sheet 10 that is wound (mainly in the diameter direction (normal direction) of the sheet roll 1) during manufacture, transportation, storage, and the like of the sheet roll 1. In the region other than the portion where the spacer 20 is provided. Therefore, by providing the spacer 20, it is possible to prevent the unevenness on the surface of the protective layer 19 from being transferred to the pressure-sensitive adhesive layer 17. In addition, in the part with which the spacer 20 is provided, the said pressure concerning the lamination sheet 10 increases compared with the case where the spacer 20 is not provided, and there exists a possibility that the dent of the spacer 20 may be stamped. However, since these portions are both ends in the width direction of the laminated sheet 10 and are usually portions that are cut out and discarded, there is no particular inconvenience.

  Examples of the spacer 20 that can be used include polyester resins such as polyethylene terephthalate, polyamide resins such as nylon, polyolefin resins such as polyethylene and polypropylene, and rigid thermoplastic resins such as polyvinyl chloride and polystyrene. Examples thereof include materials having excellent elasticity such as high-quality Japanese paper, non-woven fabric, urethane foam sheet, and polyethylene foam sheet. When a material having excellent elasticity is used as the spacer 20, a streak-like dent is less likely to occur at the end of the portion of the laminated sheet 10 where the spacer 20 is provided. Therefore, the effective area of the laminated sheet 10 (used as an optical sheet) The region that can be formed) can be widened, which is preferable.

  The arrangement position of the spacer 20 is preferably inside the end in the width direction of the pressure-sensitive adhesive layer 17 and is preferably in a range of 50 mm or less from the end in the width direction of the pressure-sensitive adhesive layer 17. That is, D shown in FIG. 1 is preferably 50 mm or less. By arranging the spacer 20 inside the widthwise end of the pressure-sensitive adhesive layer 17, it becomes easy to prevent the pressure generated when the laminated sheet 10 is rolled up from being applied to the pressure-sensitive adhesive layer 17. It becomes easy to prevent the surface irregularities from being transferred to the pressure-sensitive adhesive layer 17. Further, by arranging the spacer 20 within a range of 50 mm or less from the widthwise end of the pressure-sensitive adhesive layer 17, the unevenness of the protective layer 19 is transferred to the pressure-sensitive adhesive layer 17 while ensuring a sufficient effective area of the laminated sheet 10. It becomes easy to prevent that.

  The thickness of the spacer 20 is preferably 6 μm or more and 50 μm or less. By setting the thickness of the spacer 20 to 6 μm or more, it becomes easy to reduce the pressure applied to the laminated sheet 10 in a portion where the spacer 20 is not provided, and the unevenness of the protective layer 19 is transferred to the adhesive layer 17. It becomes easy to prevent. Moreover, when the thickness of the spacer 20 is 50 μm or less, it becomes easy to prevent the occurrence of winding deviation when the laminated sheet 10 is wound.

  Moreover, the width | variety of the laminated sheet 10 is 1000 mm or more and 1600 mm or less normally, and it is preferable that the width of the spacer 20 is 5 mm or more and 50 mm or less in this case. By setting the width of the spacer 20 to 5 mm or more, it is easy to reduce the pressure applied to the laminated sheet 10 in a portion where the spacer 20 is not provided, and the unevenness of the protective layer 19 is prevented from being transferred to the pressure-sensitive adhesive layer 17. It becomes easy to do. By setting the width of the spacer 20 to 50 mm or less, it becomes easy to prevent the unevenness of the protective layer 19 from being transferred to the pressure-sensitive adhesive layer 17 while ensuring a sufficient effective area of the laminated sheet 10.

1.2. Sheet Roll Manufacturing Method The sheet roll 1 described above is taken as an example to describe the sheet roll manufacturing method of the present invention. FIG. 4 is a flowchart showing the steps included in the method for producing an optical sheet of the present invention according to one embodiment. The sheet roll manufacturing method of the present invention shown in FIG. 4 includes a laminating step (hereinafter sometimes simply referred to as “step S10”) and a winding step (hereinafter simply referred to as “step S20”). Have).

