JP2019070793A - Method for manufacturing optical member and manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for manufacturing an optical member having less adhesion of powder such as polishing debris. SOLUTION: A method for manufacturing an optical member is a laminate having an optical film 50 and an adhesive layer 80 provided on one surface of the optical film 50, and powder f is adhered to an end surface E thereof. The step of preparing 100 and the step of colliding the dry ice particles d with the end face E of the laminated body 100 to remove the powder f from the end face E are included. [Selection diagram] Fig. 3

Description

  The present invention relates to a method and an apparatus for manufacturing an optical member.

Conventionally, an optical member provided with an optical film such as a polarizer and an adhesive layer is known.
As a method of obtaining an optical member of a desired size, it is known to cut a raw film laminate having an optical film and an adhesive layer with a laser or a blade (see Patent Documents 1 and 2).

WO 2014/189078 gazette JP, 2009-86675, A

  By the way, in recent years, the demand for the dimensional accuracy of the optical film and the optical member using the pressure-sensitive adhesive layer has become severe. Therefore, it is difficult to obtain the desired dimensional accuracy simply by cutting the raw laminate. Therefore, the end face of the cut laminate may be processed by grinding and polishing.

  However, when processing such as polishing is performed on the end face of the laminate, powder such as polishing debris may be attached to the end face of the laminate. If the powder remains in the laminate, it is not preferable because contamination of the final product including the laminate occurs.

  The present invention is made in view of the above-mentioned subject, and an object of the present invention is to provide a manufacturing method and a manufacturing device of an optical member with little adhesion of powder, such as grinding waste.

  The method for producing an optical member according to the present invention comprises an optical film and a pressure-sensitive adhesive layer provided on one side of the optical film, and preparing a laminate in which powder is attached to the end face thereof. And a step of removing the powder from the end face by causing dry ice particles to collide with the end face of the laminated body (collision step).

  According to the present invention, powder such as cutting waste, cutting waste and grinding waste is suitably removed from the end face of the laminate (optical member) by the dry ice particles.

  Here, the average particle diameter of the dry ice particles may be 100 to 1000 μm.

  Thus, chipping of the adhesive on the end face is suppressed while suitably removing powder such as grinding chips.

  Further, in the collision step, the dry ice particles can collide with an end face of a laminated structure in which a plurality of the laminated bodies are laminated.

  According to this, a large amount of processing of the laminate can be performed.

  In addition, at least one selected from the group consisting of cutting, cutting, and polishing may be performed on another portion of the end face of the laminate simultaneously with colliding the dry ice particles on a portion of the end face. Can.

  According to this, it is possible to shorten a process time by performing a plurality of processes in parallel.

  Further, at least one treatment selected from the group consisting of cutting, cutting, and polishing is performed on the end surface in the preparation step, and the dry ice particles are caused to collide with a part of the end surface. In contrast, any process selected from the group can be omitted.

  According to this, since the atmosphere (space) for removing the powder due to the collision of the dry ice particles can be divided into the processing atmosphere (space) for producing the powder, the powder produced by the processing of the end face It is possible to suppress contamination of the portion where dry ice collides.

  The optical film is a laminate including at least one selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, and a touch sensor, and at least one selected from the group It can be a film, or a laminated film comprising at least two selected from the above group.

  The relative humidity of the atmosphere in the collision process may be 30 to 75%.

  An apparatus for manufacturing an optical member according to the present invention includes an optical film and an end surface processed portion for cutting, cutting, or polishing an end surface of a laminate having an adhesive layer provided on one surface of the optical film; And a dry ice particle supply unit for causing dry ice particles to collide with a portion of the laminate processed into the end surface processed portion.

  The manufacturing apparatus of said optical member can further be provided with the conveyance part which moves the said laminated body between the said end surface process part and the said dry ice particle supply part.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method and manufacturing apparatus of an optical member with little adhesion of powder, such as grinding | polishing waste, can be provided.

(A) and (b) of FIG. 1 are cross-sectional views of a laminate 100 according to an embodiment of the present invention. (A) and (b) of FIG. 2 are cross-sectional views of other examples of the laminate, respectively. FIG. 3 is a schematic block diagram of a dry ice particle supply unit. FIG. 4 is a conceptual view showing an aspect in which dry ice particles collide with the end face of the laminated structure 120 including the plurality of laminated bodies 100. As shown in FIG. FIG. 5 is a perspective view of an optical member manufacturing apparatus according to an embodiment of the present invention. FIG. 6 is a perspective view showing another example of the end surface processed portion in FIG. FIG. 7 is a conceptual view showing an aspect in which dry ice particles are caused to collide with the inner end face of the laminated structure 120 including the through holes H ′.

  A method and apparatus for manufacturing an optical member according to an embodiment of the present invention will be described with reference to the drawings.

(Preparation of a laminate in which powder adheres to the end face)
First, as shown in (a) of FIG. 1, an optical film 50 and a pressure-sensitive adhesive layer 80 provided on one surface of the optical film 50, and a laminated body in which powder f adheres to the end surface E Prepare 100. The end face E is not limited to the outer end face of the laminate 100. For example, as shown in (b) of FIG. 1, when the laminated body 100 has the holes H penetrating in the laminating direction, the inner wall of the holes H, that is, the inner end face E of the laminated body 100 Powder f may be attached.

(Optical film)
The optical film 50 is a film that transmits at least a part of visible light.
Examples of the optical film 50 are a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, a touch sensor, and the optical film 50 has a laminated structure having a plurality of single types of these films. It may well have a laminated structure having a plurality of types of these films.

(Polarizer)
A polarizer is a film in which the transmittance of linearly polarized light differs in two orthogonal directions in the plane. As a material of a polarizer, the well-known material conventionally used for manufacture of a polarizer can be used, For example, polyvinyl alcohol-type resin, polyvinyl acetate resin, ethylene / vinyl acetate (EVA) resin, a polyamide resin And polyester resins. Among them, polyvinyl alcohol resins are preferable. A film-like polarizer (film-type polarizer) can be obtained by subjecting these resin films to a stretching treatment, and then dyeing and boric acid treatment with iodine or a dichroic dye.

  The thickness of the film type polarizer can be, for example, 1 to 75 μm.

  Moreover, as another example of the said polarizer, the liquid-crystal application | coating type | mold polarizer formed from a liquid crystalline compound may be sufficient. The liquid crystal coated polarizer can be produced, for example, by using a suitable base material and coating the liquid crystal polarizing composition on the base material. An alignment film may be formed on this substrate before applying the liquid crystal polarizing composition. The liquid crystal polarizing composition may include a liquid crystal compound and a dichroic dye compound. The liquid crystal compound may have a property of exhibiting a liquid crystal state, and in particular, having a high-order liquid crystal state such as a smectic phase, the liquid crystal coated polarizer obtained has high polarization performance. It is preferable because it can be exhibited. Moreover, it is also preferable that the said liquid crystalline compound has a polymerizable functional group. The dichroic dye compound is a dye which is oriented with the liquid crystal compound to exhibit dichroism, and the dichroic dye itself may have liquid crystallinity, or may have a polymerizable functional group. You can also It is preferable that any compound contained in the liquid crystal polarizing composition have a polymerizable functional group. The liquid crystal polarizing composition may further include an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, a silane coupling agent, and the like.

Here, a typical example of a method for producing a liquid crystal coated polarizer is shown by forming an alignment film on a substrate and applying a liquid crystal polarizing composition on the substrate on which the alignment film is formed.
The liquid crystal coated light type polarizer manufactured by this method can be thinner than the film type polarizer. The thickness of the liquid crystal coated light type polarizer is 0.5 to 10 μm, preferably 1 to 5 μm.

