JP2019191464A - Resin sheet and method for producing the same - Google Patents

Resin sheet and method for producing the same Download PDF

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Publication number
JP2019191464A
JP2019191464A JP2018086481A JP2018086481A JP2019191464A JP 2019191464 A JP2019191464 A JP 2019191464A JP 2018086481 A JP2018086481 A JP 2018086481A JP 2018086481 A JP2018086481 A JP 2018086481A JP 2019191464 A JP2019191464 A JP 2019191464A
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Prior art keywords
cutting
resin sheet
workpiece
cutting blade
outer peripheral
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JP7255974B2 (en
Inventor
寛 友久
Hiroshi TOMOHISA
寛 友久
章典 伊▲崎▼
Akinori Isaki
章典 伊▲崎▼
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Nitto Denko Corp
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Nitto Denko Corp
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Priority to JP2018086481A priority Critical patent/JP7255974B2/en
Priority to KR1020207029658A priority patent/KR20210002485A/en
Priority to PCT/JP2019/014850 priority patent/WO2019208138A1/en
Priority to CN201980027734.XA priority patent/CN112005142B/en
Priority to TW108113043A priority patent/TWI803617B/en
Publication of JP2019191464A publication Critical patent/JP2019191464A/en
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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/13—Surface milling of plates, sheets or strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/023—Optical properties
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements

Abstract

To provide a resin sheet in which cracking is suppressed even though the resin sheet is subjected to a cutting work, and a method for producing the resin sheet.SOLUTION: A resin sheet is subjected to a cutting work, in which a ratio RR/DR of regular reflectance RR and diffuse reflectance DR in a cut end face is 0.10 or more. A method for producing the resin sheet includes: overlapping a plurality of resin sheets to form a workpiece 1; and bringing a cutting edge of cutting means 20 having a rotation axis extending in a lamination direction of a workpiece and a cutting edge constituted as the outermost diameter of a body rotating around the rotation axis into contact with an outer peripheral surface of the workpiece, and cutting the outer peripheral surface of the workpiece. In one embodiment, HV hardness of the cutting edge is 7,000 or larger, and a ratio F/T of a feed speed F of the cutting means and a contact number T of the cutting edge is 0.012 or more. Alternatively, the HV hardness of the cutting edge is 2,000 or larger, and F/T is 0.015 or larger.SELECTED DRAWING: Figure 4

Description

本発明は、樹脂シートおよびその製造方法に関する。   The present invention relates to a resin sheet and a method for producing the same.

用途に応じた種々の樹脂シートが幅広く利用されている。樹脂シートは、所定形状に切断された後、切断面を切削による仕上げ加工に供する場合がある。さらに、近年、樹脂シートを矩形以外に加工（異形加工）することが望まれる場合がある。このような切削加工においては、エンドミルによる切削が行われる場合がある。しかし、エンドミルにより切削加工された樹脂シートは、クラックが発生する場合がある。   Various resin sheets according to applications are widely used. After the resin sheet is cut into a predetermined shape, the cut surface may be subjected to finishing by cutting. Furthermore, in recent years, it may be desired to process the resin sheet in a shape other than a rectangle (deformation processing). In such cutting, cutting by an end mill may be performed. However, cracks may occur in the resin sheet cut by the end mill.

特開２００７−１８７７８１号公報JP 2007-187781 A 特開２０１８−０２２１４０号公報Japanese Patent Laid-Open No. 2018-022140

本発明は上記従来の課題を解決するためになされたものであり、その主たる目的は、切削加工されているにもかかわらずクラックの抑制された樹脂シートおよびそのような樹脂シートを製造し得る方法を提供することにある。   The present invention has been made to solve the above-described conventional problems, and its main object is to provide a resin sheet in which cracks are suppressed despite being cut and a method for producing such a resin sheet. Is to provide.

本発明の樹脂シートは切削加工された樹脂シートであり、切削端面における正反射率ＲＲと拡散反射率ＤＲとの比ＲＲ／ＤＲが０．１０以上である。
１つの実施形態においては、上記樹脂シートは接着剤層および／または粘着剤層を含む。
１つの実施形態においては、上記樹脂シートは偏光子を含む。
本発明の別の局面によれば、上記樹脂シートの製造方法が提供される。この製造方法は、該樹脂シートを複数枚重ねてワークを形成すること；および、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること；を含む。
１つの実施形態においては、該切削刃のＨＶ硬度は７０００以上であり、該切削手段の送り速度Ｆと該切削刃の接触回数Ｔとの比Ｆ／Ｔは０．０１２以上である。この場合、切削刃は焼結ダイヤモンドを含む。
別の実施形態においては、該切削刃のＨＶ硬度は２０００以上であり、該切削手段の送り速度Ｆと該切削刃の接触回数Ｔとの比Ｆ／Ｔは０．０１５以上である。この場合、切削刃は超硬合金で構成されている。 The resin sheet of the present invention is a cut resin sheet, and the ratio RR / DR between the regular reflectance RR and the diffuse reflectance DR at the cut end face is 0.10 or more.
In one embodiment, the resin sheet includes an adhesive layer and / or an adhesive layer.
In one embodiment, the resin sheet includes a polarizer.
According to another situation of this invention, the manufacturing method of the said resin sheet is provided. The manufacturing method includes forming a workpiece by stacking a plurality of the resin sheets; and a rotating blade extending in a stacking direction of the workpiece and a cutting blade configured as an outermost diameter of a main body that rotates about the rotating shaft Cutting the outer peripheral surface of the workpiece by bringing the cutting blade of the cutting means into contact with the outer peripheral surface of the workpiece.
In one embodiment, the cutting blade has an HV hardness of 7000 or more, and the ratio F / T between the feed speed F of the cutting means and the contact frequency T of the cutting blade is 0.012 or more. In this case, the cutting blade includes sintered diamond.
In another embodiment, the cutting blade has an HV hardness of 2000 or more, and the ratio F / T between the feed speed F of the cutting means and the contact frequency T of the cutting blade is 0.015 or more. In this case, the cutting blade is made of cemented carbide.