<Lamination process (process S10)>
Step S <b> 10 is a step of manufacturing the laminated sheet 10. As shown in FIG. 4, the step S10 may be described as an optical functional layer forming step (hereinafter sometimes simply referred to as “step S11”) and a protective layer forming step (hereinafter simply referred to as “step S12”). ), A pressure-sensitive adhesive layer forming step (hereinafter sometimes simply referred to as “step S13”), and a bonding step (hereinafter simply referred to as “step S14”). Yes. These steps will be described below.

(Optical function layer forming step (step S11))
Step S <b> 11 is a step of forming the optical function layer 12 on the first base material layer 11. In order to form the optical functional layer 12, first, light transmitting portions 13, 13,... That are arranged in parallel along the surface of the first base material layer 11 and can transmit light are formed. FIG. 5A is a cross-sectional view schematically showing an example of a process for forming the light transmitting portions 13, 13,... FIG. 5B is a diagram schematically showing a cross section of the sheet obtained through this process. Referring to FIGS. 5A and 5B, the process of forming the light transmission parts 13, 13,... Will be described below.

  In order to form the light transmitting portions 13, 13,..., First, a die roll 42 having grooves having a shape corresponding to the shape of the light transmitting portions 13, 13,. Next, the base material 11 ′ to be the base material layer 11 or including the layer to be the base material layer 11 is fed between the mold roll 42 and the nip roll 41. An arrow x1 shown in FIG. 5A is a direction in which the base material 11 'is fed. In accordance with the feeding of the base material 11 ′, the droplets of the light transmitting portion constituting composition 40 are continuously supplied from the supply device 45 between the mold roll 42 and the base material 11 ′. When the light transmitting portion constituting composition 40 is supplied from the supply device 45 onto the base material 11 ′, a bank in which the light transmitting portion constituting composition 40 is accumulated is formed between the mold roll 42 and the base material 11 ′. So that In this bank, the light transmitting portion constituting composition 40 spreads in the width direction of the base material 11 ′.

  The light transmitting portion constituting composition 40 supplied between the mold roll 42 and the base material 11 ′ as described above is formed by the pressing force between the mold roll 42 and the nip roll 41. It is filled between the rolls 42. Then, the light transmissive portions 13, 13... Can be formed by irradiating the light transmissive portion constituting composition 40 with ultraviolet rays or the like by the light irradiation device 44 and curing the light transmissive portion constituting composition. After the light transmitting portions 13, 13,... Are formed, the sheet on which the light transmitting portions 13, 13,. Torn off.

  In this way, a sheet in which the light transmitting portions 13, 13,... Are formed on the base material layer 11 as shown in FIG. The sheet has grooves 13a, 13a,... Between the light transmission portions 13, 13,.

  Next, light absorbing portions 14, 14,... Capable of absorbing light are formed between the light transmitting portions 13, 13,. FIG. 6A is a perspective view schematically showing an example of a process for forming the light absorbing portions 14 and 14. FIG. 6B is a diagram schematically showing a cross section of the sheet obtained through the process. Referring to FIGS. 6A and 6B, the process of forming the light absorbing portions 14, 14,... Will be described below.

  In order to form the light absorbing portions 14, 14,..., First, as shown in FIG. 6A, the light absorbing portion constituting composition 46 is supplied onto the light transmitting portions 13, 13,. Next, while the doctor blade 47 fills the light absorbing portion constituting composition 46 into the grooves 13a, 13a,... Between the light transmitting portions 13, 13,..., The excess light absorbing portion constituting composition 46 is scraped off. . Then, the light absorbing portions 14, 14,... Are formed by irradiating and curing the light absorbing portion constituting composition 46 in the grooves 13a, 13a,... Between the light transmitting portions 13, 13,. can do. The arrow x2 shown in FIG. 6A is the sheet feeding direction obtained through the step S11.