  The alignment film is formed, for example, by applying an alignment film-forming composition on a base material to form an alignment film on the base material by imparting alignment property to the coating film by rubbing, irradiation with polarized light, etc. be able to. The composition for forming an alignment film contains an alignment agent, and may contain, in addition to the alignment agent, a solvent, a crosslinking agent, an initiator, a dispersant, a leveling agent, a silane coupling agent, and the like. Examples of the alignment agent include polyvinyl alcohols, polyacrylates, polyamic acids, and polyimides. In the case of applying photoalignment as a method of imparting the orientation, an alignment agent containing a cinnamate group is preferred.

  The alignment agent may be a polymer. The high molecular weight alignment agent has a weight average molecular weight of about 10,000 to 1,000,000. The thickness of the alignment film formed on the substrate is preferably 5 nm to 10000 nm, and particularly preferably 10 to 500 nm because a sufficient alignment control force is expressed.

A liquid crystal polarizing composition is coated on a substrate on which an alignment film is formed, and dried if necessary to form a coating film of the liquid crystal polarizing composition, and from the coating film of the liquid crystal polarizing composition, a liquid crystal coating type Manufacture a polarizer.
The liquid crystal polarizer thus produced may be peeled off from the substrate. As a method of peeling a liquid crystal application type polarizer from a base material, for example, the second base material is attached to the surface of the liquid crystal application type polarizer on which the base material is not laminated, and then the base material is peeled. The liquid crystal coated polarizer can be transferred to the second substrate by using a method of obtaining a laminate comprising the liquid crystal coated polarizer and the second substrate, and the transfer to the second substrate is also possible. It is also possible to leave it laminated to the substrate without doing so. It is also preferable that the base material or the second base material plays a role as a transparent base material of a protective film, a retardation plate or a window film.

(Protective film)
The protective film is another optical film such as a polarizer and / or a transparent film that prevents damage such as scratching of an optical device (such as a liquid crystal cell) to which the laminate 100 is then attached. The protective film can be various transparent resin films.

Here, a protective film for protecting a polarizer is described. Examples of resins that form this protective film are
Cellulose resins represented by triacetyl cellulose;
Polyolefin resins represented by polypropylene resins;
Cyclic olefin resins represented by norbornene resins;
Acrylic resins represented by polymethyl methacrylate resins; and polyester resins represented by polyethylene terephthalate resins. Among these, cellulose resins are representative.
The thickness of the protective film can be, for example, 5 to 90 μm.

  The protective film may, if necessary, be a plasticizer, an ultraviolet absorber, an infrared absorber, a coloring agent such as a pigment or a dye, a fluorescent whitening agent, a dispersing agent, a heat stabilizer, a light stabilizer, an antistatic agent, an antioxidant. , Lubricants, solvents, etc. may be contained.

  A hard coat layer may be provided on at least one surface of the protective film in order to increase the scratch resistance of the surface of the protective film. The thickness of the hard coat layer is usually in the range of 2 to 100 μm. When the thickness of the hard coat layer is less than 2 μm, it is difficult to secure sufficient scratch resistance, and when it exceeds 100 μm, the bending resistance decreases, and when the protective film is bonded to a polarizer or the like, curing occurs. The problem of curling due to shrinkage may occur.

  The hard coat layer can be formed of a hard coat composition including a reactive material that forms a crosslinked structure by irradiation with active energy rays or thermal energy rays. Among these, the hard coat layer obtained by active energy ray irradiation is preferable. An active energy ray is defined as an energy ray capable of decomposing a compound that generates an active species to generate an active species. As active energy rays, visible light, ultraviolet rays, infrared rays, X-rays, α-rays, β-rays, γ-rays, electron rays and the like can be mentioned. Among these, ultraviolet light is particularly preferred. The hard coat composition preferably contains at least one of a radically polymerizable compound and a cationically polymerizable compound. The hard coat composition may contain an oligomer obtained by partially polymerizing the radically polymerizable compound and the cationically polymerizable compound.

First, the radically polymerizable compound will be described.
The radically polymerizable compound is a compound having a radically polymerizable group. The radical polymerizable group may be any functional group capable of causing a radical polymerization reaction, and includes a group containing a carbon-carbon unsaturated double bond and the like, and a vinyl group and a (meth) acryloyl group are exemplified. . In addition, when the said radically polymerizable compound has 2 or more radically polymerizable groups in 1 molecule, these radically polymerizable groups may be same or different, respectively. When the radically polymerizable compound has two or more radically polymerizable groups in one molecule, the hardness of the obtained hard coat layer tends to be improved. Among them, compounds having a (meth) acryloyl group are preferable as the radical polymerizable compound from the viewpoint of reactivity, and, for example, polyfunctional acrylates having 2 to 6 (meth) acryloyl groups in one molecule. It has several (meth) acryloyl groups in the molecule called compounds called monomers, epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, and has a molecular weight of several hundred to several One thousand oligomers are mentioned. Among the compounds having a (meth) acryloyl group, at least one selected from epoxy (meth) acrylate, urethane (meth) acrylate and polyester (meth) acrylate is preferable.

Next, the cationically polymerizable compound will be described.
The cationically polymerizable compound is a compound having a cationically polymerizable group such as an epoxy group, an oxetanyl group, and a vinyl ether group. The number of cationically polymerizable groups contained in one molecule of the cationically polymerizable compound is preferably 2 or more, and more preferably 3 or more, from the viewpoint of improving the hardness of the obtained hard coat layer. . Further, as the cationically polymerizable compound, a compound having at least one cationically polymerizable group of an epoxy group and an oxetanyl group is preferable. The cyclic ether group of the epoxy group or the oxetanyl group has an advantage that the shrinkage accompanying the polymerization reaction is small. In addition, compounds having an epoxy group among cyclic ether groups are easily obtained from the market as compounds having various structures, and the durability of the resulting hard coat layer is unlikely to be adversely affected. When the hard coat composition is a combination of a radically polymerizable compound and a cationically polymerizable compound, the compound having an epoxy group has an advantage that the compatibility with the radically polymerizable compound can be easily controlled. Further, among the cyclic ether groups, oxetanyl group tends to have a high degree of polymerization and is less toxic than epoxy groups, and accelerates the network formation speed obtained from the cationically polymerizable compound of the obtained hard coat layer, and radical polymerization. Even in the region mixed with the sex compound, there is an advantage such as forming an independent network without leaving unreacted monomers in the film.

As a compound which has an epoxy group, for example,
Polyglycidyl ether of polyhydric alcohol having an alicyclic ring;
Alicyclic epoxy resin obtained by epoxidizing a cyclohexene ring or cyclopentene ring-containing compound with a suitable oxidizing agent such as hydrogen peroxide or peracid;
Aliphatic polyhydric alcohols, or polyglycidyl ethers of alkylene oxide adducts thereof;
Polyglycidyl esters of aliphatic long chain polybasic acids;
Aliphatic epoxy resins such as homopolymers and copolymers of glycidyl (meth) acrylates;
A glycidyl ether produced by the reaction of epichlorohydrin with a bisphenol such as bisphenol A, bisphenol F or hydrogenated bisphenol A, or an alkylene oxide adduct thereof or a derivative such as caprolactone adduct;
And glycidyl ether type epoxy resins derived from bisphenols, and the like.

  The hard coat composition may further include a polymerization initiator. As a polymerization initiator, an appropriate thing (a radical polymerization initiator, a cationic polymerization initiator, etc.) can be selected and used according to the kind of polymeric compound contained in a hard-coat composition. These polymerization initiators are decomposed by at least one of active energy ray irradiation and heating to generate a radical or a cation to advance radical polymerization or cationic polymerization.

