JP2015031751A - Foreign matter removal method from film laminate, manufacturing method and manufacturing apparatus for film laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foreign matter removal method from a film laminate, capable of sufficiently removing a foreign matter while suppressing a damage, and a manufacturing method and manufacturing apparatus for a film laminate, capable of inhibiting a foreign matter from attaching while suppressing a damage.SOLUTION: A foreign matter removal method from a film laminate transfers a film laminate including an optical film, an adhesive layer laminated on the optical film and a protective film laminated on the adhesive layer and protecting the optical film, to a downstream side, while making at least one of two edges in the width direction of the film laminate pass toward the downstream side, the one of two edges being held by an adhesive roller pair arranged closer to the one of the two edges, so that a foreign matter can be removed.

Description

  The present invention relates to a method for removing foreign matter from a film laminate, a method for producing a film laminate, and a production apparatus.

  Conventionally, for example, a polarizing plate (polarizing film) is used as an optical film applied to an image display unit of an image display device. Usually, a polarizing plate is shipped as a film laminate in which a protective film is laminated on at least one surface via an adhesive layer, and when the image display device is manufactured, the protective film is peeled off to form an image display unit. It is designed to be incorporated.

  In this type of optical film, if foreign matter adheres, the optical properties may be affected.

Therefore, a method for removing foreign substances from the optical film has been proposed.
For example, a technique has been proposed in which air is blown onto the surface of an organic EL film, and the blown air is sucked from both ends of the surface to remove foreign matter on the surface (see Patent Document 1).

  Further, for example, a technique has been proposed in which the peripheral surface of the adhesive roller is brought into contact with the end surface of the substrate, and the foreign material on the end surface portion of the substrate is removed by rotating the adhesive roller (see Patent Document 2).

JP 2010-140705 A JP 2006-165072 A

  However, since the film laminate described above has an adhesive layer exposed to the external environment on the end face side, foreign substances tend to adhere to the end face. Therefore, it is difficult to sufficiently remove the foreign matter adhering to the end face by the technique as described in Patent Document 1.

  Moreover, since an optical film is comparatively thin, in the technique like patent document 2, there exists a possibility that the end surface of a film laminated body may be damaged by the contact with the surrounding surface of an adhesion roller.

  In view of the above circumstances, the present invention provides a method for removing foreign matter from a film laminate that can sufficiently remove foreign matter while suppressing damage, and a film laminate that can suppress adhesion of foreign matter while suppressing damage. It is an object to provide a manufacturing method and a manufacturing apparatus.

The foreign matter removal method from the film laminate according to the present invention,
While sending downstream a film laminate having an optical film, an adhesive layer formed on the optical film, and a protective film laminated on the adhesive layer to protect the optical film,
Foreign matters are removed by passing at least one of both end edges in the width direction of the film laminate to the downstream side while being sandwiched between a pair of adhesive rollers disposed on at least one side of the both end edges.

According to this structure, the foreign material adhering to the end surface of the film laminate can be removed by adhering to the adhesive roller pair. Thereby, a foreign material can fully be removed. And since a foreign material can be removed with this adhesive roller pair, avoiding the press to the end surface of the film laminated body from an adhesive roller pair, damage to a film laminated body can be suppressed.
Accordingly, foreign matters can be sufficiently removed from the film laminate while suppressing damage to the film laminate.

In the foreign matter removal method of the film laminate of the above configuration,
Remove the foreign matter by passing the both end edges in the width direction of the film laminate to the downstream side while being sandwiched between the pair of adhesive rollers disposed on the both end edge sides, and
It is preferable that the adhesive roller pair is inclined so as to be positioned on the downstream side toward the center side in the width direction of the film laminate.

  According to this structure, it can prevent that a wrinkle generate | occur | produces in a film laminated body by pinching the said both ends edge with the adhesive roller pair inclined as mentioned above. Therefore, damage to the film laminate can be further suppressed.

In the foreign matter removal method of the film laminate of the above configuration,
The hardness of each peripheral surface portion of the adhesive roller pair is preferably 30 to 60 °.

