JP2020175502A - Perforated laminate manufacturing method and manufacturing apparatus - Google Patents

Abstract

To provide a perforated laminate manufacturing method and manufacturing apparatus for efficiently manufacturing a perforated laminate having a hole penetrating in the stacking direction.SOLUTION: A manufacturing method of a perforated laminate 10c having a hole 11c penetrating in the stacking direction comprises steps of: preparing a slit laminate 10b in which one or more resin film layers and one or more bonding layers are stacked, where the slit laminate has a slit 11b penetrating in the stacking direction and a piece to be cut out formed by the slit 11b; and forming a hole 11c by removing the piece to be cut out from the slit laminate 10b while continuously or intermittently transporting the slit laminate 10b.SELECTED DRAWING: Figure 4

Description

The present invention relates to a method and an apparatus for manufacturing a perforated laminate in which at least a resin film layer and a bonding layer are laminated and have holes penetrating in the stacking direction.

The polarizing plate is widely used as a polarization supply element in a display device such as a liquid crystal display device or an organic electroluminescence (EL) display device, and as a polarization detection element. Conventionally, a polarizing plate having a protective film adhered to one side or both sides of a polarizing element has been used.

Display devices equipped with polarizing plates are also being deployed in mobile devices such as notebook personal computers and mobile phones, and due to demands for diversification of display purposes, clarification of display categories, decoration, etc., the transmittance is high. Polarizing plates with different regions are required. In particular, in small and medium-sized mobile terminals such as smartphones and tablet terminals, a polarizing plate may be attached to the entire surface in order to make the design seamless over the entire surface from the viewpoint of decorativeness. In this case, since the polarizing plate also overlaps the area of the camera lens and the area of the icon or logo printing at the bottom of the screen, there is a problem that the sensitivity of the camera is deteriorated or the design is inferior.

Therefore, usually, a process such as forming a hole in the polarizing plate is performed to suppress deterioration of the sensitivity and design of the camera. Patent Document 1 describes a processing method and a processing apparatus for forming a hole or the like in an optical member such as a polarizing plate, and Patent Document 2 describes a processing method and a processing apparatus for punching an optical member into a predetermined shape. Has been done.

JP-A-2017-226034 JP-A-2007-307683

When forming holes in the polarizing plate, when punching is performed using a punching blade, the punched debris remains without being removed from the polarizing plate, and the holes may not be formed well. The punching debris remaining on the polarizing plate needs to be removed from the polarizing plate.

An object of the present invention is to provide a method for manufacturing a perforated laminate and a manufacturing apparatus for efficiently producing a perforated laminate having holes penetrating in the stacking direction.