  In the step of forming the light absorbing portions 14, 14,..., The elastic modulus of the light transmitting portions 13, 13,... Is preferably 10 MPa or more and less than 2000 MPa. When the elastic modulus of the light transmission parts 13, 13,... Is 2000 MPa or more, the optical function layer becomes hard when cracks or chipping occurs, or when the light absorption parts 14, 14,. There is a possibility that an appearance defect may occur on the surface of 12 or the transmittance of the optical functional layer 12 may decrease. That is, when the light transmitting parts 13, 13,... Are too hard, when the doctor blade 47 scrapes off the surplus portion of the light absorbing part constituting composition 46 supplied onto the light transmitting parts 13, 13,. Are not deformed even if they are pressed against the light transmitting portions 13, 13,..., And therefore there is a possibility that the excess light absorbing portion constituting composition 46 cannot be scraped off. When the elastic modulus of the light transmitting portions 13, 13,... Is in the above range, when the doctor blade 47 is pressed, the excess light absorbing portion constituting composition 46 is scraped off due to the deformation of the light transmitting portions 13, 13,. Defects can be reduced and appearance defects on the surface of the optical functional layer 12 can be prevented, and the transmittance of the optical functional layer 12 can be prevented from decreasing. If the elastic modulus of the light transmission parts 13, 13,... Is less than 10 MPa, the light transmission parts 13, 13,... Are too soft, so when forming the light transmission parts 13, 13,. 13, 13,... May be difficult to release from the mold roll 42.

  In this way, according to step S11, as shown in FIG. 6B, the optical functional layer having the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,. 12 can be formed.

(Protective layer forming step (step S12))
FIG. 7A is a diagram illustrating step S12. Step S12 is a step of forming the protective layer 19 on the opposite side of the first base material layer 11 from which the optical functional layer 12 is formed, as shown in FIG. 7A. The protective layer 19 can be formed by bonding the above-described protective film so that the adhesive layer is on the first base material layer 11 side.

  FIG. 4 illustrates a mode in which step S12 is performed between step S11 and step S14. However, step S12 may be performed before step S11 or after step S14. Good.

(Adhesive layer forming step (step S13))
FIG. 7B is a diagram illustrating step S13. Step S13 is a step of forming the pressure-sensitive adhesive layer 17 on one surface side of the second base material layer 18 as shown in FIG. The formation method of the adhesive layer 17 is not specifically limited. For example, the pressure-sensitive adhesive layer 17 can be formed by coating and drying the above-described pressure-sensitive adhesive composition on one surface side of the second base material layer 18. Moreover, the coating method of an adhesive composition is not specifically limited, either. Specific examples of the method for applying the pressure-sensitive adhesive composition include a method of discharging the pressure-sensitive adhesive composition using a slit-like nozzle so that the pressure-sensitive adhesive composition has a constant thickness.

(Bonding process (process S14))
Step S14 is a step in which the optical functional layer 12 formed in step S11 and the pressure-sensitive adhesive layer 17 formed in step S13 are bonded to produce a laminated sheet 10 (see FIG. 2). The method for bonding the optical functional layer 12 and the pressure-sensitive adhesive layer 17 is not particularly limited. For example, by laminating the sheet produced in step S11 and the sheet produced in step S13 so that the optical functional layer 12 and the adhesive layer 17 face each other, and applying a predetermined pressure in the laminating direction, the optical functional layer 12 and the adhesive layer 17 can be bonded together.

  At this time, even if the concave portion is formed on the light absorbing portion 14 as described above by bonding the pressure sensitive adhesive layer 17 and the optical functional layer 12 before curing the pressure sensitive adhesive layer 17. Since the concave portion can be filled with the pressure-sensitive adhesive layer 17, it is possible to prevent bubbles from entering between the optical function layer 12 and the pressure-sensitive adhesive layer 17. By preventing bubbles from entering between the optical functional layer 12 and the pressure-sensitive adhesive layer 17, it is possible to prevent image light from being irregularly reflected when a part of the laminated sheet 10 is used as an optical sheet. Can be prevented from becoming cloudy.

