JP2017215614A - Manufacturing method of film laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a film laminate capable of sufficiently removing foreign substances while preventing damage thereto.SOLUTION: In a manufacturing method of a film laminate, while feeding a film laminate having an optical film, an adhesive layer formed on the optical film and a protective film laminated on the adhesive layer and protecting the optical film to a downstream side, a foreign substance removal method from the film laminate is carried out in which the protective film is peeled off from the film laminate and a portion where the protective film is peeled is sucked from a side thereof to remove foreign substances. Thereafter, the protective film is laminated on the adhesive layer to form a film laminate again.SELECTED DRAWING: Figure 1

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 kind of optical film laminated body, when a foreign material adheres, there exists a possibility of affecting the optical characteristic of an optical film.

Therefore, a method for removing foreign substances from the film laminate 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).

  In addition, 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 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 a film laminated body is comparatively thin, with 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.

In view of the above problems, the present inventors have intensively researched and found that by peeling off the protective film while feeding the film laminate to the downstream side, the foreign matter adhering to the end face of the film laminate rises. did. This is presumed to be due to the fact that the end face area of the film laminate decreased due to the peeling of the protective film, and the adhesion force of the foreign matter adhering to the end face was weakened.
It has also been found that the soared foreign matter adheres to the surface of the adhesive layer exposed by peeling off the protective film.
And based on these findings, the present inventors conducted further studies, and when the protective film was peeled off, the separated foreign matter was removed by sucking the peeled portion from the side. It is possible to suppress foreign matter from adhering to the surface of the pressure-sensitive adhesive layer exposed by peeling off the protective film, and as a result, find that the foreign matter can be sufficiently removed from the film laminate, The present invention has been completed.

That is, the foreign matter removal method from the film laminate according to the present invention,
While feeding 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, the film laminate The protective film is peeled off, and the part from which the protective film is peeled is sucked from the side to remove foreign matters.

According to such a configuration, when the protective film is peeled off, the foreign matter adhering to the end face of the film laminate rises, but this foreign matter can be removed by suction from the side. Thereby, a foreign material can fully be removed. Moreover, since a foreign material can be removed in a non-contact state with a film laminated body, damage to a film laminated body can be suppressed.
Therefore, according to the said structure, a foreign material can fully be removed from this film laminated body, suppressing the damage of a film laminated body.

  The foreign substance removal method from the film laminated body of the said structure 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 carries out the foreign material removal method from the said film laminated body, Then, a protective film is laminated | stacked on the said adhesion layer, and it is set as a film laminated body again.

According to this configuration, the foreign matter can be sufficiently removed from the film laminate while suppressing damage to the film laminate by the above-described foreign matter removal method. Thereby, it can suppress that a foreign material adheres to the surface of an adhesion layer, and can pinch a foreign material when laminating | stacking a protective film on an adhesion layer again. Moreover, damage can also be suppressed.
Therefore, according to the said structure, adhesion of a foreign material can be suppressed, suppressing damage.

  The manufacturing method of the film laminated body of the said structure 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 apparatus of the film laminated body which concerns on this invention is
Conveying means for sending the film laminate to the downstream side;
Peeling means for peeling the protective film from the film laminate sent by the conveying means;
Foreign matter removing means for removing foreign matter by sucking from the side the part where the protective film is peeled off,
Laminating means is formed by laminating a protective film again on the adhesive layer of the remaining laminate obtained by peeling the protective film by the peeling means.

  ADVANTAGE OF THE INVENTION According to this invention, the removal method of the foreign material from the film laminated body which can fully remove a foreign material, suppressing damage, and the manufacturing method of the film laminated body which can suppress adhesion of a foreign material, suppressing damage And a manufacturing apparatus is 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 side view which shows the layer structure 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 process (method) from the film laminated body of one Embodiment of this invention IV-IV sectional view of FIG. The schematic top view which shows the implementation state of the foreign material removal process (method) from the film laminated body of other embodiment of this invention. Schematic sectional drawing which shows the implementation state of the manufacturing method of the film laminated body of other embodiment of this invention.

  Hereinafter, the foreign substance removal method from the film laminated body which concerns on embodiment of this invention, and the manufacturing method of a film laminated body are demonstrated. In addition, this embodiment demonstrates the manufacturing method of the film laminated body provided with the foreign material removal method as a foreign material removal process.