  According to such a configuration, each peripheral surface portion of the adhesive roller pair is deformed so as to follow the shape of the end edge and the end surface of the film laminate, and can easily come into contact with the end surface of the film laminate. It is possible to more reliably remove foreign matter on the end face of the.

  Moreover, the foreign material removal method from the said film laminated body is suitable when the said optical film is a polarizing plate.

  In the polarizing plate, even the adhesion of foreign matter having a size of several μm can be a problem. Therefore, it is very effective if the foreign matter attached to the end face of the film laminate can be reliably removed.

  Moreover, the manufacturing method of the film laminated body which concerns on this invention is equipped with the foreign material removal process which implements the said foreign material removal method.

According to this configuration, the foreign matter can be sufficiently removed from the film laminate while suppressing damage to the film laminate by the foreign matter removing method described above.
Therefore, the film laminated body which can suppress adhesion of a foreign material can be manufactured, suppressing damage, by providing the foreign material removal process which implements this foreign material removal method.

The apparatus for producing a film laminate according to the present invention comprises:
Conveying means for conveying the film laminate to the downstream side;
A foreign matter removing means having an adhesive roller pair that is disposed on at least one side of both end edges in the width direction of the film laminate and passes the film laminate to the downstream side while sandwiching at least one of the end edges. I have.

  ADVANTAGE OF THE INVENTION According to this invention, the foreign material removal method from the film laminated body which can fully remove a foreign material, suppressing damage, and the film laminated body which can suppress adhesion of a foreign material while suppressing damage can be manufactured. An optical film manufacturing method and manufacturing apparatus are provided.

The schematic side view which shows the manufacturing apparatus used for the manufacturing method of the film laminated body of one Embodiment of this invention. The schematic top view which shows the implementation state of the foreign material removal method of the optical film of this embodiment The schematic side view which shows the implementation state of the foreign material removal method of the optical film of this embodiment The schematic front view which shows the implementation state of the foreign material removal method of the optical film of this embodiment The schematic side view which shows the implementation state of the foreign material removal method of the optical film of other embodiment of this invention

  Hereinafter, the foreign substance removal method from the film laminated body which concerns on embodiment of this invention, the manufacturing method of a film laminated body, and a manufacturing apparatus are demonstrated.

  First, the manufacturing apparatus of the film laminated body of this embodiment is demonstrated.

  As shown in FIGS. 1 and 2, the film laminate manufacturing apparatus 1 of the present embodiment includes a transport roller 3 as a transport unit that transports the film stack 10 fed from the roll body 19 to the downstream side. The film laminated body 10 is arranged on at least one side of both end edges 10a and 10b in the width direction (Y direction in FIG. 2), and sandwiches at least one of the both end edges 10a and 10b (nips). Foreign matter removing means 4 having a pair of adhesive rollers 60 that allow the laminated body 10 to pass downstream is provided.

  The conveying roller pair 3 is configured to send the film laminate 10 to the downstream side by rotating while sandwiching the film laminate 10 with a predetermined pressure.

  As shown in FIG. 2, the adhesive roller pair 60 of the present embodiment is disposed on the both end edges 10 a and 10 b side of the film laminate 10. More specifically, a total of two adhesive roller pairs 60 are provided, one on each of the end edges 10a, 10b side of the film laminate 10. As shown in FIG. 3, the adhesive roller pair 60 includes a rotatable first adhesive roller 61 and a rotatable second adhesive roller 63, and these first and second adhesive rollers. 61 and 63 have adhesive layers (adhesive layers for removing foreign matter) 61b and 63b on their surface portions. Specifically, the first and second adhesive rollers 61 and 63 include roller bodies 61a and 63a and adhesive layers 61b and 63b formed on the surfaces of the roller bodies 61a and 63a, respectively. As shown in FIGS. 2 to 4, the adhesive roller pair 60 has a predetermined adhesive so that the first adhesive roller 61 and the second adhesive roller 63 pass downstream while sandwiching the film laminate 10. It is configured to be contacted by pressure. Further, these adhesive roller pairs 60 are arranged in parallel with the width direction (Y direction).