The radical polymerization initiator may be capable of releasing a substance that initiates radical polymerization by at least one of active energy ray irradiation and heating. For example, examples of the thermal radical polymerization initiator include organic peroxides such as hydrogen peroxide and perbenzoic acid, and azo compounds such as azobisbutyronitrile.
As active energy ray radical polymerization initiators, Type 1 type radical polymerization initiators that generate radicals by molecular decomposition, and Type 2 type radical polymerization initiators that generate radicals by hydrogen abstraction reaction in coexistence with tertiary amines They can also be used alone or in combination.
The cationic polymerization initiator may be capable of releasing a substance that initiates cationic polymerization by at least one of active energy ray irradiation and heating. As the cationic polymerization initiator, aromatic iodonium salts, aromatic sulfonium salts, cyclopentadienyl iron (II) complexes and the like can be used. These can initiate cationic polymerization either by active energy ray irradiation or heating or any of them depending on the difference in structure.

  The polymerization initiator may include 0.1 to 10% by weight with respect to the total weight of the hard coat composition. When the content of the polymerization initiator is less than 0.1% by weight, curing can not be sufficiently progressed, the mechanical properties of the finally obtained hard coat layer are lowered, the hard coat layer and protection It is difficult or easy to realize the adhesion of the film. If it exceeds 10% by weight, adhesion failure or cracking due to curing shrinkage during formation of the hard coat layer, and curling may occur.

The hard coat composition may further contain one or more selected from the group consisting of a solvent and an additive.
The solvent can dissolve or disperse the polymerizable compound and the polymerization initiator, and any solvent known as a solvent for a hard coat composition in the technical field can be used without limitation.
The additives are inorganic particles, leveling agents, stabilizers, surfactants, antistatic agents, lubricants, antifouling agents, and the like.

Then, the method in the case of bonding a protective film together to a polarizer is demonstrated.
The protective film of the polarizer is preferably attached to the polarizer via an adhesive. As this adhesive,
Water-based adhesive using polyvinyl alcohol-based resin aqueous solution, water-based two-component urethane-based emulsion adhesive, etc .;
An active energy ray curable adhesive using a curable composition containing a polymerizable compound and a photopolymerization initiator, a curable composition containing a photoreactive resin, a curable composition containing a binder resin and a photoreactive crosslinking agent, etc. Agents and the like.

  The polyvinyl alcohol-based resin contained in the aqueous solution of polyvinyl alcohol-based resin used as the adhesive includes vinyl alcohol homopolymer and vinyl acetate homopolymer as well as vinyl alcohol homopolymer obtained by saponifying polyvinyl acetate which is a homopolymer of vinyl acetate. These include vinyl alcohol-based copolymers obtained by saponifying a copolymer with other copolymerizable monomers, and further, modified polyvinyl alcohol-based polymers in which their hydroxyl groups are partially modified. A polyvalent aldehyde, a water-soluble epoxy compound, a melamine compound, a zirconia compound, a zinc compound or the like may be further added to such a water-based adhesive as an additive.

  Further, the active energy ray-curable adhesive used as the adhesive is the same as the one including the reactive material which forms the crosslinked structure by irradiating the active energy ray exemplified as one of the above-mentioned hard coat compositions. Can be mentioned.

In the above, the method of using a resin film as a protective film (or a protective film having a hard coat layer) and bonding it to a polarizer has been described, but instead of the resin film, a thinner protective layer is directly laminated to the polarizer It can also be used as a protective film.
As a method of laminating a thinner protective layer directly on a polarizer, for example, a coating film containing an active energy ray curable resin is formed on the surface of the polarizer, and the coating film is cured by irradiation with active energy rays (UV etc.) Then, a protective film thinner than conventional protective films can be formed directly on the surface of the polarizer. Examples of the active energy ray-curable resin include those containing a reactive material which forms a crosslinked structure by irradiating an active energy ray, which is exemplified as one of the above-mentioned hard coat compositions.

(Window film)
On the other hand, a transparent protective film for preventing damage such as damage of an optical device (such as a liquid crystal cell) to which the laminate 100 is attached thereafter is also referred to as a window film. For example, when the optical film 50 has a laminated structure having a plurality of films, the window film is disposed on the outermost surface of the plurality of films opposite to the surface on which the adhesive layer 80 is provided.

  The window film is disposed on the viewing side of the flexible image display device, and plays a role of protecting other components from environmental changes such as external impact or temperature and humidity. Conventionally, glass has been used as such a protective layer, but the window film in the flexible image display is not rigid and rigid like glass, but has flexible properties. The window film may be made of a flexible transparent substrate and may include a hard coat layer on at least one side.

(Transparent substrate)
A transparent substrate that can be used as a window film will be described.
The transparent substrate has a visible light transmittance of 70% or more, preferably 80% or more. As the transparent substrate, any transparent polymer film can be used. In particular,
Polyolefins such as cycloolefin derivatives having units of monomers including polyethylene, polypropylene, polymethylpentene, norbornene or cycloolefin;
(Modified) celluloses such as diacetyl cellulose, triacetyl cellulose, propionyl cellulose;
Acrylics such as methyl methacrylate (co) polymer;
Polystyrenes such as styrene (co) polymers;
Acrylonitrile-butadiene-styrene copolymers, acrylonitrile-styrene copolymers;
Ethylene-vinyl acetate copolymers;
Polyvinyl chlorides, polyvinylidene chlorides;
Polyesters such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyarylate, etc.
Polyamides such as nylon;
Polyimides, polyamide imides, polyether imides;
Polyether sulfones, polysulfones;
Polyvinyl alcohols, polyvinyl acetals;
Polyurethanes;
It may be a film formed of a polymer such as an epoxy resin, and the polymer may be a film formed by individually or in combination of two or more. Moreover, this film can also use an unstretched, uniaxial or biaxial stretched film. Preferably, a polyamide film, a polyamide imide film or a polyimide film, a polyester film, an olefin film, an acrylic film, and a cellulose film, which are excellent in transparency and heat resistance, are preferred among the illustrated transparent substrates of the polymer. Further, it is also preferable to disperse inorganic particles such as silica, organic fine particles, rubber particles and the like in the transparent substrate. Furthermore, colorants such as pigments and dyes, fluorescent whitening agents, dispersants, plasticizers, heat stabilizers, light stabilizers, infrared absorbers, ultraviolet absorbers, antistatic agents, antioxidants, lubricants, solvents, etc. The following ingredients may be contained. The thickness of the transparent substrate is 5 to 200 μm, preferably 20 to 100 μm.

(Hard coat)
A window film may also be provided with a hard coat layer provided on at least one surface of the transparent substrate. As a hard-coat layer, the thing similar to the hard-coat layer of the above-mentioned protective film can be used.

(Retardation film)
The retardation film is a transparent film having different refractive indexes in two directions perpendicular to each other in the plane, and gives retardation to transmitted light.
Examples of the material of the retardation film are a polycarbonate resin film, a polysulfone resin film, a polyether sulfone resin film, a polyarylate resin film, and a norbornene resin film.
These resin films can be provided with a desired phase difference by stretching.
In addition, retardation films readily available from the market can also be used.

  The thickness of the retardation film can be, for example, 0.5 to 80 μm.

(Brightness improvement film)
The brightness enhancement film is a film that transmits polarized light parallel to a first direction in the plane, and reflects polarized light parallel to a second direction orthogonal to the first direction in the plane. When the optical film used in the present invention has a polarizer, it is preferable to make the first direction coincide with the transmission axis of the polarizer.