本発明によれば、切削加工された樹脂シートにおいて切削端面の正反射率ＲＲと拡散反射率ＤＲとの比ＲＲ／ＤＲを０．１０以上とすることにより、クラック（特に、ヒートサイクル試験後のクラック）を抑制することができる。このような樹脂シートは、切削加工（代表的には、エンドミル加工）において、切削刃のＨＶ硬度と、切削手段の送り速度と切削刃の接触回数との比と、の関係を最適化することにより実現され得る。   According to the present invention, in the cut resin sheet, by setting the ratio RR / DR between the regular reflectance RR and the diffuse reflectance DR of the cutting end surface to 0.10 or more, cracks (particularly after the heat cycle test). Cracks) can be suppressed. Such a resin sheet optimizes the relationship between the HV hardness of the cutting blade and the ratio between the feed speed of the cutting means and the number of contact times of the cutting blade in cutting processing (typically end mill processing). Can be realized.

本発明の１つの実施形態による樹脂シートを所定厚みに積層した状態で切削端面の透過光の状態を観察した写真である。It is the photograph which observed the state of the transmitted light of the cutting end surface in the state which laminated | stacked the resin sheet by one Embodiment of this invention on predetermined thickness. 本発明の実施形態の範囲外である樹脂シートを所定厚みに積層した状態で切削端面の透過光の状態を観察した写真である。It is the photograph which observed the state of the transmitted light of the cutting end surface in the state which laminated | stacked the resin sheet which is outside the range of embodiment of this invention in predetermined thickness. 本発明の切削加工された樹脂シートの形状の一例を示す概略平面図である。It is a schematic plan view which shows an example of the shape of the cut resin sheet of this invention. 本発明の樹脂シートの切削加工の一例を説明するための概略斜視図である。It is a schematic perspective view for demonstrating an example of the cutting process of the resin sheet of this invention. 本発明の樹脂シートの製造方法における切削加工に用いられる切削手段の一例を説明するための概略斜視図である。It is a schematic perspective view for demonstrating an example of the cutting means used for the cutting in the manufacturing method of the resin sheet of this invention. 図６（ａ）は、本発明の樹脂シートの製造方法における切削加工に用いられる切削手段の別の例を説明するための軸方向から見た概略断面図であり；図６（ｂ）は、図６（ａ）の切削手段の概略斜視図である。FIG. 6 (a) is a schematic cross-sectional view seen from the axial direction for explaining another example of cutting means used for cutting in the method for producing a resin sheet of the present invention; FIG. 6 (b) It is a schematic perspective view of the cutting means of Fig.6 (a).

以下、図面を参照して本発明の具体的な実施形態について説明するが、本発明はこれらの実施形態には限定されない。なお、見やすくするために図面は模式的に表されており、さらに、図面における長さ、幅、厚み等の比率、ならびに角度等は、実際とは異なっている。   Hereinafter, specific embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. Note that the drawings are schematically shown for ease of viewing, and the ratios of length, width, thickness, etc., angles, and the like in the drawings are different from actual ones.

Ａ．樹脂シート
樹脂シートとしては、切削加工が必要とされる用途に用いられ得る任意の適切な樹脂シートが挙げられる。樹脂シートは、単一層で構成されるフィルムであってもよく、積層体であってもよい。樹脂シートの具体例としては、光学フィルムが挙げられる。光学フィルムの具体例としては、偏光子、位相差フィルム、偏光板（代表的には、偏光子と保護フィルムとの積層体）、タッチパネル用導電性フィルム、表面処理フィルム、ならびに、これらを目的に応じて適切に積層した積層体（例えば、反射防止用円偏光板、タッチパネル用導電層付偏光板）が挙げられる。本発明の実施形態によれば、特に、偏光子のような収縮しやすい光学フィルムを含む樹脂フィルムにおいてクラックを顕著に抑制することができる。１つの実施形態においては、樹脂シートは、接着剤層および／または粘着剤層を含む。本発明の実施形態によれば、接着剤層および／または粘着剤層を含む樹脂シートを切削加工した場合であっても、クラック（特に、ヒートサイクル試験後のクラック）を抑制することができる。 A. Resin Sheet Examples of the resin sheet include any appropriate resin sheet that can be used for applications that require cutting. The resin sheet may be a film composed of a single layer or a laminate. A specific example of the resin sheet is an optical film. Specific examples of the optical film include a polarizer, a retardation film, a polarizing plate (typically, a laminate of a polarizer and a protective film), a conductive film for a touch panel, a surface treatment film, and for these purposes. The laminated body appropriately laminated | stacked according to it (for example, the circularly-polarizing plate for reflection prevention, the polarizing plate with the conductive layer for touchscreens) is mentioned. According to the embodiment of the present invention, cracks can be remarkably suppressed particularly in a resin film including an optical film that easily contracts, such as a polarizer. In one embodiment, the resin sheet includes an adhesive layer and / or an adhesive layer. According to the embodiment of the present invention, even when the resin sheet including the adhesive layer and / or the pressure-sensitive adhesive layer is cut, cracks (particularly, cracks after the heat cycle test) can be suppressed.