Next, the film laminated body 10 used by this embodiment is demonstrated.
As shown in FIG. 3, the film laminate 10 of the present embodiment includes a strip-shaped optical film 11 and an adhesive layer 13 formed on one surface (here, referred to as a surface) 11 a of the optical film 11. And a belt-like protective film 15 laminated on the adhesive layer 13.

  Examples of the optical film 11 include a polarizing plate (polarizing film), a retardation film, an antireflection film, a brightness enhancement film, and a laminate thereof.

  The pressure-sensitive adhesive layer 13 bonds the optical film 11 and the protective film 15. The pressure-sensitive adhesive layer 13 is formed by applying a pressure-sensitive adhesive as a material for forming the pressure-sensitive adhesive layer 13 on the optical film 11 and drying or curing it as necessary.

  The protective film 15 protects the surface 11 a of the optical film 11. Moreover, in this embodiment, the protective film 15 is peeled from the adhesion layer 13, and such a protective film is also called a separator.

The film laminated body 10 provided with such an optical film 11, the adhesion layer 13, and the protective film 15 can be manufactured as follows, for example.
That is, first, the pressure-sensitive adhesive layer 13 is formed by applying the pressure-sensitive adhesive to the surface 11a of the optical film 11 and drying or curing as necessary. The protective film 15 is placed on the adhesive layer 13, and the obtained laminate is passed between a pair of rollers (not shown) set to a predetermined pressure. Thereby, the film laminated body 10 can be manufactured. In the embodiment of FIG. 1, the film laminate 10 is wound up into a roll shape to form a roll body 19. However, in the present invention, the film laminate 10 may be used without forming the roll body 19.

Next, the manufacturing method of the film laminated body of this embodiment is demonstrated.
The manufacturing method of the film laminated body 20 of this embodiment is the optical film 11, the adhesion layer 13 formed on this optical film 11, and the protective film laminated | stacked on this adhesion layer 13, and protecting the said optical film 11 15, at least one of both end edges 10 a, 10 b in the width direction (Y direction) of the film laminate 10 is connected to at least one side of the both end edges 10 a, 10 b. A foreign matter removing step is implemented in which a foreign matter removing method for removing the foreign matter is performed by passing it to the downstream side while being sandwiched between the adhesive roller pair 60 disposed on the surface.

  In the foreign matter removing step, first, as shown in FIG. 1, the belt-shaped optical film 10 is unwound from the roll body 19 along the longitudinal direction (X direction, see FIG. 2), and a pair of conveying rollers. 3 to send downstream. In this way, while feeding the film laminate 10 to the downstream side, both end edges 10a and 10b of the film laminate 10 are passed through the adhesive roller pair 60, that is, the first adhesive roller 61 and the second adhesive roller 63. Pass between each. As shown in FIGS. 3 and 4, the first adhesive roller 61 and the second adhesive roller 63 allow the film laminate 10 to pass downstream while sandwiching both end edges 10a and 10b.

  In this way, by passing the both end edges 10a, 10b to the downstream side while being sandwiched between the respective adhesive roller pairs 60, the foreign matters attached to the both end surfaces of the film laminate 10 in the width direction (Y direction) are removed. At this time, the foreign matter on the surface in the vicinity of both end edges 10a and 10b on the surface of the film laminate 10 can be removed at the same time.

  Moreover, in the said width direction (Y direction), the width direction (Y direction) length of the adhesion roller pair 60 which is contacting the film laminated body 10, and the film laminated body 10 are not contacted (from film laminated body) The length of the adhesive roller pair 60 in the width direction (Y direction) can be appropriately set according to the degree to which foreign matter on the end face of the adhesive layer 13 is removed.

  2 shows an embodiment in which the two adhesive roller pairs 60 are arranged on the both end edges 10a, 10b side of the film laminate 10, but in the present invention, they are arranged on the both end edges 10a, 10b side. The quantity of the adhesive roller pair 60 is not particularly limited, and can be set as appropriate.