The present invention provides a method for manufacturing a perforated laminate and an apparatus for producing a perforated laminate shown below.
[1] A method for manufacturing a perforated laminate having holes penetrating in the stacking direction.
A step of preparing a notched laminate having one or more resin film layers and one or more laminating layers laminated, and having a notch penetrating in the laminating direction and a cutout piece formed by the notch.
A method for producing a perforated laminate, which comprises a step of forming the holes by removing the cutout pieces from the notched laminate while continuously or intermittently transporting the notched laminate.
[2] The method for producing a perforated laminate according to [1], wherein in the step of forming the holes, the holes are formed by applying an external force to the cutout pieces.
[3] The external force is at least one of a force for pressing the cutout piece by a pressing member, a force for sucking the cutout piece, and a force for blowing a fluid on the cutout piece, according to [2]. Method of manufacturing a perforated laminate.
[4] The preparation step is an operation of forming the notch by cutting a punching blade in the laminating direction of the material laminate in which the one or more resin film layers and the one or more laminating layers are laminated. The method for producing a perforated laminate according to any one of [1] to [3], which comprises.
[5] The method for producing a perforated laminate according to any one of [1] to [4], wherein the hole diameter is 1 mm or more and 20 mm or less.
[6] The method according to any one of [1] to [5], wherein in the step of forming the hole, the laminated body with a notch is conveyed by at least one of a conveying belt, a conveying roller, and a rotary table. A method for manufacturing a perforated laminate.
[7] In the step of forming the holes, the notched laminate is intermittently conveyed, and the cutout pieces are removed while the notched laminate is stopped. [1] to [6] The method for manufacturing a perforated laminate according to any one.
[8] The step of forming the holes further includes an operation of removing the cutout pieces from the notched laminate and then transporting the perforated laminate obtained by the removal operation [1] to [7]. ]. The method for manufacturing a perforated laminate according to any one of.
[9] The method for producing a perforated laminate according to any one of [1] to [8], wherein the notched laminate is a single-wafer.
[10] The notched laminate includes a base film and a release film as the resin film layer.
The method for producing a perforated laminate according to any one of [1] to [9], wherein the base film, the bonding layer, and the release film are laminated in this order.
[11] The notched laminate includes a linear polarizer and a protective film as the resin film layer.
The method for producing a perforated laminate according to any one of [1] to [9], wherein the protective film is laminated on one side or both sides of the linear polarizer.
[12] The method for producing a perforated laminate according to any one of [1] to [11], wherein the bonding layer is an adhesive layer or an adhesive layer.
[13] An apparatus for manufacturing a perforated laminate having holes penetrating in the stacking direction.
A notched laminate having one or more resin film layers and one or more laminating layers laminated and having a notch penetrating in the laminating direction and a cutout piece formed by the notch is continuously or. A transport unit for intermittent transport and
A perforated laminate comprising a hole forming portion for forming the hole by removing the cutout piece from the notched laminate that is continuously or intermittently conveyed by the conveying portion. manufacturing device.
[14] The hole forming portion is among a pressing portion for pressing the cutout piece with a pressing member, a suction portion for sucking the cutout piece, and a spraying portion for spraying a fluid on the cutout piece. The apparatus for producing a perforated laminate according to [13], which comprises at least one.
[15] Further, a mechanism for obtaining the notched laminate from the material laminate in which the one or more resin film layers and the one or more bonded layers are laminated is provided [13] or [14]. The apparatus for manufacturing a perforated laminate according to.
[16] The perforated laminate according to [15], wherein the mechanism for obtaining the notched laminate from the material laminate includes a punching blade for forming the notch in the stacking direction of the material laminate. manufacturing device.
[17] Any one of [13] to [16], wherein the transport unit is provided with at least one of a transport belt, a transport roller, and a rotary table for transporting the notched laminate. The described perforated laminate manufacturing apparatus.
[18] The apparatus for manufacturing a perforated laminate according to any one of [13] to [17], wherein the transport unit can transport the perforated laminate immediately after removing the cutout piece.

According to the present invention, it is possible to efficiently manufacture a perforated laminate having holes penetrating in the stacking direction.

(A) is a schematic plan view schematically showing an example of a material laminate used in the method for producing a perforated laminate of the present invention, and (b) is a cross-sectional view taken along the line xx'of (a). .. (A) is a schematic plan view schematically showing an example of a notched laminate used in the method for producing a perforated laminate of the present invention, and (b) is a sectional view taken along line yy'of (a). is there. (A) is a schematic plan view schematically showing an example of a perforated laminate of the present invention, and (b) is a cross-sectional view taken along the line z-z'of (a). It is the schematic which shows typically an example of the manufacturing apparatus of the perforated laminate of this invention. It is the schematic which shows typically another example of the manufacturing apparatus of the perforated laminate of this invention. It is the schematic which shows typically another example of the manufacturing apparatus of the perforated laminate of this invention. It is the schematic which shows typically another example of the manufacturing apparatus of the perforated laminate of this invention.

Hereinafter, preferred embodiments of the method for producing a perforated laminate of the present invention will be described with reference to the drawings. Each of the following embodiments may be combined arbitrarily. In each embodiment, the same members as those described in the previous embodiments are designated by the same reference numerals, and the description thereof will be omitted.