<Winding process (process S20)>
FIG. 8 is a perspective view illustrating the winding process. Step S20 is a step of manufacturing the sheet roll 1 by winding the laminated sheet 10 in a roll shape while arranging the spacers 20 at both ends in the width direction of the laminated sheet 10 produced in Step S10 as shown in FIG. is there. Since the position where the spacer 20 is disposed, the width and thickness of the spacer 20 and the like are as described above, description thereof will be omitted.

  The method for winding the laminated sheet 10 is not particularly limited, and a method similar to the conventional method can be used. For example, the sheet roll 10 can be manufactured by winding an appropriate tension in the longitudinal direction (winding direction) of the laminated sheet 10 and winding it around an axis having an appropriate thickness.

  According to the method for producing a sheet roll of the present invention, the laminated sheet is wound via the spacer, so that, as described above, in the region other than the portion where the spacer is provided, the pressure applied to the laminated sheet is reduced. And it can prevent that the unevenness | corrugation of the surface of a protective layer is transcribe | transferred to an adhesive layer.

2. Next, a method for manufacturing the optical sheet of the present invention will be described. The optical sheet manufacturing method of the present invention is a method of manufacturing an optical sheet that is arranged on the viewer side from the video source, and controls the light incident from the video source side to be emitted to the viewer side. More specifically, the optical sheet manufacturing method of the present invention includes a step of manufacturing a sheet roll by the above-described method of manufacturing a sheet roll of the present invention, and a step of unwinding the sheet roll and cutting out a sheet having a predetermined size. It is a method including.

  Since the method for manufacturing the sheet roll is as described above, the description thereof is omitted. A method for unwinding the sheet roll and cutting out a sheet having a predetermined size is not particularly limited, and a method similar to the conventional method can be used. After cutting out a sheet having a predetermined size in this way, an optical sheet can be obtained by removing a layer unnecessary as an optical sheet such as a protective layer. In addition, the other layers provided in the laminated sheet described above may be provided in a sheet roll, and may be bonded to the sheet after cutting out a sheet having a predetermined size as described above. .

  As described above, according to the method for producing a sheet roll of the present invention, it is possible to prevent unevenness on the surface of the protective layer from being transferred to the pressure-sensitive adhesive layer. Therefore, according to the manufacturing method of the optical sheet of the present invention using the sheet roll manufactured by the manufacturing method of the sheet roll of the present invention, the optical in which unevenness on the surface of the protective layer is prevented from being transferred to the adhesive layer. Sheets can be manufactured. Therefore, according to the method for producing an optical sheet of the present invention, it is possible to produce an optical sheet capable of preventing image distortion and the like from being caused when the display device is provided and preventing deterioration of image quality. Can do.

3. Next, a method for manufacturing a display device according to the present invention will be described. A method for manufacturing a display device according to the present invention is a method for manufacturing a display device having an image source and an optical sheet disposed on an observer side of the image source, and the method for manufacturing an optical sheet according to the present invention described above. A step of manufacturing the optical sheet, and a step of arranging the optical sheet on the viewer side of the image source. The manufacturing method of the display device of the present invention will be described with reference to FIGS.

  FIG. 9 is an exploded perspective view schematically showing a display device 100 (plasma television 100) manufactured by the display device manufacturing method of the present invention according to one embodiment. In FIG. 9, the upper right side of the drawing shows the observer side, and the lower left side of the drawing shows the back side. As can be seen from FIG. 9, the plasma television 100 includes a plasma display panel unit 103 (PDP unit 103) inside the casing formed by the front casing 101 and the rear casing 102. In addition to the PDP unit 103, the plasma television 100 is provided with usual devices included in the plasma television in the casing. Examples thereof include various electric circuits and cooling means.