本発明の実施形態においては、樹脂シートの切削端面における正反射率ＲＲと拡散反射率ＤＲとの比ＲＲ／ＤＲは０．１０以上であり、好ましくは０．１４以上であり、より好ましくは０．１６以上であり、さらに好ましくは０．１８以上である。比ＲＲ／ＤＲの上限は、例えば０．３０であり、好ましくは０．２４である。比ＲＲ／ＤＲがこのような範囲であれば、切削加工（例えば、エンドミル加工）された樹脂シートにおけるクラック（特に、ヒートサイクル試験後のクラック）を抑制することができる。   In the embodiment of the present invention, the ratio RR / DR between the regular reflectance RR and the diffuse reflectance DR at the cutting end surface of the resin sheet is 0.10 or more, preferably 0.14 or more, more preferably 0. .16 or more, more preferably 0.18 or more. The upper limit of the ratio RR / DR is, for example, 0.30, and preferably 0.24. If ratio RR / DR is such a range, the crack (especially the crack after a heat cycle test) in the resin sheet by which the cutting process (for example, end mill process) was carried out can be suppressed.

樹脂シートの切削端面における正反射率ＲＲは、好ましくは０．３０％以上であり、より好ましくは０．４０％以上であり、さらに好ましくは０．５０％以上である。正反射率ＲＲの上限は、例えば０．７５％であり、好ましくは０．６５％である。樹脂シートの切削端面における拡散反射率ＤＲは、好ましくは２．４０％〜５．００％であり、より好ましくは２．５０％〜３．５０％である。   The regular reflectance RR at the cut end surface of the resin sheet is preferably 0.30% or more, more preferably 0.40% or more, and further preferably 0.50% or more. The upper limit of the regular reflectance RR is, for example, 0.75%, and preferably 0.65%. The diffuse reflectance DR at the cut end surface of the resin sheet is preferably 2.40% to 5.00%, more preferably 2.50% to 3.50%.

正反射率ＲＲおよび拡散反射率ＤＲは例えば下記のようにして求められ、得られたＲＲおよびＤＲから比ＲＲ／ＤＲが算出される。切削加工された樹脂シートをランダムに選び出し、選出した樹脂シートを積層して厚み約１５ｍｍの束を作製する。より詳細には、樹脂シートは、異なる複数のワーク（ワークについては後述）からランダムに選出される。作製した束の測定面を面一とした状態で、束の測定面方向の両端部から所定の距離の位置（２か所）に輪ゴムを巻いて束を拘束する。拘束した束の測定面について、分光測色計（例えば、コニカミノルタ社製「ＣＭ−２６００ｄ」）を用いてＳＣＩ（Ｓｐｅｃｕｌａｒ Ｃｏｍｐｏｎｅｎｔ Ｉｎｃｌｕｄｅ）およびＳＣＥ（Ｓｐｅｃｕｌａｒ Ｃｏｍｐｏｎｅｎｔ Ｅｘｃｌｕｄｅ）を測定し、以下の式から正反射率ＲＲおよび拡散反射率ＤＲを求める。
正反射率ＲＲ＝ＳＣＩ−ＳＣＥ
拡散反射率ＤＲ＝ＳＣＥ The regular reflectance RR and the diffuse reflectance DR are obtained, for example, as follows, and the ratio RR / DR is calculated from the obtained RR and DR. The cut resin sheets are selected at random, and the selected resin sheets are stacked to produce a bundle having a thickness of about 15 mm. More specifically, the resin sheet is randomly selected from a plurality of different works (the work will be described later). In a state where the measurement surface of the produced bundle is flush, a rubber band is wound around a predetermined distance (two locations) from both ends in the measurement surface direction of the bundle to restrain the bundle. With respect to the measurement surface of the restrained bundle, SCI (Special Component Include) and SCE (Special Component Exclude) are measured using a spectrocolorimeter (for example, “CM-2600d” manufactured by Konica Minolta, Inc.). The reflectance RR and the diffuse reflectance DR are obtained.
Regular reflectance RR = SCI-SCE
Diffuse reflectance DR = SCE