2 shows an embodiment in which the adhesive roller pair 60 is arranged in parallel with the film laminate 10, but in the present invention, the arrangement of the adhesive roller pair 60 is not particularly limited and is appropriately set. can do. For example, as shown in FIG. 5, a mode is adopted in which the adhesive roller pair 60 is arranged so as to be inclined so as to be positioned on the downstream side toward the center side in the width direction (Y direction) of the film laminate 10. May be. In other words, the adhesive roller pair 60 may be arranged so as to form a square shape whose width becomes narrower toward the downstream side. It is possible to prevent wrinkles from being generated in the film laminate 10 by sandwiching the both end edges 10a and 10b of the film laminate 10 with the adhesive roller pair 60 inclined in this way. Therefore, damage to the film laminate 10 can be further suppressed.
As described above, when the adhesive roller pair 60 is inclined and disposed, the inclination angle θ is preferably greater than 0 ° and 30 ° or less with respect to the width direction (Y direction). When the inclination angle θ is larger than 0 °, there is an advantage that wrinkles can be prevented from occurring in the film laminate 10, and when the inclination angle θ is 30 ° or less, the meandering of the film laminate 10 is prevented. This has the advantage that the straight running stability is improved.

The hardness of each peripheral surface portion of the adhesive roller pair 60, that is, the hardness of the peripheral surface portions of the first and second adhesive rollers 61, 63 is preferably 30 to 60 °. Such hardness is measured by using a hardness meter (durometer) on the peripheral surfaces (surfaces) of the first and second adhesive rollers 61 and 63.
When the film hardness is 60 ° or less, when the film laminate 10 is sandwiched between the adhesive roller pair 60, as shown in FIG. In other words, the adhesive layers 61b and 63b and a part of the roller body 61a and 63a on the surface side are deformed so as to follow the edge and the end face of the film laminate 10, and the end face of the film laminate 10 is formed. It becomes easy to touch. Thereby, the foreign material of the end surface of the film laminated body 10 can be removed more reliably. Further, when the hardness is 30 ° or more, the durability of the adhesive roller pair 60, that is, the durability of the first and second adhesive rollers 61 and 63 is sufficiently improved.
Examples of the material for forming the roller bodies 61a and 63a that can have the above-described hardness of 30 to 60 ° include butyl rubber and urethane rubber.

  And a foreign substance removal process is performed in this way, and the laminated body after this foreign substance removal process is obtained as the film laminated body 20. FIG.

  As described above, the foreign matter removal method from the film laminate 10 according to the present embodiment allows the edge of the both end edges 10a and 10b in the width direction (Y direction) of the film laminate 10 while feeding the film laminate 10 to the downstream side. While sandwiching at least one (here, both end edges 10a, 10b) between a pair of adhesive rollers 60 disposed on at least one side (here, both end edges 10a, 10b) of the both end edges 10a, 10b, the downstream side Foreign matter is removed by passing it through.

According to such a configuration, the foreign matter adhering to the end face of the film laminate 10 can be removed by adhering to the adhesive roller pair 60. Thereby, a foreign material can fully be removed. In addition, since the foreign matter can be removed by the pressure-sensitive adhesive roller pair 60 while avoiding the pressing of the pressure-sensitive adhesive roller pair 60 to the end surface of the film-layered body 10, damage to the film laminated body 10 can be suppressed.
Accordingly, foreign matters can be sufficiently removed from the film laminate 10 while suppressing damage to the film laminate 10.
Here, for example, when the adhesive member or the like is brought into contact with the side surface of the roll body 19 and the foreign matter on the side surface is to be removed before the film laminate 10 is fed out, Since there are irregularities, it is difficult to sufficiently remove foreign matter. In addition, when trying to remove the foreign matter on the end face by sandwiching the entire surface of the film laminate 10 between one adhesive roller pair and passing it to the downstream side, the thickness unevenness in the width direction of the film laminate 10, Due to non-uniform pressure in the width direction of the roller pair, a phenomenon that wrinkles may occur in the film laminate 10 may occur.
However, according to the foreign matter removing method, it is possible to sufficiently remove foreign matters while avoiding generation of wrinkles as compared with these methods.