  FIG. 10 schematically shows the configuration of the PDP unit 103. In FIG. 10, the right side of the drawing is the observer side. The PDP unit 103 includes a PDP 104 that is a video source, and an optical sheet 10 a that is disposed on the video light emission side of the PDP 104. Here, a known PDP can be applied to the PDP 104. The optical sheet 10a is manufactured by the above-described optical sheet manufacturing method of the present invention. The optical sheet 10a includes a wavelength filter layer 31, an electromagnetic wave shielding layer 32 having a metal mesh layer 32b formed on a base material layer 32a, an adhesive layer 17, an optical functional layer 12, a first base material layer 11, and an antireflection layer. 33 is provided.

  The optical sheet 10a is an optical sheet manufactured by the method for manufacturing an optical sheet of the present invention, and the manufacturing method is as described above, and thus the description thereof is omitted. The method of disposing the optical sheet 10a manufactured as described above on the viewer side of the PDP 104 is not particularly limited, and a known method can be used. In this way, the plasma television 100 can be manufactured by disposing the optical sheet 10a on the viewer side of the PDP 104 and incorporating the PDP unit 103 and other members into the housing.

  As described above, according to the method for manufacturing an optical sheet of the present invention, an optical sheet that can prevent image distortion and the like from being deteriorated when the display device is provided and prevent deterioration in image quality is provided. Can be manufactured. Therefore, according to the display device manufacturing method of the present invention using the optical sheet manufactured by the optical sheet manufacturing method of the present invention, it is possible to prevent image distortion and the like and to prevent deterioration of the image quality. A display device that can be manufactured can be manufactured.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples.

<Example 1>
(1) Preparation of light transmission part composition composition 56 parts by mass of urethane acrylate prepolymer composed of isophorone diisocyanate and bisphenol A-ethoxy modified acrylate, 4 parts by mass of 2-hydroxyethyl acrylate, and 37 parts by mass of phenoxyethyl acrylate are mixed. The resulting composition was mixed with 3 parts by mass of 1-hydroxycyclohexylphenyl-ketone as a photopolymerization initiator, and homogenized to obtain a light transmitting part constituting composition.

(2) Formation of light transmitting portion The pitch (p shown in FIG. 5B) is 51 μm, the opening width (w shown in FIG. 5B) is 10 μm and the depth (shown in FIG. 5B). A mold roll capable of forming a groove d) of 69 μm was prepared. A PET film (A4300, manufactured by Toyobo Co., Ltd., thickness 100 μm) serving as the first base material layer was fed between the mold roll and the nip roll. In accordance with the feeding of the PET film, the light transmission part constituting composition obtained above was filled between the mold roll and the PET film. Then, 800 mJ / cm < ² > of ultraviolet rays were irradiated from the PET film side with the high pressure mercury lamp, the light transmissive part constituent composition was hardened, and the light transmissive part was formed. The thickness of the sheet (intermediate member) including the base material layer and the light transmission part was 189 ± 20 μm.

(3) Adjustment of light absorption part composition composition 28 parts by mass of tripropylene glycol diacrylate as a reactive dilution monomer in a prepolymer in which 33.6 parts by mass of urethane acrylate and 14.4 parts by mass of epoxy acrylate were mixed. In addition, the composition prepared by adding 4 parts by mass of methoxytriethylene glycol acrylate contains 4 parts by mass of 1-hydroxycyclohexyl phenyl ketone as a photopolymerization initiator and carbon black having an average particle size of 4.0 μm as light absorbing particles. 16 parts by mass of acrylic crosslinked fine particles (Gantz Kasei Co., Ltd.) were mixed and homogenized to prepare a light absorbing part constituting composition.

(4) Formation of light absorption part The light absorption part composition obtained above was supplied onto the intermediate member from the supply device. In addition, the doctor blade is used to fill the light absorbing part constituent composition supplied onto the intermediate member into a substantially V-shaped groove (groove between the light transmitting parts) formed in the intermediate member, The light absorbing part constituting composition was scraped off. Then, the light absorption part constituent composition was hardened by irradiating with ultraviolet rays, and the light absorption part was formed with the hardened light absorption part constituent composition.