[Embodiment 1]
In the present embodiment, the perforated laminate and the notched laminate have a linear polarizing element (hereinafter, may be referred to as “polarizer”) and a protective film as a resin film layer, and a bonding layer. A case of a linearly polarizing plate having a protective film on one surface of the linearly polarizing element via a bonding layer (hereinafter, may be referred to as “polarizing plate”) will be described as an example.

(Manufacturing method of perforated laminate)
The method for manufacturing the perforated laminate 10c (FIGS. 3A and 3B) of the present embodiment is a step of preparing the notched laminate 10b (FIGS. 2A and 2B) (hereinafter, "preparation"). A step of forming a hole 11c (FIGS. 3A and 3B) penetrating in the stacking direction (hereinafter, may be referred to as a “hole forming step”). .. In FIGS. 2A and 2B, the notch 11b is indicated by a chain double-dashed line to indicate that the cutout piece 11a is present in the notched laminate 10b.

The notched laminate 10b can be manufactured by forming a notch 11b in the material laminate 10a (FIGS. 1A and 1B) described later. The notch 11b is for forming the hole 11c.
The method of forming the notch 11b will be described in the “preparation step” described later.

The hole forming step may further include an operation of removing the cutout piece 11a formed by the notch 11b from the notched laminate 10b and then transporting the perforated laminate 10c obtained by the removal operation. .. The perforated laminate 10c may be conveyed continuously or intermittently. In the hole forming step, when the cutout piece 11a is removed while continuously transporting the notched laminate 10b, the perforated laminate 10c obtained by the removal operation may be continuously conveyed. In the hole forming step, when the transport of the notched laminate 10b is stopped when the cutout piece 11a is removed, the perforated laminate 10c obtained by the removal operation may be continuously transported, which is intermittent. May be transported to.

(Perforated laminate)
As shown in FIG. 3A, the perforated laminate 10c is a rounded quadrangle having four rounded corners (a shape having R) in a plan view. As shown in FIG. 3B, for example, the perforated laminate 10c is formed by laminating a polarizer 12c (resin film layer), a bonding layer 13c, and a protective film 14c (resin film layer) in this order. .. The perforated laminate 10c has holes 11c penetrating in the laminating direction, and the polarizing elements 12c forming each layer of the perforated laminate 10c, the bonding layer 13c, and the protective film 14c also have holes penetrating in the thickness direction thereof. Each has.

The planar shape of the perforated laminate 10c is not particularly limited, but is usually a quadrangle or a rounded quadrangle in which at least one corner of the quadrangle is rounded, and a part thereof is U-shaped or V-shaped. It may have a notch in a U-shape, a semicircular shape, or the like. The perforated laminated body 10c shown in FIG. 3A is a single-wafered body, but may be a long continuous body.

The shape of the hole 11c is not particularly limited, and is circular; elliptical; oval; polygon such as triangle or quadrangle; rounded polygon with at least one corner of the polygon having rounded corners (shape having R), etc. Can be.
The diameter of the hole 11c is preferably 1 mm or more, preferably 3 mm or more, 5 mm or more, 7 mm or more, 20 mm or less, and 18 mm or less. It may be 15 mm or less, or 12 mm or less.
In the present specification, the diameter of a hole means the diameter of a hole when the hole is circular (round), and the diameter of the circumscribed circle (round) of the hole when the hole is other than circular (round). It shall be said. As will be described later, the manufacturing method and manufacturing apparatus of the present embodiment can be suitably used when manufacturing a perforated laminate 10c in which the diameter of the hole 11c is in the above range.

The perforated laminate 10c shown in FIGS. 3A and 3B shows a case where the hole 11c is one, but it may have two or more holes. When the polarizing plate is a long continuous body, it is usually cut to the product size (single frond) in a later process. Therefore, the continuous body is provided with a plurality of holes according to the shape at the time of cutting. Is preferable. The perforated laminate 10c shown in FIG. 3B has a protective film 14c on one side of the polarizing element 12c, but even if it has a protective film on both sides of the polarizing element via a bonding layer. Good.