  Moreover, in this embodiment, it is suitable when the said optical film 11 is a polarizing plate. In the polarizing plate, even a foreign matter having a size of several μm can be a problem. Therefore, it is very effective if the foreign matter attached to the end face of the film laminate 10 can be removed reliably.

  Moreover, the manufacturing method of the film laminated body 20 of this embodiment is equipped with the foreign material removal process which implements the foreign material removal method from the said film laminated body 10. FIG.

According to such a configuration, the foreign matter can be sufficiently removed from the film laminate 10 while suppressing damage to the film laminate 10 by the foreign matter removing method described above.
Therefore, the film laminated body 20 which can suppress adhesion of a foreign material can be manufactured by providing the foreign material removal process which implements this foreign material removal method, suppressing damage.

  Moreover, the manufacturing apparatus of the film laminated body 20 of this embodiment is the conveyance means 3 which conveys the film laminated body 10 to the downstream, and at least one side of the width direction both-ends edge 10a, 10b of the said film laminated body 10. And a foreign matter removing means 4 having a pair of adhesive rollers 60 that allow the film laminate 10 to pass downstream while sandwiching at least one of the both end edges 10a, 10b.

  According to this structure, the film laminated body 20 which can suppress adhesion of a foreign material can be manufactured similarly to the above, suppressing damage.

  In addition, although the foreign material removal method from the film laminated body of this embodiment, the manufacturing method of a film laminated body, and a manufacturing apparatus are as above-mentioned, this invention is not limited to the said embodiment, This invention intends. The design can be changed as appropriate within the range.

  For example, the above embodiment shows a configuration in which the both end edges 10a and 10b are sandwiched between the pair of adhesive rollers 60 arranged on the both end edges 10a and 10b side. It is also possible to adopt a configuration in which either one is sandwiched by the adhesive roller pair 60 on either one of the both end edges 10a, 10b.

  DESCRIPTION OF SYMBOLS 1: Manufacturing apparatus, 3: Roller for conveyance (conveyance means), 4: Foreign substance removal means, 10: Film laminated body, 11: Optical film, 13: Adhesive layer, 15: Protective film, 20: Film after foreign substance removal process Laminated body, 60: adhesive roller pair, 61: first adhesive roller, 61a: roller body, 61b: adhesive layer, 63: second adhesive roller, 63a: roller body, 63b: adhesive layer

Claims (6)

While sending downstream a film laminate having an optical film, an adhesive layer formed on the optical film, and a protective film laminated on the adhesive layer to protect the optical film,
From the film laminate that removes foreign matters by passing at least one of both end edges in the width direction of the film laminate to the downstream side while being sandwiched between a pair of adhesive rollers disposed on at least one side of the both end edges Foreign matter removal method. Remove the foreign matter by passing the both end edges in the width direction of the film laminate to the downstream side while being sandwiched between the pair of adhesive rollers disposed on the both end edge sides, and
2. The method for removing foreign matter from a film laminate according to claim 1, wherein the adhesive roller pair is inclined so as to be positioned on the downstream side toward the center side in the width direction of the film laminate.   The foreign matter removal method according to claim 1 or 2, wherein the hardness of each peripheral surface portion of the adhesive roller pair is 30 to 60 °.   The said optical film is a polarizing plate, The foreign material removal method from the film laminated body in any one of Claims 1-3.   The manufacturing method of the film laminated body provided with the foreign material removal process which implements the foreign material removal method from the film laminated body in any one of Claims 1-4. Conveying means for conveying the film laminate to the downstream side;
A foreign matter removing means having an adhesive roller pair that is disposed on at least one side of both end edges in the width direction of the film laminate and passes the film laminate to the downstream side while sandwiching at least one of the end edges. The manufacturing apparatus of the film laminated body provided.

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