(5) Formation of protective layer After obtaining the sheet | seat in which the optical function sheet layer which has a light transmission part and a light absorption part was formed on the base material layer (PET film) as mentioned above, the base material of the said sheet | seat A protective film (manufactured by Sumilon Co., Ltd., EC7520) was bonded to the layer side as a protective layer.

(6) Adjustment of pressure-sensitive adhesive composition 100 parts by mass of an acrylic pressure-sensitive adhesive (manufactured by Soken Chemical Co., Ltd., SK Dyne 2094) and 0.25 parts by mass of an epoxy-based curing agent (manufactured by Soken Chemical Co., Ltd., E-5XM) Then, 30 parts by mass of a diluent solvent (MIBK (methyl isobutyl ketone)) was mixed and homogenized to prepare a pressure-sensitive adhesive composition.

(7) Formation of pressure-sensitive adhesive layer The pressure-sensitive adhesive composition is applied onto a release film (Mitsui Chemicals Tosero Co., Ltd., PET-O3-BU) to be the second base material layer, and then dried. A layer was formed. The pressure-sensitive adhesive composition was applied so that the thickness of the pressure-sensitive adhesive layer after drying was 25 μm. The pressure-sensitive adhesive composition was dried at 80 ° C. for 2 minutes using a dryer.

(8) Bonding The optical functional layer and the pressure-sensitive adhesive layer prepared as described above were bonded together to prepare a laminated sheet having a width of 1550 mm and a length of 1000 m. At the time of pasting, it pressed at 0.5 MPa in the lamination direction.

(9) Winding Spacers (material: PET, width: 10 mm, thickness: 25 μm) are placed on both ends of the laminated sheet prepared as described above, and the distance from the end of the adhesive layer (D shown in FIG. 1). ) Was placed so as to be 20 mm, and the sheet was wound into a roll shape so that the spacer was on the inner side of the laminated sheet, thereby producing a sheet roll. At this time, the laminated sheet was wound while applying a tension of 5 kg / m to 20 kg / m in the longitudinal direction.

(Examples 2 and 3)
Sheet rolls according to Examples 2 and 3 were produced in the same manner as in Example 1 except that the thickness of the spacer used was changed to the dimensions shown in Table 1.

(Comparative Example 1)
A sheet roll according to Comparative Example 1 was produced in the same manner as Example 1 except that no spacer was used.

(Evaluation results)
About the sheet | seat roll which concerns on Examples 1-3 and the comparative example 1, the surface state by the side of the 2nd base material layer of a lamination sheet was evaluated. The results are shown in Table 1. “Yuzu skin” shown in Table 1 indicates which portion in the longitudinal direction of the laminated sheet unwound from the sheet roll has no yuzu skin. The part where no yuzu skin was generated was regarded as a non-defective product. Here, the length in the longitudinal direction of the laminated sheet is defined as 0 m at the end (hereinafter referred to as “fixed end”) fixed to the core of the sheet roll. Therefore, “non-defective product from 40 m” shown in Table 1 means that no skin was generated from the position 40 m from the fixed end to the other end (the outermost surface side of the sheet roll). The same applies to the evaluation results of the sheet rolls according to Examples 2 and 3 and Comparative Example 1. Note that whether or not the yuzu skin had occurred was determined by placing a laminated sheet unwound from the sheet roll between the fluorescent lamp and the observer, and using a fluorescent lamp applied perpendicularly to the surface of the laminated sheet. The image distortion was judged by visual observation. The “concave strain” shown in Table 1 means that 20 sheets having a size of 500 mm × 1000 mm are extracted from a sheet roll, the light of the fluorescent lamp is reflected on the surface of the second base material layer of the sheet, and JIS This is a result of counting the number of concave strains of 2.0 mm ² or more by visual comparison with the “contamination measurement chart” based on P 8208.