(Material laminate)
As shown in FIG. 1A, for example, the material laminate 10a is a rounded quadrangle having four rounded corners in a plan view.
The planar shape of the material laminate 10a is not particularly limited, but like the perforated laminate 10c, it is preferably a quadrangle or a quadrangle with rounded corners, and may have a notch. The material laminate 10a shown in FIG. 1A is a single-wafered body, but may be a long continuous body.
As shown in FIG. 1B, for example, the material laminate 10a is formed by laminating a polarizing element 12a, a bonding layer 13a, and a protective film 14a in this order. The polarizer 12a and the protective film 14a are resin film layers.
The material laminate 10a shown in FIG. 1B has a protective film 14a on one side of the polarizing element 12a, but may have a protective film on both sides of the polarizing element via a bonding layer. ..

The bonding layer 13a may be an adhesive layer formed by using an adhesive, or may be an adhesive layer formed by using an adhesive layer. In the notched laminate 10b (FIGS. 2A and 2B) described later, when the bonding layer is an adhesive layer, the cutout piece 11a tends to remain in the notched laminate 10b. The manufacturing method and manufacturing apparatus of the present embodiment can be suitably used even when the adhesive layer is included as the bonding layer.

(Laminate with notch)
As shown in FIG. 2A, the notched laminate 10b is a rounded quadrangle having four rounded corners in a plan view. As shown in FIG. 2B, the notched laminate 10b is formed by laminating a polarizing element 12b, a bonding layer 13b, and a protective film 14b in this order, and is an outer edge of a hole 11c of the perforated laminate 10c. A notch 11b is formed along the line. The polarizer 12b, the bonding layer 13b, and the protective film 14b also have notches penetrating in the thickness direction thereof.

The planar shape of the notched laminate 10b is not particularly limited, but like the perforated laminate 10c, it is preferably a quadrangle or a rounded quadrangle, and may have a notch. The notched laminate 10b shown in FIG. 2A is a single-wafered body, but may be a long continuous body.

The notched laminate 10b has a cutout piece 11a. The cutout piece 11a is a fragment of the material laminate 10a formed by the cutout 11b. The cutout piece 11a is in a state of being partially or completely separated from the main body (a portion other than the cutout piece 11a) of the laminated body 10b with a notch by the notch 11b. At least a part of the cutout piece 11a may exist in the region surrounded by the notch 11b, and the cutout piece 11a does not exist in the region surrounded by the notch 11b, but a part of the cutout piece 11a is a laminated body 10b with a notch. It may be in a state where it is not completely separated from the main body of the above (for example, a state in which the cutout piece 11a hangs from the main body of the notched laminate 10b). The notch 11b of the notched laminate 10b is formed so as to penetrate in the laminating direction of the polarizer 12b, the bonding layer 13b, and the protective film 14b, and the perforated laminate 10c is formed on a surface orthogonal to the laminating direction. It is continuously formed along the portion that becomes the contour (outer edge) of the hole 11c. Therefore, by removing the cutout piece 11a from the notched laminate 10b, it is possible to obtain the perforated laminate 10c in which the holes 11c are formed.

The shape of the cutout piece 11a may be set according to the shape of the hole 11c of the perforated laminate 10c. The shape of the cutout piece 11a can be an ellipse; an oval shape; a polygon such as a triangle or a quadrangle; a rounded polygon having at least one corner of the polygon rounded.
The diameter of the cutout piece 11a is preferably 1 mm or more, may be 3 mm or more, may be 5 mm or more, may be 7 mm or more, is preferably 20 mm or less, and is 18 mm or less. It may be 15 mm or less, or 12 mm or less.
In the present specification, the diameter of the cutout piece means the diameter of the cutout piece when the plane shape of the cutout piece is circular (perfect circle), and when the plane shape of the cutout piece is other than circular (perfect circle), it means. It shall mean the diameter of the circumscribing circle (perfect circle) of the cutout piece.