  The brightness enhancement film may be a multilayer laminate in which layers having birefringence and layers having substantially no birefringence are alternately stacked. Examples of the material of the layer having birefringence are naphthalene dicarboxylic acid polyester (for example, polyethylene naphthalate), polycarbonate and acrylic resin (for example, polymethyl methacrylate), and an example of a layer having substantially no birefringence. Is a copolyester of naphthalene dicarboxylic acid and terephthalic acid.

  The thickness of the brightness enhancement film may be, for example, 10 to 50 μm.

  Each of the films constituting the optical film exemplified above may have a plurality of functions. For example, the protective film may be a film having an optical function such as a retardation film or a brightness enhancement film.

(Adhesion in optical film)
When the optical film 50 has a laminated structure including a plurality of films, these films may be bonded via an adhesive. The adhesive is not particularly limited, but may be any of the above-mentioned water-based adhesive and active energy ray-curable adhesive.
Moreover, an adhesive can also be used as an adhesive. The adhesive will be described later.
The thickness of the adhesive can be 1 to 200 μm.

(Thickness of optical film in the case of a laminate)
When the optical film 50 has a laminated structure including a plurality of films, the total thickness of the optical film 50 can be 10 to 1200 μm.

(Pressure-sensitive adhesive layer)
As described above, the laminate used in the present invention has the optical film and the pressure-sensitive adhesive layer provided on one side thereof. The pressure-sensitive adhesive layer refers to one formed of a pressure-sensitive adhesive. Here, the adhesive will be described.
A pressure-sensitive adhesive is a pressure-sensitive adhesive, which exhibits a soft solid (viscoelastic) state in a temperature range near room temperature (for example, 25 ° C.) and has a property of being easily adhered to an adherend by pressure. say. The adhesive referred to here is “CA Dahlquist, Adhesion: Fundamental and Practice”, McLaren & Sons, (1966), P. Materials having a property satisfying a complex tensile elastic modulus E ^* (1 Hz) <10 ⁷ dyne / cm ² as defined in “143” (typically, a material having the above-mentioned property at 25 ° C.) It can be. The pressure-sensitive adhesive in the art disclosed herein can also be understood as a solid content (nonvolatile content) of the pressure-sensitive adhesive composition or a component of the pressure-sensitive adhesive layer.

  An example of the pressure-sensitive adhesive is a composition in which an acrylic resin, a styrene resin, a silicone resin or the like is used as a base polymer, and a crosslinking agent such as an isocyanate compound, an epoxy compound or an aziridine compound is added thereto. In this specification, the "base polymer" of the adhesive refers to the main component of the rubbery polymer contained in the adhesive. The rubbery polymer refers to a polymer exhibiting rubber elasticity in a temperature range around room temperature. Further, in the present specification, the “main component” refers to a component contained in excess of 50% by weight unless otherwise specified.

  The thickness of the adhesive can be 1 to 40 μm.

(Thickness of optical film in the case of a laminate)
When the optical film 50 has a laminated structure including a plurality of films, the total thickness of the optical film 50 can be 10 to 1200 μm.

The pressure-sensitive adhesive layer 80 is provided on at least one surface of the optical film (single-layer structure or laminated structure) 50.
As the pressure-sensitive adhesive, those described above can be used.

(Separator film)
The laminate 100 can have a separator film 90 on the side of the pressure-sensitive adhesive layer 80 opposite to the side in contact with the optical film 50.

  The separator film 90 is a film having a weaker adhesion to the pressure-sensitive adhesive layer 80 than the optical film 50. At the time of transportation or storage of the laminate 100 before attaching the optical film 50 to another member such as an optical device (liquid crystal cell) via the adhesive layer 80, the separator film 90 has the surface of the adhesive layer 80 Protect. When the pressure-sensitive adhesive layer 80 is attached to another member, the separator film 90 is easily peeled off from the pressure-sensitive adhesive layer 80.

  The separator film does not have to be transparent but is preferably transparent. An example of the material of the separator film is polyethylene terephthalate. The thickness of the separator film can be 1 to 40 μm.

(Protect film)
In addition, the laminate 100 can have a protect film 70 disposed on the outer surface of the optical film 50 opposite to the surface on which the adhesive layer 80 is provided.
The protect film 70 is an optical device during processing of the laminate 100, or when attaching the laminate 100 to an optical device (such as a liquid crystal cell), or while transporting the optical device to which the laminate 100 is attached, etc. And / or has a function of suppressing the scratching of the optical film 50.

  Examples of the material of such a protective film are polyethylene terephthalate, polyethylene, polypropylene and the like. The protective film 70 does not have to be transparent, but is preferably transparent. The thickness of the protective film can be 1 to 40 μm.

  The protective film 70 can also be a film that protects the optical film 50 until the product using the optical film 50 is used. In this case, even after the optical film 50 is attached to an optical device (such as a liquid crystal cell) via the pressure-sensitive adhesive layer 80, the protective film 70 is not peeled off from the optical film 50.

  The protect film 70 can be attached to the optical film 50 through a pressure-sensitive adhesive layer or by self-adhesion by electrostatic adsorption.

The specific example of the laminated structure of the laminated body 100 is shown to (a) and (b) of FIG.
In the laminate 100 of FIG. 2A, the protect film 70, the protective film 2, the polarizer 3, the protective film 2, the pressure-sensitive adhesive layer 80, and the separator film 90 are laminated in this order. The protective film 2, the polarizer 3 and the protective film 2 constitute an optical film 50.

  In the laminate 100 of FIG. 2B, the protect film 70, the protective film 2, the polarizer 3, the pressure-sensitive adhesive layer 80, and the separator film 90 are laminated in this order. The protective film 2 and the polarizer 3 constitute an optical film 50. And although not shown, in any of the examples, the films in each optical film 50 can be bonded with an adhesive or a pressure-sensitive adhesive.

(Laminated body for flexible image display)
The optical film 50 used in the present invention may be a laminate for a flexible image display used in a flexible image display that can be bent or the like.
As a typical example of this flexible image display device, an image display device having a laminate for a flexible image display device and an organic EL display panel. In this typical example, usually, a laminate for a flexible image display device is disposed on the viewing side with respect to the organic EL display panel, and the flexible image display device is configured to be bendable. The laminate for a flexible image display device may contain a window film, a circularly polarizing plate, and a touch sensor, and the stacking order thereof is arbitrary, but the window film, the circularly polarizing plate and the touch sensor from the viewing side It is preferable that it is comprised in order of lamination | stacking or lamination of a window film, a touch sensor, and a circularly polarizing plate. If a circularly polarizing plate is present on the viewing side of the touch sensor, the pattern of the touch sensor is less likely to be viewed and the visibility of the display image is improved. Each member can be laminated using an adhesive, an adhesive or the like. The light shielding pattern may be provided on at least one surface of any of the window film, the circularly polarizing plate, and the touch sensor.

(Circularly polarizing plate)
The circularly polarizing plate is a functional film having a function of transmitting only the right or left circularly polarized light component by laminating the λ / 4 retardation plate, which is a retardation film, on the linear polarizing plate. When the external light that has entered the display device passes through the circularly polarizing plate disposed on the viewing side, it is converted to right circularly polarized light and emitted to the organic EL panel side. When this right circularly polarized light is reflected by the metal electrode of the organic EL panel (reflected light), this reflected light becomes left circularly polarized light. As this left circularly polarized light can not pass through the circularly polarizing plate, as a result, this reflected light is not emitted out of the display device. With such a function, what is visually recognized in the display panel of the display device is only the light emitting component of the organic EL, and by transmitting only this light emitting component, it is possible to prevent the influence of the reflected light and make the image easy to see it can.