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

  As shown in FIG. 1, the film laminate manufacturing apparatus 1 according to this embodiment includes a pair of conveyance rollers 3 as a conveyance unit that conveys a film laminate 10 fed from a roll body 19 to the downstream side, and a film. A peeling roller 5 as a peeling means for peeling the protective film 15 from the laminate 10 and a foreign substance removing means for removing the foreign matter by sucking the side R of the film laminate 10 from which the protective film 15 is peeled off. The protective film (here, the protective film 15) is again applied to the remaining laminate 17 from which the protective film 15 is peeled off by the suction means 53, the support roller 7 that supports the peeled protective film 15, and the peeling roller 5. A laminating roller pair 9 is provided as a laminating means for laminating.

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.
The peeling roller 5 is arranged so as to contact the protective film 15 of the film laminate 10, and the protective film 15 is sequentially peeled from the film laminate 10 with the peeling roller 5 as a starting point.
As shown in FIGS. 3 and 4, the suction means 53 has an opening 53a, and from the side of the portion R where the protective film 10 is peeled off in the film laminate 10 through the opening 53a (film Air is sucked from at least one end side of both ends of the laminate 10 in the width direction (Y direction in FIG. 3). Examples of the suction unit 53 include a vacuum pump, a vacuum ejector, and an exhaust blower. Moreover, in this embodiment, although two suction means 53 are distribute | arranged to the both sides of the part R from which the protective film 15 is peeled, in this invention, it has distribute | arranged to either one of these both sides. May be.
The support roller 7 supports the protective film 15 from below by winding the peeled protective film 15 around the support roller 7.
The laminating roller pair 9 laminates the remaining laminate 17 and the protective film 15 by rotating while sandwiching the remaining laminate 17 from which the protective film 15 has been peeled off and the protective film 15 with a predetermined pressure. However, the film laminate 20 is formed.

Next, the film laminated body 10 used by this embodiment is demonstrated.
As shown in FIG. 2, the film laminate 10 of the present embodiment includes a band-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.

  In the method for producing a film laminate of the present embodiment, the protective film 15 is peeled from the film laminate 10 while the film laminate 10 is being sent to the downstream side, and the portion R from which the protective film 15 is peeled is removed. A foreign matter removing method from the film laminate 10 that removes foreign matter by suction from the side is provided as a foreign matter removing step. Moreover, after implementing this foreign material removal process (namely, foreign material removal method), the protective film 15 is laminated | stacked on the said adhesion layer 13, and the lamination process used as the film laminated body 20 is provided again.

  In the foreign matter removing step, a film laminate including an optical film 11, an adhesive layer 13 formed on the optical film 11, and a protective film 15 that is laminated on the adhesive layer 13 to protect the optical film 11. While feeding 10 to the downstream side, the protective film 15 is peeled off from the film laminate 10, and the portion R where the protective film 15 is peeled is sucked from the side to remove foreign matter.

Specifically, first, as shown in FIG. 1, the strip-shaped film laminate 10 is fed out from the roll body 19 along the longitudinal direction thereof and is sent to the downstream side by the conveying roller pair 3. In this way, the protective film 15 is peeled from the film laminate 10 by the peeling roller 5 while feeding the film laminate 10 to the downstream side. By peeling off the protective film 15, the adhesive layer 13 is exposed, and the laminate 17 of the optical film 11 and the adhesive layer 13 remains.
Then, as shown in FIGS. 3 and 4, while peeling off the protective film 15 in this way, the portion R of the film laminate 10 where the protective film 15 is peeled off is sucked from the side of the film laminate 10. Aspirate by 53.
In addition, in this embodiment, although the aspect attracted | sucked from the both sides of the part R from which the protective film 15 is peeled by the two suction means 53 is shown, in this invention, it attracts | sucks from either one of these both sides. Aspects may be adopted.

  The suction force of the suction means 53 can be set as appropriate depending on the foreign matter removal status or the like, or to the extent that the film laminate 10 is not distorted. Further, as shown in FIG. 3, the suction direction may be a direction parallel to the width direction Y, or may be a direction inclined with respect to the width direction Y. Moreover, it is preferable that the length which connects the opening part 53a of the suction means 53 and the edge of the film laminated body 10 by the shortest distance shall be 5-30 mm. By setting the length to 5 mm or more, there is an advantage that it is possible to prevent the film laminate 10 from being too close and adversely affecting the conveyance, and by setting the length to 30 mm or less, it is possible to more effectively suck foreign matter. There are advantages.