以下、ＲＲ／ＤＲについてより詳細に説明する。図１は、ＲＲ／ＤＲが上記のような範囲を満たす樹脂シートを所定厚みに積層した状態で切削端面の透過光の状態を観察した写真であり、図２は、ＲＲ／ＤＲが上記のような範囲から外れる樹脂シートを所定厚みに積層した状態で切削端面の透過光の状態を観察した写真である。図１と図２とを比較すると明らかなように、ＲＲ／ＤＲが上記のような範囲を満たす樹脂シートは光の輪郭が明確であり（いわゆるテカリがあり）、一方、ＲＲ／ＤＲが上記のような範囲を外れる樹脂シートは光の輪郭が不明確である（テカリがない）。本発明者らは、切削加工（代表的には、エンドミル加工）された樹脂シートにおけるクラックの問題について試行錯誤を繰り返した結果、切削端面にテカリがある樹脂シートにおいてクラックが抑制されることを発見した。さらに、本発明者らは、このような切削端面にテカリがある樹脂シートは、後述するように、切削加工（代表的には、エンドミル加工）において、切削刃のＨＶ硬度と、切削手段の送り速度と切削刃の接触回数との比と、の関係を最適化することにより実現できることを発見した。このように、本発明は樹脂シートの切削加工（代表的には、エンドミル加工）において新たに生じた課題を解決するものであり、切削端面のテカリ（またはＲＲ／ＤＲ）を最適化することによる効果は予期せぬ優れた効果である。なお、図１および図２においては差異を明確化するために透過光の状態を示しているが、反射光のテカリもこれに対応する。   Hereinafter, RR / DR will be described in more detail. FIG. 1 is a photograph observing the state of transmitted light at the cutting end face in a state where resin sheets satisfying the above range of RR / DR are laminated to a predetermined thickness, and FIG. 2 is a graph showing RR / DR as described above. It is the photograph which observed the state of the transmitted light of a cutting end surface in the state which laminated | stacked the resin sheet which remove | deviated from a certain range in predetermined thickness. As is clear from comparison between FIG. 1 and FIG. 2, the resin sheet satisfying the above range of RR / DR has a clear light outline (so-called shine), while RR / DR is the above-mentioned range. A resin sheet outside such a range has an unclear light outline (no shine). As a result of repeating trial and error on the problem of cracks in resin sheets that have been cut (typically end milled), the present inventors have found that cracks are suppressed in resin sheets that have shine on the cut end faces. did. Further, the present inventors have found that the resin sheet having the cut end face has a HV hardness of the cutting blade and the feed of the cutting means in the cutting process (typically end milling), as will be described later. We have found that this can be achieved by optimizing the relationship between the speed and the number of contact times of the cutting blade. As described above, the present invention solves a new problem in the cutting process (typically, end milling) of a resin sheet, by optimizing the cutting edge surface (or RR / DR). The effect is an unexpected and excellent effect. In FIG. 1 and FIG. 2, the state of transmitted light is shown to clarify the difference, but the reflected light also corresponds to this.

以下、一例として図３に示すような平面形状の樹脂シートの製造方法における各工程を説明する。   Hereinafter, each process in the manufacturing method of a planar resin sheet as shown in FIG. 3 will be described as an example.

Ｂ．ワークの形成
図４は、切削加工を説明するための概略斜視図であり、本図にワーク１が示されている。図４に示すように、樹脂シートを複数枚重ねたワーク１が形成される。樹脂シートは、ワーク形成に際し、代表的には任意の適切な形状に切断されている。具体的には、樹脂シートは矩形形状に切断されていてもよく、矩形形状に類似する形状に切断されていてもよく、目的に応じた適切な形状（例えば、円形）に切断されていてもよい。図示例では、光学積層体は矩形形状に切断されており、ワーク１は、互いに対向する外周面（切削面）１ａ、１ｂおよびそれらと直交する外周面（切削面）１ｃ、１ｄを有している。ワーク１は、好ましくは、クランプ手段（図示せず）により上下からクランプされている。ワークの総厚みは、好ましくは８ｍｍ〜２０ｍｍであり、より好ましくは９ｍｍ〜１５ｍｍであり、さらに好ましくは約１０ｍｍである。このような厚みであれば、クランプ手段による押圧または切削加工時の衝撃による損傷を防止し得る。樹脂シートは、ワークがこのような総厚みとなるように重ねられる。ワークを構成する樹脂シートの枚数は、例えば１０枚〜５０枚であり得る。クランプ手段（例えば、治具）は、軟質材料で構成されてもよく硬質材料で構成されてもよい。軟質材料で構成される場合、その硬度（ＪＩＳ Ａ）は、好ましくは６０°〜８０°である。硬度が高すぎると、クランプ手段による押し跡が残る場合がある。硬度が低すぎると、治具の変形により位置ずれが生じ、切削精度が不十分となる場合がある。 B. Formation of Workpiece FIG. 4 is a schematic perspective view for explaining the cutting process, and the work 1 is shown in this drawing. As shown in FIG. 4, a workpiece 1 in which a plurality of resin sheets are stacked is formed. The resin sheet is typically cut into any appropriate shape when forming a workpiece. Specifically, the resin sheet may be cut into a rectangular shape, may be cut into a shape similar to the rectangular shape, or may be cut into an appropriate shape (for example, a circle) according to the purpose. Good. In the illustrated example, the optical laminated body is cut into a rectangular shape, and the workpiece 1 has outer peripheral surfaces (cutting surfaces) 1a and 1b facing each other and outer peripheral surfaces (cutting surfaces) 1c and 1d orthogonal to them. Yes. The workpiece 1 is preferably clamped from above and below by clamping means (not shown). The total thickness of the workpiece is preferably 8 mm to 20 mm, more preferably 9 mm to 15 mm, and even more preferably about 10 mm. If it is such thickness, the damage by the impact at the time of the press by a clamp means or a cutting process can be prevented. The resin sheets are stacked so that the workpiece has such a total thickness. The number of resin sheets constituting the workpiece may be, for example, 10 to 50 sheets. The clamp means (for example, a jig) may be made of a soft material or a hard material. When composed of a soft material, the hardness (JIS A) is preferably 60 ° to 80 °. If the hardness is too high, there may be a case where a mark is left by the clamping means. If the hardness is too low, displacement may occur due to deformation of the jig and cutting accuracy may be insufficient.