When the diameter of the cutout piece 11a is within the above range, the cutout piece 11a is difficult to be removed from the notched laminate 10b, easily remains in the region surrounded by the notch 11b, and is completely separated from the main body of the notched laminate 10b. It tends to be difficult to do. When the diameter of the planar shape of the cutout piece 11a is within the above range, in other words, the cutout piece 11a having the above diameter is removed from the laminated body 10b with a notch, and a hole 11c having a diameter corresponding to the diameter of the cutout piece 11a is formed. When manufacturing the perforated laminated body 10c (FIG. 3A) having the same, the manufacturing method and the manufacturing apparatus of the present embodiment can be preferably used.

The bonding layer 13b may be an adhesive layer formed of an adhesive or an adhesive layer formed of an adhesive, but is notched when the bonding layer is an adhesive layer. The cutout piece 11a is difficult to be completely separated from the main body of the laminated body 10b, and the cutout piece 11a tends to remain in the notched laminated body 10b. The manufacturing method and manufacturing apparatus of the present embodiment can be suitably used even when the notched laminate 10b includes an adhesive layer as a bonding layer.

The notched laminate 10b shown in FIGS. 2A and 2B shows a case where there is only one notch 11b, but it may have two or more notches. When the laminated body with cuts is a long continuous body, it is usually cut to the product size (single frond) in a later process. Therefore, the continuous body has a plurality of cuts according to the shape at the time of cutting. It is preferable that it is provided. The notched laminate 10b shown in FIG. 2B has a protective film 14b on one side of the polarizing element 12b, but even if the laminate has a protective film on both sides of the polarizing element via a bonding layer. Good.

(Preparation process)
The preparatory step in the method for manufacturing the perforated laminate 10c may be, for example, a step of preparing a notched laminate 10b (FIGS. 2A and 2B) having a notch 11b and a cutout piece 11a. The preparatory step may include an operation of manufacturing the notched laminate 10b by forming the notch 11b in the material laminate 10a (FIGS. 1A and 1B). As a method for manufacturing the laminated body 10b with a notch, for example, an operation of forming a notch 11b by cutting a punching blade in the laminating direction of the material laminated body 10a can be included. The punching blade is not particularly limited, and for example, a Thomson blade, a corroded blade (Pinnacle (registered trademark) blade), or the like can be used.

(Hole forming process)
In the hole forming step in the method for manufacturing the perforated laminate 10c, for example, the apparatus for producing the perforated laminate 10c shown in FIG. 4 can be used.

In the manufacturing apparatus shown in FIG. 4, a pressing force (external force) is applied to the transport portion 31 for continuously or intermittently transporting the notched laminate 10b and the cutout piece 11a of the notched laminate 10b. A pin 32 (pressing member, pressing portion) for pressing and removing the cutout piece 11a from the notched laminate 10b is provided. The pin 32 is for forming a hole 11c by removing the cutout piece 11a from the notched laminate 10b conveyed by the conveying unit 31. The pin 32 is provided on the upper portion of the transport unit 31 so as to face the notched laminate 10b transported by the transport unit 31. The manufacturing apparatus may further have a pressing fixing portion 33 (fixing portion) for pressing and fixing the position of the notched laminate 10b when the pin 32 presses the cutout piece 11a. The pressing fixing portion 33 is provided on the same side as the pin 32, that is, on the upper portion of the conveying portion 31.

The transport unit 31 includes a transport belt 34, and a pin 32 is provided on the upper portion of the transport surface of the transport belt 34. The transport belt 34 is provided with a belt hole 34c through which the cutout piece 11a can pass so that the cutout piece 11a pushed out by the pin 32 is removed. Therefore, the laminated body 10b with a notch is placed on the transport belt 34 and conveyed so that the cutout piece 11a is arranged at the position of the belt hole 34c.