According to the foreign matter removing step, when the protective film 15 is peeled off, the adhesion force of the foreign matter attached to the end surface of the film laminate 10 is weakened or soared. Can be removed. Thereby, a foreign material can fully be removed. Moreover, since a foreign material can be removed in a non-contact state with the film laminated 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.

  In the laminating step, after the foreign matter removing step is performed, that is, after the foreign matter is removed by the suction means 53, a protective film is formed on the adhesive layer 13 of the remaining laminate 17 by the laminating roller pair 9. 15 is laminated to form a film laminate 20 again. More specifically, in this embodiment, the protective film 15 peeled off in the foreign matter removing step is laminated on the adhesive layer 13 of the remaining laminated body 17 to form the film laminated body 20 again.

  Thus, in this embodiment, the aspect which employ | adopts the film | membrane laminated body 20 again by laminating | stacking the protective film 15 which peeled as it is on the adhesion layer 13 is employ | adopted. However, in the present invention, for example, the protective film 15 peeled off as shown in FIG. 5 is temporarily recovered, and then a protective film 25 different from the peeled protective film 15 is placed as shown in FIG. A mode of laminating on the adhesive layer 13 of the remaining laminate 17 can also be adopted.

  Specifically, for example, in the foreign matter removing step, as shown in FIG. 5, while the film laminate 10 is sent to the downstream side, for example, the protective film 15 is peeled off by the winding roller (winding means) 61. It is wound up and collected as a roll body 29. As described above, it is possible to employ a mode in which the portion R to be peeled is sucked by the suction means 53 while being peeled while collecting the protective film 15.

  In this case, for example, in the laminating step, as shown in FIG. 6, while feeding the remaining laminated body 17 from which the protective film 15 has been removed to the downstream side, another protective film 25 is fed, for example, a feeding roller ( It is also possible to adopt a mode in which the film laminate 30 is fed out from the roll body 39 by the feeding means) 63 and bonded onto the adhesive layer 13 and is used as the film laminate 30 by the laminating roller pair 9. The peeled protective film 15 can be used for laminating on the adhesive layer of a laminate different from the remaining laminate 17.

  Thus, in the laminating step of the present invention, the protective film 15 peeled off on the adhesive layer 13 of the remaining laminate 17 formed by peeling the protective film 15 by the peeling roller 5 in the foreign matter removing step, or The protective film 25 different from the protective film 15 can be laminated by the laminating roller pair 9 to form the film laminates 20 and 30 again.

According to the manufacturing method of the present embodiment, the foreign matter can be sufficiently removed from the film laminate 10, 20, 30 while suppressing damage to the film laminate 10, 20, 30 by the foreign matter removing step described above. . Thereby, it can suppress that a foreign material adheres to the surface of the adhesion layer 13, and can suppress that a foreign material is inserted | pinched when the protective films 15 and 25 are laminated | stacked on the adhesion layer 13 again. Moreover, damage can also be suppressed.
Accordingly, it is possible to manufacture the film laminates 20 and 30 with little damage and reduced foreign matter adhesion.

  Moreover, according to the manufacturing apparatus of this embodiment, the film laminated bodies 20 and 30 with little damage and the adhesion of a foreign material can be manufactured as described above.

  Moreover, the foreign material removal method from the film laminated body of this embodiment, the manufacturing method of a film laminated body, and its manufacturing apparatus are inspection means after peeling the protective film 15 of the film laminated body 10, for example, the remaining laminated body 17 further. It is suitable when the protective films 15 and 25 are again laminated on the remaining laminate 17 after being inspected by the above-mentioned method or after being treated by the treatment means.

  In addition, although the foreign material removal method from the film laminated body of this invention, 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, The range which this invention intends The design can be changed as appropriate.

  DESCRIPTION OF SYMBOLS 1: Manufacturing apparatus, 3: Roller pair for conveyance, 5: Roller for peeling, 9: Roller pair for lamination, 10: Film laminated body, 11: Optical film, 11a: One side, 13: Adhesive layer, 15: Protection Film, 20: film laminate, 25: protective film, 30: film laminate, 53: suction means

Claims (2)

  While feeding 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, the film laminate The protective film is peeled off, and the foreign matter is removed from the film laminate by removing the foreign matter by sucking the part from which the protective film is peeled from the side, and then laminating the protective film on the adhesive layer. And the manufacturing method of the film laminated body which makes it a film laminated body again.   The method for producing a film laminate according to claim 1, wherein the optical film is a polarizing plate.

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