Ｃ．切削加工
次に、ワーク１の外周面を、切削手段２０により切削する。切削は、切削手段の切削刃をワーク１の外周面に当接させることにより行われる。切削は、ワークの外周面の全周にわたって行ってもよく、所定の位置のみに行ってもよい。図３に示すような平面形状の樹脂シートを作製する場合、切削は、代表的にはワークの外周面の全周にわたって行われる。切削加工は、代表的には図４〜図６に示すように、いわゆるエンドミル加工である。すなわち、切削手段（エンドミル）２０の側面を用いて、ワーク１の外周面を切削する。切削手段（エンドミル）２０としては、代表的にはストレートエンドミルが用いられ得る。 C. Next, the outer peripheral surface of the workpiece 1 is cut by the cutting means 20. Cutting is performed by bringing the cutting blade of the cutting means into contact with the outer peripheral surface of the workpiece 1. Cutting may be performed over the entire circumference of the outer peripheral surface of the workpiece, or may be performed only at a predetermined position. When producing a planar resin sheet as shown in FIG. 3, cutting is typically performed over the entire circumference of the outer peripheral surface of the workpiece. The cutting process is typically so-called end milling as shown in FIGS. That is, the outer peripheral surface of the workpiece 1 is cut using the side surface of the cutting means (end mill) 20. As the cutting means (end mill) 20, a straight end mill can be typically used.

エンドミル２０は、図５および図６に示すように、ワーク１の積層方向（鉛直方向）に延びる回転軸２１と、回転軸２１を中心として回転する本体の最外径として構成される切削刃２２と、を有する。切削刃２２は、図５に示すように回転軸２１に沿ってねじれた最外径として構成されてもよく（所定のねじれ角を有していてもよく）、図６に示すように回転軸２１に実質的に平行な方向に延びるよう構成されていてもよい（ねじれ角が０°であってもよい）。なお、「０°」は実質的に０°であるという意味であり、加工誤差等によりわずかな角度ねじれている場合も包含する。切削刃が所定のねじれ角を有する場合、ねじれ角は好ましくは７０°以下であり、より好ましくは６５°以下であり、さらに好ましくは４５°以下である。切削刃２２は、刃先２２ａと、すくい面２２ｂと、逃がし面２２ｃと、を含む。切削刃２２の刃数は、後述の所望の接触回数が得られる限りにおいて適切に設定され得る。図５における刃数は３枚であり図６における刃数は２枚であるが、刃数は１枚であってもよく、４枚であってもよく、５枚以上であってもよい。好ましくは、刃数は２枚である。このような構成であれば、刃の剛性が確保され、かつ、ポケットが確保されて削りカスを良好に排出することができる。   As shown in FIGS. 5 and 6, the end mill 20 includes a rotating shaft 21 extending in the stacking direction (vertical direction) of the workpiece 1 and a cutting blade 22 configured as an outermost diameter of a main body that rotates around the rotating shaft 21. And having. The cutting blade 22 may be configured as the outermost diameter twisted along the rotation shaft 21 as shown in FIG. 5 (may have a predetermined twist angle), or the rotation shaft as shown in FIG. 21 may extend in a direction substantially parallel to 21 (the twist angle may be 0 °). Note that “0 °” means substantially 0 °, and includes a case where a slight angle is twisted due to a processing error or the like. When the cutting blade has a predetermined twist angle, the twist angle is preferably 70 ° or less, more preferably 65 ° or less, and further preferably 45 ° or less. The cutting blade 22 includes a cutting edge 22a, a rake surface 22b, and a relief surface 22c. The number of cutting blades 22 can be appropriately set as long as the desired number of contacts described later can be obtained. The number of blades in FIG. 5 is three and the number of blades in FIG. 6 is two, but the number of blades may be one, four, or five or more. Preferably, the number of blades is two. With such a configuration, the rigidity of the blade is ensured, the pocket is secured, and the scrap can be discharged well.

１つの実施形態においては、切削刃２２のＨＶ硬度は、代表的には１５００以上であり、好ましくは１７００以上であり、より好ましくは２０００以上である。ＨＶ硬度の上限は、例えば２３５０であり得る。この場合、切削刃は、代表的には超硬合金で構成される。超硬合金は、代表的には、金属炭化物の粉末を焼結して得られる。超硬合金の具体例としては、ＷＣ−Ｃｏ系合金、ＷＣ−ＴｉＣ−Ｃｏ系合金、ＷＣ−ＴａＣ−Ｃｏ系合金、ＷＣ−ＴｉＣ−ＴａＣ−Ｃｏ系合金が挙げられる。本実施形態においては、エンドミル２０の送り速度Ｆと切削刃２２の接触回数（ワークとの接触回数）Ｔとの比Ｆ／Ｔは、代表的には０．０１５以上であり、好ましくは０．０２０以上であり、より好ましくは０．０３０以上である。Ｆ／Ｔの上限は、例えば０．０７０であり得る。ここで、切削刃の接触回数とは、エンドミルの回転数（ｒｐｍ）と刃数との積で表される。なお、ＨＶ硬度はビッカーズ硬さとも称され、ＪＩＳ Ｚ ２２４４に準じて測定され得る。また、本明細書において「送り速度」は、切削手段（エンドミル）とワークとの相対速度を意味する。したがって、切削加工においては、エンドミルのみを移動させてもよく、ワークのみを移動させてもよく、エンドミルおよびワークの両方を移動させてもよい。   In one embodiment, the HV hardness of the cutting blade 22 is typically 1500 or more, preferably 1700 or more, and more preferably 2000 or more. The upper limit of the HV hardness can be 2350, for example. In this case, the cutting blade is typically made of a cemented carbide. The cemented carbide is typically obtained by sintering metal carbide powder. Specific examples of the cemented carbide include WC—Co alloys, WC—TiC—Co alloys, WC—TaC—Co alloys, and WC—TiC—TaC—Co alloys. In the present embodiment, the ratio F / T between the feed rate F of the end mill 20 and the number of times of contact of the cutting blade 22 (number of times of contact with the workpiece) T is typically 0.015 or more, preferably 0. It is 020 or more, More preferably, it is 0.030 or more. The upper limit of F / T may be 0.070, for example. Here, the contact frequency of the cutting blade is represented by the product of the rotation speed (rpm) of the end mill and the number of blades. In addition, HV hardness is also called Vickers hardness and can be measured according to JIS Z 2244. Further, in this specification, “feed speed” means a relative speed between the cutting means (end mill) and the workpiece. Therefore, in the cutting process, only the end mill may be moved, only the workpiece may be moved, or both the end mill and the workpiece may be moved.