  In order to achieve the circular polarization function, the absorption axis of the linear polarization plate and the slow axis of the λ / 4 retardation plate theoretically need to be 45 °, but practically 45 ± 10 °. The linear polarizing plate and the λ / 4 retardation plate do not necessarily have to be stacked adjacent to each other, as long as the relationship between the absorption axis and the slow axis satisfies the above-mentioned range. Although it is preferable to achieve perfect circular polarization at all wavelengths, it is not necessary in practice, so the circularly polarizing plate in the present invention also includes an elliptically polarizing plate. It is also preferable to improve the visibility in the state where polarized sunglasses are worn by further laminating a λ / 4 retardation plate on the viewing side of the linear polarizing plate to make the outgoing light circularly polarized.

  The linear polarizing plate is a functional layer having a function of blocking light polarized in a vibration component perpendicular to the light passing therethrough while passing light vibrating in the transmission axis direction. The linear polarizer is usually configured to include a polarizer and a protective film attached to at least one surface thereof. The polarizer may be any of the above-mentioned film type polarizer or liquid crystal coated type polarizer. The protective film can also be used as described above. 200 micrometers or less are preferable and, as for the thickness of the linear-polarizing plate which comprises a circularly-polarizing plate, 0.5 micrometer-100 micrometers are more preferable. When the thickness exceeds 200 μm, the flexibility (flexibility) applicable to the laminate for a flexible image display may be reduced. The thickness of a suitable linear polarizer can be adjusted by adjusting the thickness of the above-mentioned polarizer and protective film suitably.

  The λ / 4 retardation plate, which is a retardation film, is also referred to as a 1⁄4 wavelength plate, and gives a phase difference of π / 2 (= λ / 4) to the polarization plane of incident light. is there. Although a retardation film having such performance can be selected from the above-mentioned retardation films and a λ / 4 retardation plate can be prepared, as another example, a liquid crystal formed by applying a liquid crystal composition The coating type retardation plate may be a λ / 4 retardation plate. The liquid crystal coated retardation plate formed by applying the liquid crystal composition can obtain a very thin λ / 4 retardation plate as described later. Therefore, this liquid crystal coating type retardation plate is particularly preferable as a λ / 4 retardation plate constituting a circularly polarizing plate of a laminate for a flexible image display device.

Here, a liquid crystal composition forming the λ / 4 retardation plate will be described.
The liquid crystal composition includes a liquid crystal compound having a property of exhibiting a liquid crystal state such as nematic, cholesteric or smectic. The liquid crystal compound has a polymerizable functional group. The liquid crystal composition may contain a plurality of liquid crystal compounds. When the liquid crystal composition contains a plurality of liquid crystal compounds, at least one of the liquid crystal compounds has a polymerizable functional group. The liquid crystal composition may further include an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, a silane coupling agent, and the like. The liquid crystal coating type retardation plate is an alignment film by applying and curing a liquid crystal composition on an alignment film of a base material on which an alignment film is formed in advance, as described in the method of manufacturing the liquid crystal polarizer. It can manufacture by forming a liquid-crystal phase difference layer on it. The liquid crystal coated retardation plate can be formed thinner than a stretched retardation plate. The thickness of the liquid crystal polarizing layer is 0.5 to 10 μm, preferably 1 to 5 μm. The liquid crystal coated retardation plate may be separated from the substrate, transferred and laminated, or the substrate may be laminated as it is. It is also preferable that the substrate plays a role as a transparent substrate of a protective film or a retardation plate.

  Many common materials constituting the retardation film show large birefringence as the wavelength is short, and small birefringence as the wavelength is long. In this case, a phase difference of λ / 4 can not be achieved in the entire visible light region, so an in-plane phase difference of 100 to 180 nm, preferably 130, is such that λ / 4 is around 560 nm, which is high in visibility. It is often designed to be ̃150 nm. It is preferable to use an inverse dispersion λ / 4 retardation plate using a material having a birefringence and wavelength dispersion characteristics reverse to normal, because visibility can be improved. As such a material, it is preferable to use those described in JP-A-2007-232873, etc. in the case of a stretching type retardation plate, and JP-A-2010-30979 in the case of a liquid crystal coated type retardation plate. .

  Further, as another method of forming a preferable retardation film constituting a circularly polarizing plate, there is also known a technique of obtaining a wide band λ / 4 retardation plate by combining it with a λ / 2 retardation plate 10-90521). The λ / 2 retardation plate is also manufactured by the same material method as the λ / 4 retardation plate. Although the combination of the stretching type retardation plate and the liquid crystal coating type retardation plate is optional, it is preferable to use the liquid crystal coating type retardation plate because the thickness of the film can be reduced.

  There is also known a method of laminating a positive C plate on the circularly polarizing plate in order to enhance the visibility in the oblique direction (Japanese Patent Laid-Open No. 2014-224837). The positive C plate may also be a liquid crystal coated retardation plate or a stretched retardation plate. The thickness direction retardation of this positive C plate is -200 to -20 nm, preferably -140 to -40 nm.

(Touch sensor)
The touch sensor is used as an input means. As a touch sensor, various styles such as a resistive film type, a surface acoustic wave type, an infrared type, an electromagnetic induction type, and a capacitance type have been proposed, and any type may be used. Among these, the capacitance method is preferable.

The capacitive touch sensor may be divided into an active area and a non-active area located at an outer portion of the active area as viewed from the display panel surface. The active area is an area corresponding to an area (display portion) in which the screen is displayed on the display panel, and is an area where a user's touch is sensed, and the inactive area is an area in which the screen is not displayed on the display device Area corresponding to the display unit).
The touch sensor comprises: a substrate having flexible characteristics; a sensing pattern formed on an active area of the substrate; and a sensing pattern formed on a non-active area of the substrate, and connected to an external drive circuit through the sensing pattern and the pad portion Each sensing line can be included. As a substrate having a flexible property, a substrate formed of the same material as the transparent substrate of the window film can be used. The substrate of the touch sensor preferably has a toughness of 2,000 MPa% or more from the viewpoint of crack suppression of the touch sensor. More preferably, the toughness may be 2,000 MPa% to 30,000 MPa%.