  As shown in Table 1, in the sheet rolls according to Examples 1 to 3, the surface irregularities on the surface of the protective layer are suppressed from being transferred to the adhesive layer, and the surface state on the second base material layer side is It was good. On the other hand, in the sheet roll according to Comparative Example 1, the unevenness on the surface of the protective layer was transferred to the adhesive layer, and the surface state on the second base material layer side was poor.

DESCRIPTION OF SYMBOLS 10 Laminated sheet 10a Optical sheet 11 1st base material layer 12 Optical functional layer 13 Light transmission part 13a Groove 14 Light absorption part 15 Binder 16 Light absorption particle 17 Adhesive layer 18 2nd base material layer 19 Protection layer 100 Plasma television (display) apparatus)
101 Front Side Case 102 Back Side Case 103 PDP Unit 104 PDP (Video Source)

Claims (8)

A method for producing a sheet roll comprising a laminated sheet wound into a roll,
In the lamination direction, the laminated sheet is
A light-transmitting portion that is arranged on the outermost surface of the laminated sheet and that is peelable and is formed in parallel along the surface of the first base material layer and along the surface of the first base material layer; And an optical functional layer having a light absorbing portion formed so as to be able to absorb light between the light transmitting portions, a pressure-sensitive adhesive layer containing a pressure-sensitive adhesive, and a second base material layer serving as a base material of the pressure-sensitive adhesive layer, In that order,
A laminating step for producing the laminated sheet;
A winding step of winding the laminated sheet in a roll shape while arranging a spacer in the vicinity of both ends in the width direction of the laminated sheet;
The manufacturing method of the sheet roll containing this. The laminating step
An optical functional layer forming step of forming the optical functional layer on one surface side of the first base material layer;
A protective layer forming step of forming the protective layer on the other surface side of the first base material layer;
An adhesive layer forming step of forming the adhesive layer on one surface side of the second base material layer;
After forming the pressure-sensitive adhesive layer and the optical functional layer, a bonding step of bonding the pressure-sensitive adhesive layer and the optical functional layer;
The manufacturing method of the sheet roll of Claim 1 containing this.   The manufacturing method of the sheet roll of Claim 1 or 2 which arrange | positions the said spacer inside the edge of the width direction of the said adhesive layer in the said winding process.   The manufacturing method of the sheet roll in any one of Claims 1-3 using the said spacer whose width is 5 mm or more and 50 mm or less.   The manufacturing method of the sheet roll in any one of Claims 1-4 using the said spacer whose thickness is 6 micrometers or more and 50 micrometers or less. A sheet roll comprising a laminated sheet wound into a roll,
In the lamination direction, the laminated sheet is
A light-transmitting portion that is arranged on the outermost surface of the laminated sheet and that is peelable and is formed in parallel along the surface of the first base material layer and along the surface of the first base material layer; And an optical functional layer having a light absorbing portion formed so as to be able to absorb light between the light transmitting portions, a pressure-sensitive adhesive layer containing a pressure-sensitive adhesive, and a second base material layer serving as a base material of the pressure-sensitive adhesive layer, In that order,
A sheet roll in which spacers are disposed in the vicinity of both end portions in the width direction of the laminated sheet, and the laminated sheet is wound through the spacer. A method of manufacturing an optical sheet that is arranged on the viewer side from the video source and controls the light incident from the video source side to be emitted to the viewer side,
A step of producing a sheet roll by the method for producing a sheet roll according to claim 1;
Rewinding the sheet roll and cutting out a sheet of a predetermined size;
A method for producing an optical sheet, comprising: A method for manufacturing a display device, comprising: an image source; and an optical sheet disposed on an observer side of the image source,
A step of producing an optical sheet by the method of producing an optical sheet according to claim 7;
Placing the optical sheet on the viewer side of the video source;
A method for manufacturing a display device, comprising:

Images