別の実施形態においては、切削刃２２のＨＶ硬度は、代表的には７０００以上であり、好ましくは８０００以上であり、より好ましくは９０００以上であり、さらに好ましくは１００００以上である。ＨＶ硬度の上限は、例えば１５０００であり得る。この場合、切削刃は、代表的には焼結ダイヤモンドを含む。より詳細には、切削刃は、超硬合金で構成された基部に焼結ダイヤモンド層が形成されている。焼結ダイヤモンド（ＰＣＤ：Ｐｏｌｙｃｒｙｓｔａｌｌｉｎｅ ｄｉａｍｏｎｄ）は、ダイヤモンドの小さな粒を金属および／またはセラミックスの粉と一緒に高温・高圧で焼き固めた多結晶ダイヤモンドをいう。 本実施形態においては、エンドミル２０の送り速度Ｆと切削刃２２の接触回数（ワークとの接触回数）Ｔとの比Ｆ／Ｔは、代表的には０．０１２以上であり、好ましくは０．０２０以上であり、より好ましくは０．０３０以上である。Ｆ／Ｔの上限は、例えば０．０７０であり得る。   In another embodiment, the HV hardness of the cutting blade 22 is typically 7000 or more, preferably 8000 or more, more preferably 9000 or more, and further preferably 10,000 or more. The upper limit of HV hardness can be 15000, for example. In this case, the cutting blade typically includes sintered diamond. More specifically, the cutting blade has a sintered diamond layer formed on a base portion made of a cemented carbide. Sintered diamond (PCD: Polycrystalline diamond) refers to polycrystalline diamond obtained by baking small grains of diamond together with metal and / or ceramic powder at high temperature and high pressure. In the present embodiment, the ratio F / T between the feed rate F of the end mill 20 and the number of times of contact of the cutting blade 22 (number of times of contact with the workpiece) T is typically 0.012 or more, preferably 0. It is 020 or more, More preferably, it is 0.030 or more. The upper limit of F / T may be 0.070, for example.

切削加工の条件は、上記所望のＦ／Ｔが得られる限りにおいて適切に設定され得る。エンドミルの送り速度Ｆは、好ましくは５００ｍｍ／分〜１００００ｍｍ／分であり、より好ましくは５００ｍｍ／分〜２５００ｍｍ／分である。エンドミルの回転数は、好ましくは５０００ｒｐｍ〜６００００ｒｐｍであり、より好ましくは１５０００ｒｐｍ〜４５０００ｒｐｍである。切削回数は、１回削り、２回削り、３回削りまたはそれ以上であり得る。１つの実施形態においては、エンドミル２０の直径は、好ましくは３ｍｍ〜２０ｍｍである。   Cutting conditions can be appropriately set as long as the desired F / T is obtained. The feed rate F of the end mill is preferably 500 mm / min to 10000 mm / min, more preferably 500 mm / min to 2500 mm / min. The rotation speed of the end mill is preferably 5000 rpm to 60000 rpm, more preferably 15000 rpm to 45000 rpm. The number of cuts can be one cut, two cuts, three cuts or more. In one embodiment, the diameter of the end mill 20 is preferably 3 mm to 20 mm.

以上のようにして、所定のＲＲ／ＤＲを有する切削加工された樹脂シートが得られ得る。なお、切削加工された樹脂シートは、代表的には、切削痕を有し得る。   As described above, a cut resin sheet having a predetermined RR / DR can be obtained. In addition, the cut resin sheet may typically have cutting marks.

以下、実施例により本発明を具体的に説明するが、本発明はこれらの実施例には限定されない。実施例における評価項目は以下のとおりである。   EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to these Examples. Evaluation items in the examples are as follows.

（１）ＲＲ／ＤＲ
実施例および比較例で得られた異なる複数のワークから偏光板をランダムに選び出し、選出した偏光板を積層して厚み約１５ｍｍの束を作製した。作製した束の測定面を面一とした状態で、束の測定面方向の両端部から１０ｍｍの位置（２か所）に輪ゴム（アイ・ジー・オー社製、＃７）を巻いて束を拘束した。拘束した束の測定面について、分光測色計（コニカミノルタ社製「ＣＭ−２６００ｄ」）を用いてＳＣＩおよびＳＣＥを測定し、以下の式から正反射率ＲＲおよび拡散反射率ＤＲを求めた。
正反射率ＲＲ＝ＳＣＩ−ＳＣＥ
拡散反射率ＤＲ＝ＳＣＥ
（２）クラック
実施例および比較例で得られた偏光板について、−４０℃〜８５℃で２００サイクルのヒートサイクル（ヒートショック）試験を行った。試験後のクラックの発生状況について、光学顕微鏡で拡大した画像を用いてクラックの長さを測定した。観測されたクラックの最大長さを評価の指標とした。具体的には、クラックの最大長さが１５０μｍ未満である場合を「良好」、１５０μｍ以上である場合を「不良」と評価した。 (1) RR / DR
A polarizing plate was randomly selected from a plurality of different workpieces obtained in the examples and comparative examples, and the selected polarizing plates were laminated to produce a bundle having a thickness of about 15 mm. While keeping the measurement surface of the bundle to be flush with each other, wrap a rubber band (# 7, manufactured by IG-O Inc.) at 10 mm positions (two locations) from both ends in the measurement surface direction of the bundle. Restrained. With respect to the measurement surface of the restrained bundle, SCI and SCE were measured using a spectrocolorimeter (“CM-2600d” manufactured by Konica Minolta), and regular reflectance RR and diffuse reflectance DR were obtained from the following equations.
Regular reflectance RR = SCI-SCE
Diffuse reflectance DR = SCE
(2) Crack About the polarizing plate obtained by the Example and the comparative example, the heat cycle (heat shock) test of 200 cycles was performed at -40 degreeC-85 degreeC. About the generation | occurrence | production state of the crack after a test, the length of the crack was measured using the image expanded with the optical microscope. The maximum observed crack length was used as an evaluation index. Specifically, the case where the maximum length of the crack was less than 150 μm was evaluated as “good”, and the case where it was 150 μm or more was evaluated as “bad”.