The sensing pattern may include a first pattern formed in a first direction and a second pattern formed in a second direction. The first pattern and the second pattern are arranged in different directions. The first pattern and the second pattern are formed in the same layer, and in order to sense a point to be touched, the respective patterns must be electrically connected. The first pattern is a form in which each unit pattern is connected to each other through a joint, but since the second pattern has a structure in which each unit pattern is separated from each other in an island form, the second pattern is electrically A separate bridge electrode is required to make the connection. The sensing pattern is formed of a known transparent electrode material. Examples of the transparent electrode material include indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium zinc tin oxide (IZTO), cadmium tin oxide (CTO), and PEDOT. (Poly (3,4-ethylenedioxythiophene)), carbon nanotube (CNT), graphene, metal wire (metal used for the metal wire is not particularly limited, for example, silver, gold, aluminum, copper, iron, nickel, titanium , Terrenium, chromium, etc. These can be used singly or in combination of two or more types) and the like, and these can be used alone or in combination of two or more types. . Preferably, it is ITO. The bridge electrode may be formed on the sensing pattern via the insulating layer, and the bridge electrode may be formed on the substrate, and the insulating layer and the sensing pattern may be formed thereon. The bridge electrode may be formed of the same material as the sensing pattern, and may be formed of a metal such as molybdenum, silver, aluminum, copper, palladium, gold, platinum, zinc, tin, titanium or an alloy of two or more of them. You can also Since the first pattern and the second pattern must be electrically isolated, an insulating layer is formed between the sensing pattern and the bridge electrode. The insulating layer can be formed only between the joint of the first pattern and the bridge electrode, or can be formed in the structure of the layer covering the sensing pattern. In the latter case, the bridge electrode can connect the second pattern through the contact hole formed in the insulating layer. The touch sensor has a difference in transmittance between a patterned region and a non-patterned region, specifically, a difference in refractive index between the two regions. An optical tuning layer may further be included between the substrate and the electrode as a means to properly compensate for the difference. The optical control layer may include an inorganic insulating material or an organic insulating material. The optical control layer can be formed by coating a photocurable composition containing a photocurable organic binder and a solvent on a substrate. The photocurable composition can further include inorganic particles. The inorganic particles may increase the refractive index of the optical control layer.
The said photocurable organic binder can contain the copolymer of each monomers, such as an acrylate-type monomer, a styrene-type monomer, a carboxylic acid-type monomer, for example. The photocurable organic binder may be, for example, a copolymer including mutually different repeating units such as an epoxy group-containing repeating unit, an acrylate repeating unit, and a carboxylic acid repeating unit.
The inorganic particles can include, for example, zirconia particles, titania particles, alumina particles, and the like.
The photocurable composition may further include various additives such as a photopolymerization initiator, a polymerizable monomer, and a curing aid.

  Each layer (a window film, a circularly polarizing plate, and a touch sensor) which forms the said laminated body for flexible image display apparatuses can be formed with an adhesive agent. As the adhesive, the above-described water-based adhesive, active energy ray-curable adhesive, and pressure-sensitive adhesive are often used.

(Light blocking pattern)
The light blocking pattern may be applied as at least a part of a bezel or a housing of the flexible image display. The visibility of the image is improved by hiding the wiring disposed at the peripheral portion of the flexible image display device by the light shielding pattern and making it difficult to be visually recognized. The light blocking pattern may be in the form of a single layer or multiple layers. The color of the light shielding pattern is not particularly limited, and may be various colors such as black, white and metal. The light shielding pattern may be formed of a pigment for realizing a color and a polymer such as an acrylic resin, an ester resin, an epoxy resin, a polyurethane, and a silicone resin. These may be used alone or in combination of two or more. The light shielding pattern can be formed by various methods such as printing, lithography, and inkjet. The thickness of the light shielding pattern may be 1 μm to 100 μm, preferably 2 μm to 50 μm. In addition, a shape such as an inclination may be provided in the thickness direction of the light shielding pattern.

  In the above, the optical film and the adhesive which are contained in the laminated body used for the manufacturing method of this invention were demonstrated. Then, the manufacturing method of this invention is demonstrated.

(powder)
The manufacturing method of the present invention will be described with reference to (a) and (b) of FIG. 1 again.
The powder f attached to the end face E of the optical film 50 adheres to the end face by processing the end face of the laminate 100. Usually, the end face of the laminate 100 is processed from the raw fabric of the laminate 100 in order to obtain the laminate 100 having a desired size. Examples of processing are cutting, cutting and polishing. Here, cutting is a concept including drilling. Therefore, as described above, the end face of the laminate 100 is not only the end face E of the outer side of the laminate 100 as shown in FIG. 1A but also the inner wall of the hole (opening) H of the laminate 100. It also includes the inner end face E to be formed.

  The cutting is a step of making a cut from the front surface to the back surface of the laminate by insertion of a blade, removal by a laser or the like, whereby an outline of the laminate can be determined.

  Cutting is a process of scraping a part of the end to form a new end face by bringing a relatively moving bit (blade) into contact with the end of the laminate. Moreover, this cutting includes drilling as described above. The drilling process is, for example, a process of providing a hole H at a desired position using a drill or the like on the laminated body 100 as shown in (b) of FIG. 1. In such a drilling process, powder f (drilling process debris) may adhere to the inner end face E forming the inner wall of the hole H.

  Polishing is a process of scraping a part of the end face by bringing relatively moving abrasive grains (which may be fixed abrasive grains or loose abrasive grains) into contact with the end face of the laminate. Polishing also includes a process called grinding.

  For example, after the raw fabric of the laminate 100 is cut into a planar shape slightly larger than a desired size by a blade or a laser, the planar shape of the laminate is predetermined by grinding and / or polishing the end face of the cut laminate. It can be dimensioned, and furthermore, the squareness and flatness of the end face can be enhanced.

  There is no limitation in particular in the planar shape (shape seen from the thickness direction) of a laminated body. For example, it can be square, rectangular, circular, etc.

  By these processes on the end face of the laminate, powder of the material constituting the laminate 100 is generated, and a part thereof adheres to the end face E of the laminate 100. Therefore, it is one embodiment of the preparatory process in the manufacturing method of this invention to perform these processes to the said laminated body. The end surface E can be a surface connecting the two main surfaces of the laminate 100.

  The average particle size of the powder can be, for example, 10 to 3000 μm. This particle size is D50 of particle size distribution based on weight by laser diffraction method.

(Collision process (Powder removal process by collision of dry ice particles))
Subsequently, dry ice particles are caused to collide with the end face E of the laminate 100, and the powder f on the end face is removed from the end face.

  Specifically, it is preferable that the dry ice particles be transported by gas and collide with the end face E of the laminate 100.

  The average particle size of the dry ice particles to be collided is not particularly limited, but is preferably 100 μm or more from the viewpoint of efficiently removing the powder. Moreover, it is preferable that it is 1000 micrometers or less from a viewpoint of suppressing that an adhesive layer chip | tips by the collision of dry ice.

  The average particle size of the dry ice particles can be measured by a laser Doppler flowmeter.

  The velocity of the dry ice particles to be collided can be 5 m / sec to 100 m / sec.

  The carrier gas for dry ice is not particularly limited, and may be, for example, nitrogen, air, or carbon dioxide gas.

  Specifically, a dry ice particle supply unit (apparatus) 300 as shown in FIG. 3 can be used.

  This apparatus comprises a liquid carbon dioxide source 310, a nozzle 320, a carrier gas source 330, a line L1 connecting the liquid carbon dioxide source 310 and the nozzle 320, and a line L2 connecting the carrier gas source 330 and the nozzle 320.

  In the line L1, a valve 340 and an orifice 350 are provided, and in the line L2, a valve 360 is provided.

  The valve 340 is opened and the liquid of the liquid carbon dioxide source 310 is adiabatically expanded at the orifice 350 to generate dry ice particles (dry ice snow), which are sent to the nozzle 320. The valve 360 is opened to supply the gas from the carrier gas source 330 to the nozzle 320, and the dry ice particles d are blown out from the nozzle 320 and supplied to the end surface E of the laminate 100.

  The particle diameter of the dry ice particle d can be adjusted by the distance (adiabatic expansion distance) from the adiabatic expansion at the orifice 350 to the blowout by the nozzle 320, and the distance (injection distance) between the nozzle 320 and the supply target of dry ice particles. . In addition, it is possible to conduct an appropriate preliminary experiment using a dry ice particle supply unit (apparatus), confirm the removal degree of the powder f, and adjust the adiabatic expansion distance and the injection distance.

  The distance (injection distance) between the nozzle 320 and the end face E of the laminate 100 is preferably less than 20 mm. In addition, the adiabatic expansion distance can be, for example, 10 to 500 mm.