＜実施例１＞
常法により、視認側から順に表面保護フィルム（４８μｍ）／ハードコート層（５μｍ）／シクロオレフィン系保護フィルム（４７μｍ）／偏光子（５μｍ）／シクロオレフィン系保護フィルム（２４μｍ）／粘着剤層（２０μｍ）／セパレーターの構成を有する視認側偏光板を作製した。得られた偏光板を図３に類似した形状（概略サイズ１４２．０ｍｍ×６６．８ｍｍで四隅のＲ６．２５ｍｍ）に打ち抜き、打ち抜いた偏光板を複数枚重ねてワーク（総厚み約１０ｍｍ）とした。得られたワークをクランプ（治具）で挟んだ状態で、エンドミル加工により周縁部を切削し、図３に示すような切削加工された偏光板を得た。エンドミルの切削刃は焼結ダイヤモンドを用いたものであり、ＨＶ硬度は１００００であった。また、エンドミルの刃数は２枚、ねじれ角は０°であった。また、エンドミルの送り速度（直線部を切削する際の送り速度）は１５００ｍｍ／分であり、回転数は１５０００ｒｐｍであり、切削回数は２回（１回目０．１ｍｍ、２回目０．２ｍｍの切削しろ０．３ｍｍ）であった。 <Example 1>
Surface protection film (48 μm) / hard coat layer (5 μm) / cycloolefin-based protective film (47 μm) / polarizer (5 μm) / cycloolefin-based protective film (24 μm) / adhesive layer (in order from the viewer side) A viewing-side polarizing plate having a configuration of 20 μm) / separator was produced. The obtained polarizing plate was punched into a shape similar to FIG. 3 (rough size of 142.0 mm × 66.8 mm and four corners of R6.25 mm), and a plurality of punched polarizing plates were stacked to form a workpiece (total thickness of about 10 mm). . With the obtained work sandwiched between clamps (jigs), the peripheral edge was cut by end milling to obtain a cut polarizing plate as shown in FIG. The cutting blade of the end mill used sintered diamond, and the HV hardness was 10,000. The number of blades of the end mill was 2, and the twist angle was 0 °. Further, the feed rate of the end mill (feed rate when cutting the straight portion) is 1500 mm / min, the rotational speed is 15000 rpm, and the number of times of cutting is 2 times (first 0.1 mm, second 0.2 mm). 0.3 mm).

最終的に得られた切削加工された偏光板を、上記（１）および（２）の評価に供した。結果を表１に示す。   The finally obtained polarizing plate subjected to cutting was subjected to the evaluations (1) and (2). The results are shown in Table 1.

＜実施例２〜８および比較例１＞
切削加工の条件を表１に示すように変更したこと以外は実施例１と同様にして、図３に示すような切削加工された偏光板を得た。得られた偏光板を上記（１）および（２）の評価に供した。結果を表１に示す。 <Examples 2 to 8 and Comparative Example 1>
3 was obtained in the same manner as in Example 1 except that the cutting conditions were changed as shown in Table 1. The obtained polarizing plate was subjected to the evaluations (1) and (2) above. The results are shown in Table 1.

＜実施例９＞
エンドミルの切削刃として超硬合金製のもの（ＨＶ硬度：２０５０）を用いたこと、および、切削加工の条件を表１に示すように変更したこと以外は実施例１と同様にして、図３に示すような切削加工された偏光板を得た。得られた偏光板を上記（１）および（２）の評価に供した。結果を表１に示す。 <Example 9>
3 except that a cemented carbide (HV hardness: 2050) was used as the cutting blade of the end mill and that the cutting conditions were changed as shown in Table 1. A polarizing plate cut as shown in FIG. The obtained polarizing plate was subjected to the evaluations (1) and (2) above. The results are shown in Table 1.

＜実施例１０〜１６および比較例２〜５＞
切削加工の条件を表１に示すように変更したこと以外は実施例９と同様にして、図３に示すような切削加工された偏光板を得た。得られた偏光板を上記（１）および（２）の評価に供した。結果を表１に示す。 <Examples 10 to 16 and Comparative Examples 2 to 5>
3 was obtained in the same manner as in Example 9 except that the cutting conditions were changed as shown in Table 1. The obtained polarizing plate was subjected to the evaluations (1) and (2) above. The results are shown in Table 1.

＜実施例１７＞
常法により、背面側から順に表面保護フィルム（４８μｍ）／輝度向上フィルム（３０μｍ）／粘着剤層（１２μｍ）／偏光子（５μｍ）／アクリル系保護フィルム（２０μｍ）／粘着剤層（２０μｍ）／セパレーターの構成を有する背面側偏光板を作製した。この偏光板を用いたこと、および、切削加工の条件を表１に示すように変更したこと以外は実施例１と同様にして、図３に示すような切削加工された偏光板を得た。得られた偏光板を上記（１）および（２）の評価に供した。結果を表１に示す。 <Example 17>
According to a conventional method, the surface protective film (48 μm) / brightness enhancement film (30 μm) / adhesive layer (12 μm) / polarizer (5 μm) / acrylic protective film (20 μm) / adhesive layer (20 μm) / A back side polarizing plate having a separator configuration was prepared. A polarizing plate cut as shown in FIG. 3 was obtained in the same manner as in Example 1 except that this polarizing plate was used and the cutting conditions were changed as shown in Table 1. The obtained polarizing plate was subjected to the evaluations (1) and (2) above. The results are shown in Table 1.

＜実施例１８〜２８および比較例６＞
切削加工の条件を表１に示すように変更したこと以外は実施例１７と同様にして、図３に示すような切削加工された偏光板を得た。得られた偏光板を上記（１）および（２）の評価に供した。結果を表１に示す。 <Examples 18 to 28 and Comparative Example 6>
3 was obtained in the same manner as in Example 17 except that the cutting conditions were changed as shown in Table 1. The obtained polarizing plate was subjected to the evaluations (1) and (2) above. The results are shown in Table 1.

＜評価＞
表１から明らかなように、本発明の実施例によれば、ヒートサイクル試験後のクラックが抑制されていることがわかる。 <Evaluation>
As is clear from Table 1, according to the example of the present invention, it can be seen that cracks after the heat cycle test are suppressed.

本発明の切削加工された樹脂シートは、光学フィルムとして好適に用いられ得る。光学フィルム（特に、偏光板）は、パーソナルコンピューター（ＰＣ）やタブレット端末に代表される矩形の画像表示部、および／または、自動車のインストゥルメントパネルやスマートウォッチに代表される異形の画像表示部に好適に用いられ得る。   The cut resin sheet of the present invention can be suitably used as an optical film. An optical film (particularly a polarizing plate) is a rectangular image display unit represented by a personal computer (PC) or a tablet terminal, and / or an irregular image display unit represented by an automobile instrument panel or smart watch. Can be suitably used.

１ ワーク
２０ 切削手段

1 Work 20 Cutting means

Claims (7)

切削加工された樹脂シートであって、
切削端面における正反射率ＲＲと拡散反射率ＤＲとの比ＲＲ／ＤＲが０．１０以上である、
樹脂シート。 A resin sheet that has been machined,
The ratio RR / DR between the regular reflectance RR and the diffuse reflectance DR at the cutting end surface is 0.10 or more,
Resin sheet. 前記樹脂シートが接着剤層および／または粘着剤層を含む、請求項１に記載の樹脂シート。   The resin sheet according to claim 1, wherein the resin sheet includes an adhesive layer and / or a pressure-sensitive adhesive layer. 前記樹脂シートが偏光子を含む、請求項１に記載の樹脂シート。   The resin sheet according to claim 1, wherein the resin sheet includes a polarizer. 請求項１から３のいずれかに記載の樹脂シートの製造方法であって、
該樹脂シートを複数枚重ねてワークを形成すること；および、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること；を含み、
該切削刃のＨＶ硬度が７０００以上であり、
該切削手段の送り速度Ｆと該切削刃の接触回数Ｔとの比Ｆ／Ｔが０．０１２以上である、
方法。 A method for producing a resin sheet according to any one of claims 1 to 3,
A plurality of the resin sheets are stacked to form a workpiece; and a cutting means having a rotating shaft extending in the stacking direction of the workpiece and a cutting blade configured as an outermost diameter of a main body rotating around the rotating shaft Cutting the outer peripheral surface of the workpiece by bringing the cutting blade into contact with the outer peripheral surface of the workpiece,
HV hardness of the cutting blade is 7000 or more,
The ratio F / T between the feed speed F of the cutting means and the contact frequency T of the cutting blade is 0.012 or more.
Method. 前記切削刃が焼結ダイヤモンドを含む、請求項４に記載の製造方法。   The manufacturing method according to claim 4, wherein the cutting blade includes sintered diamond. 請求項１から３のいずれかに記載の樹脂シートの製造方法であって、
該樹脂シートを複数枚重ねてワークを形成すること；および、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること；を含み、
該切削刃のＨＶ硬度が２０００以上であり、
該切削手段の送り速度Ｆと該切削刃の接触回数Ｔとの比Ｆ／Ｔが０．０１５以上である、
方法。 A method for producing a resin sheet according to any one of claims 1 to 3,
A plurality of the resin sheets are stacked to form a workpiece; and a cutting means having a rotating shaft extending in the stacking direction of the workpiece and a cutting blade configured as an outermost diameter of a main body rotating around the rotating shaft Cutting the outer peripheral surface of the workpiece by bringing the cutting blade into contact with the outer peripheral surface of the workpiece,
HV hardness of the cutting blade is 2000 or more,
The ratio F / T between the feed speed F of the cutting means and the contact frequency T of the cutting blade is 0.015 or more.
Method. 前記切削刃が超硬合金で構成されている、請求項６に記載の製造方法。

The manufacturing method of Claim 6 with which the said cutting blade is comprised with the cemented carbide.

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