It is preferable that the position where the stacked body 100 and the nozzle 320 are moved relative to each other by the transport unit 400 so that the portion where the dry ice particles d collide is scanned on the end surface E. For example, in FIG. 3, the stacked body 100 is moved such that the collision portion of the dry ice particles d at the end face E moves in a plane orthogonal to the blowout direction (lateral direction) of the dry ice particles d using the transport unit 400. Can be scanned.
The scanning speed of the collision portion of the dry ice particles d on the end face E can be 1 to 100 m / sec.

(Action)
According to the present embodiment, the dry ice particles d are blown to the end face E of the laminate 100, so that powder such as cutting waste, cutting waste, drilling waste, grinding waste and the like is suitably removed from the end face . This is preferable because contamination by powder in the post-process is reduced. In addition, the time taken for the removal of the powder is also shorter than in the case of tape sticking and peeling.
When the particle diameter of dry ice particles to be collided is set to 100 to 1000 μm, chipping of the pressure-sensitive adhesive layer at the end face can be suppressed while increasing the removal rate of powder, and 200 to 700 μm is more preferable.

(Removal of powder to laminated structure in which plural laminated bodies are laminated)
Although dry ice particles are caused to collide with one laminate 100 in the above description, as shown in FIG. 4, dry ice is applied to the end face E of the laminated structure 120 in which a plurality of laminates 100 are laminated in the thickness direction. It is also preferable to make them collide. According to this, a large amount of processing of the stacked body 100 becomes possible.

(Order of processing of end face and removal of powder)
After processing (cutting, cutting, and polishing) of a part of the end face of the laminate 100 is completed, while processing of other parts of the end face of the laminate 100 is being performed, parallel processing at the end face is completed. The powder may be removed by blowing dry ice particles onto the portion where it has been used. Thereby, the process time can be shortened.

  On the other hand, after all processing such as cutting, cutting, and polishing for the end face of the laminate is completed, dry ice particles are made to collide with the end face of the laminate 100 to clean powder on the end face and make dry ice particles collide with the end face. At the same time, other parts of the end face of the laminate may not be processed. In this case, since the atmosphere (space) for removing the powder due to the collision of the dry ice particles and the atmosphere (space) for processing the end face can be divided, it is also possible to prevent the contamination of the end face by the powder generated by the processing. It becomes.

(Atmosphere during collision process (powder removal process))
The atmosphere around the laminate and laminate structure during the step of removing the powder on the end face of the laminate and laminate structure with dry ice particles can be an air atmosphere, but if necessary nitrogen, carbon dioxide etc. It may be an atmosphere. Moreover, the temperature of atmosphere is 20-30 degreeC normally, and 20-27 degreeC is preferable. The relative humidity of the atmosphere is usually less than 80%, preferably 30 to 75%, more preferably 40 to 70%. When the relative humidity of the atmosphere is 80% or more, condensation occurs due to cooling of the laminate or the laminate structure, and a film (for example, a polarizer) having high water absorbability in the laminate absorbs water and swells, etc. It may cause defects in the appearance or optical properties of the body or laminated structure.

(Manufacturing device of optical member)
Subsequently, with reference to FIG. 5, an optical member manufacturing apparatus 1000 suitable for carrying out the above-described method will be described.

  The manufacturing apparatus 1000 includes dry ice in a portion processed into an end surface processed portion 200 for processing such as cutting, cutting or polishing of an end surface of the laminated body 100 or the laminated structure 120 and a portion processed into the end surface processed portion 200 in the laminated body 100. The dry ice particle supply unit 300 for colliding particles is provided, and the transport unit 400 for transporting the laminated body 100.

  In FIG. 5, a cutting device is depicted as the end surface processed portion 200. The cutting apparatus includes a horizontally extending rotating shaft 210, a disk 220 attached to the rotating shaft, and a cutting tool 230 attached to the disk 220. The rotation of the cutting tool 230 enables cutting of the end face of the laminate or the like.

  In the dry ice particle supply unit 300, only the nozzle 320 is described for simplicity.

  The transport unit 400 includes a pair of upper jig 420 and lower jig 422 which sandwich and support the laminated body 100 or the laminated structure 120 in the thickness direction, and a cylinder which presses the upper jig 420 in the thickness direction (downward direction). 430, a rotation mechanism 410 connected to the lower jig 422 to rotate the upper jig 420 and the lower jig 422 around the vertical axis (Z axis), and the upper jig 420 and the lower jig 422 in the horizontal direction (X Moving mechanism 440 for moving in the

  Next, a method of manufacturing an optical member using this apparatus will be described. First, the stack 100 or the stack structure 120 is sandwiched between the upper jig 420 and the lower jig 422. Next, the upper jig 420 is pressed toward the lower jig 422 by the cylinder 430 to fix the stack 100 or the stack structure 120. In the present embodiment, the stacked body 100 or the stacked structure 120 is rectangular as viewed from above and has four end faces. Therefore, the rotational position of the stack 100 or the stack structure 120 is adjusted by the rotation mechanism 410 so that the two end faces E face parallel to the X axis.

  Subsequently, the end face processing unit 200 is activated. Specifically, the disk 220 is rotated. Next, the stacked body 100 and the stacked structure 120 are moved in the X direction by the moving mechanism 440 to bring the cutting tool 230 of the end surface processed portion 200 into contact with the end surface E. Thereby, a pair of end surfaces E facing each other of the stacked body 100 and the stacked structure 120 are cut by the cutting tool 230. At this time, cutting waste adheres to the end face E.

  Subsequently, the stacked body 100 and the stacked structure 120 are moved in the −X direction by the transport unit 400, and dry ice particles are supplied from the nozzle 320 of the dry ice particle supply unit 300. Thus, the dry ice particles collide with the cut end face E of the laminate 100 and the laminated structure 120, and the powder on the end face E is removed.

  Subsequently, the stacked body 100 and the stacked structure 120 are further moved by the transport unit 400 in the − direction, and the rotating mechanism 410 causes the remaining two end faces to be parallel to the X direction. Rotate 120. Thereafter, processing of the remaining two end faces and subsequent removal of powder by dry ice particles may be performed in the same manner as described above.

  The end surface processed portion 200 can be in various forms depending on the processing mode. For example, as shown in FIG. 6, cutting is performed with a canna type rotary blade having a cylindrical body 240 rotating around a vertical axis and a long blade 250 provided so as to extend axially on the outer peripheral surface of the cylindrical body 240 You may

  Also, instead of the cutting tool 230, polishing can be performed by using a polishing plate provided with a large number of abrasive grains on the surface of a disk.

  In addition, when cutting and polishing are not required, a cutting device can be used.

  Lastly, an example of a method for removing the powder f (the drilling scraps) attached to the end face E of the hole H provided in the laminate 100 will be described with reference to FIG.

  First, each laminate 100 is subjected to a drilling process to prepare a plurality of laminates 100 having powder (drilling scraps) f attached to the inner end face E of the hole H. As shown in (b) of FIG. 1, each laminate 100 has holes H provided at predetermined positions by drilling. Next, these laminates 100 are laminated so that the positions of the holes H of the laminates 100 are aligned on one axis (an axis extending in the thickness direction) to obtain a laminate structure 120. Then, the holes H of the stacked bodies 100 are connected to each other, and the through holes H 'penetrating in the thickness direction of the stacked structure 120 are formed in the stacked structure 120.

  In the pair of upper jig 420 and lower jig 422 for pressing the laminated structure 120 in the thickness direction, one jig is provided with a dry ice particle supply port 420a and the other jig is provided with a dry ice particle recovery port 422b in advance. Set up. The upper jig 420 and the lower jig 422 are disposed such that the through holes H 'communicate with the dry ice particle supply port 420a and the dry ice particle recovery port 422b, and the laminated structure 120 is arranged in the thickness direction. Press. Thus, the preparation process before the dry ice collision process is completed.

  Next, dry ice particles are supplied from the nozzle 320 into the through hole H 'via the dry ice particle supply port 420a (collision step). The dry ice particles jetted from the nozzle 320 spread in the width direction as it proceeds, collide with the end face E of the through hole H 'of the laminated structure 120, and are discharged from the dry ice particle recovery port 422b together with the powder f. By using such an apparatus, the powder f can be efficiently removed from the laminate 100 in which the powder f is attached to the end face E, which is the inner wall of the hole H, by drilling.

(Laminated stack)
Protecting film (made of PET (polyethylene terephthalate): 53 μm) / protective film (made of TAC (triacetyl cellulose): 32 μm) / polarizer (PVA (iodine-adsorbed polyvinyl alcohol): 12 μm) / protective film (COP (cyclic olefin resin) ): An original laminate having a layer structure of: 23 μm) / adhesive layer (acrylic adhesive: 20 μm) / separator film (PET: 38 μm) was obtained.
The protective film and the polarizer were adhered by a water-based adhesive. The thickness of the laminate was 178 μm.

(Processing of the end face of the laminate)
The raw laminate was punched into a rectangular shape of 140 × 65 mm by a Thomson blade to obtain a laminate.

  Next, 50 stacks were stacked to obtain a stacked structure. Each end face of the laminated structure was cut by a cutting device. Thereafter, each end face of the laminated structure was polished by a polishing apparatus.

(Removal of powder on end face of laminate)
The powder on the end face of the laminate was removed for each of the examples and the comparative examples under the following conditions.

Example 1
Dry ice particle supply device: carbon dioxide gas type dry ice blast CO ₂ pressure: 5 MPa (Note that the CO ₂ pressure is the supply pressure to the orifice.)
Air pressure: 0.5MPa
Distance between nozzle tip and end face: about 50 mm
Nozzle scanning speed: 50 mm / 5 seconds Center position of nozzle and nozzle scanning direction: The nozzle was directed to the center in the thickness direction of the end face of the laminated structure, and the nozzle was scanned in the direction orthogonal to the thickness of the end face of the laminated structure .
Average particle size of dry ice particles: 1 to 100 μm
Ambient temperature: 24 ° C to 26 ° C, relative humidity of the atmosphere: 45% to 65%

(Example 2)
Dry ice particle supply device: CO ₂ dry ice blast CO ₂ pressure: 7 MPa
Air pressure: 0.5MPa
Distance between nozzle tip and end face: about 50 mm
Nozzle scanning speed: 50 mm / 5 seconds Center position of nozzle and nozzle scanning direction: The nozzle was directed to the center in the thickness direction of the end face of the laminated structure, and the nozzle was scanned in the direction orthogonal to the thickness of the end face of the laminated structure .
Average particle size of dry ice particles: 200 to 700 μm or less Atmosphere temperature: 24 ° C. to 26 ° C. Relative humidity of atmosphere: 45% to 65%

(Example 3)
Dry ice particle supply device: pellet type dry ice blast pellet diameter: φ 3 mm
Air pressure: 0.5MPa
Distance between nozzle tip and end face: about 50 mm
Nozzle scanning speed: 50 mm / 5 seconds Center position of nozzle and nozzle scanning direction: The nozzle was directed to the center in the thickness direction of the end face of the laminated structure, and the nozzle was scanned in the direction orthogonal to the thickness of the end face of the laminated structure .
Average particle size of dry ice particles: 1000 μm or more Ambient temperature: 24 ° C. to 26 ° C. Relative humidity of the atmosphere: 45% to 65%

(Example 4)
The powder on the end face of the laminate was removed under the same conditions as in Example 2 except that the atmosphere temperature was 26 ° C. and the relative humidity of the atmosphere was 80 to 90%.
In addition, the laminated body was cooled by contacting with dry ice particle | grains at the time of removal, and dew condensation generate | occur | produced in the laminated body. When a portion where dew condensation had occurred was confirmed, there was no occurrence of polishing debris or chipping, but swelling occurred at the end of the laminate.

(Comparative example 1)
The end face of the laminated structure was rubbed with a clean room wiper impregnated with ethanol (manufactured by Kuraray Kuraflex).

(Comparative example 2)
The OLFA cutter knife was moved along the end face of the laminated structure.

(Comparative example 3)
After sticking an adhesive tape (Sellotape (manufactured by Nichiban Co., Ltd.)) on the end face of the laminated structure, the adhesive tape was peeled off from the end face.

(Comparative example 4)
An air flow was blown to the end face of the laminated structure in the same manner as in Example 1 except that liquid carbon dioxide was not supplied.

(Evaluation)
The end face was observed with a microscope to check the state of powder residue on the end face and the presence or absence of chipping of the adhesive layer on the end face.

The results are shown in Table 1.

  “○ of“ powder residue on end face ”indicates that no powder is observed in a field of 30 mm in length (hereinafter simply referred to as“ length ”) in the direction orthogonal to the thickness, and Δ indicates a length of 30 mm It is indicated that 1 to 2 powders were observed in the field of view, and x indicates that 3 or more powders were observed in the field of 30 mm in length.

  In addition, “○” of “chipping of the adhesive layer on the end face” indicates that no chipping is observed in the field of 30 mm length (hereinafter simply referred to as length) in the direction orthogonal to the thickness, and Δ indicates 30 mm It is indicated that 1 to 2 chippings were observed in the length field of view, and x indicates that 3 or more chippings were observed in the 30 mm length field of view.

DESCRIPTION OF SYMBOLS 50 ... optical film, 80 ... adhesive layer, 100 ... laminated body, 120 ... laminated structure, 200 ... end surface process part, 300 ... dry ice particle supply part, 400 ... conveyance part, 1000 ... manufacturing apparatus of an optical member, f ... powder, E ... end face.

Claims (9)

Preparing an optical film and a laminate having an adhesive layer provided on one side of the optical film and having a powder attached to the end face thereof;
And D. colliding dry ice particles with the end face of the laminate to remove the powder from the end face.   The method according to claim 1, wherein the dry ice particles have an average particle size of 100 to 1000 μm.   The method according to claim 1 or 2, wherein in the collision step, the dry ice particles collide with an end face of a laminated structure in which a plurality of the laminated bodies are laminated.   The collision with the dry ice particles on a part of the end face, at the same time, at least one selected from the group consisting of cutting, cutting, and polishing is performed on the other part of the end face of the laminate. The method according to 1 or 2.   In the preparing step, at least one selected from the group consisting of cutting, cutting, and polishing is performed on the end surface, and when the dry ice particles are caused to collide with a part of the end surface, the end surface is The method according to claim 1 or 2, wherein none of the groups selected from the group is performed.   The optical film is at least one selected from the group selected from the group consisting of at least one selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, and a touch sensor. The method according to any one of claims 1 to 5, which is a laminated film containing at least two, or a laminated film containing at least two selected from the group described above.   The method according to any one of claims 1 to 6, wherein the relative humidity of the atmosphere in the step of causing the dry ice particles to collide with the end face is 30 to 75%. An optical film and an end face processed portion for cutting, cutting, or polishing an end face of a laminate having a pressure-sensitive adhesive layer provided on one surface of the optical film;
An apparatus for manufacturing an optical member, comprising: a dry ice particle supply unit configured to cause dry ice particles to collide with a portion processed into the end surface processed portion in the laminate.   The manufacturing apparatus of the optical member of Claim 8 further provided with the conveyance part which moves the said laminated body between the said end surface process part and the said dry ice particle supply part.

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