As shown by the double-headed arrow in FIG. 4, the pin 32 is provided so as to be able to move forward and backward with respect to the transport surface of the transport belt 34, and presses the cutout piece 11a of the notched laminate 10b transported by the transport belt 34. , The cutout piece 11a is punched out. The pin 32 can be, for example, a rod-shaped member, and the cross-sectional area of the tip portion in contact with the cutout piece 11a is preferably smaller than the area of the cutout piece 11a. The tip of the pin 32 on the side in contact with the cutout piece 11a may be tapered, and a soft member such as sponge or rubber may be attached to the tip.

The pressing fixing portion 33 is, for example, a pressing rod that presses the periphery of the notch 11b of the laminated body 10b with a notch. By pressing and fixing the position of the notched laminate 10b using the pressing fixing portion 33, the pin 32 presses the cutout piece 11a, releases the pressing, and moves the pin 32 forward and backward. Problems such as the transport position of the notched laminate 10b and the perforated laminate 10c being displaced can be suppressed. In the manufacturing apparatus shown in FIG. 4, an example is shown in which two holding rods are provided around the notch 11b in a direction orthogonal to the transport direction. The pressing fixing portion 33 may be, for example, a plate-shaped or rod-shaped member, and may have a length capable of pressing the entire length in a direction orthogonal to the transport direction of the notched laminate 10b. It is preferable that the pressing fixing portion 33 is pressed at a position where it does not come into contact with the end face of the product extending in the direction orthogonal to the conveying direction of the notched laminate 10b. The bonding layer 13b is exposed on the end surface of the laminated body 10b with a notch, and when the end surface and the pressing fixing portion 33 come into contact with each other, the adhesive or the adhesive forming the bonding layer 13 adheres to the pressing fixing portion 33. This is because it may cause foreign matter to be generated and the transport route to be contaminated. As shown by the double-headed arrow in FIG. 4, the pressing fixing portion 33 advances and retreats in synchronization with the advancing / retreating movement of the pin 32 to the notched laminate 10b, and coincides with the timing at which the pin 32 presses the cutout piece 11a. Therefore, the laminated body 10b with a notch can be pressed.

In the hole forming step, the laminated body 10b with a notch is sequentially conveyed in the direction indicated by the single arrow in FIG. 4 by driving the conveying belt 34. When the cutout piece 11a portion of the notched laminate 10b reaches the installation position of the pin 32, the pressing fixing portion 33 advances toward the transport belt 34. As a result, the pressing fixing portion 33 presses the periphery of the notch 11b of the notched laminate 10b to fix the position of the notched laminate 10b, and in this state, the pin 32 advances toward the transport belt 34 and the cutout piece. By pressing 11a, the cutout piece 11a is punched out, and a perforated laminate 10c is obtained (FIG. 4). The punched out piece 11a is removed from the belt hole 34c of the transport belt 34 to the outside of the transport portion 31. After that, the pin 32 and the pressing fixing portion 33 move in a direction away from the transport belt 34, and the obtained perforated laminate 10c (FIG. 4) is continuously or intermittently transported by the transport belt 34.

The pressing of the cutout piece 11a by the pin 32 may be performed while continuously transporting the notched laminate 10b, while intermittently transporting the notched laminate 10b and stopping the transport of the notched laminate 10b. You may go to. The pressing of the cutout piece 11a by the pin 32 is accompanied by an advancing / retreating motion (vertical movement in FIG. 4) of the pin 32 and the pressing fixing portion 33 to the notched laminated body 10b on the transport belt 34. Therefore, the notched laminate 10b and the perforated laminate 10c are intermittently conveyed so that the pin 32 can appropriately press the cutout piece 11a, and the pressing and fixing portion is held during the stop period in which the conveyance is temporarily stopped. It is preferable that 33 presses the notched laminate 10b and the pin 32 presses the cutout piece 11a. In this case, it is preferable that the notched laminate 10b and the perforated laminate 10c are conveyed while the pressing fixing portion 33 and the pin 32 are not pressing.

According to the present embodiment, as shown in FIG. 4, since the cutout piece 11a is removed by pressing the cutout piece 11a while carrying the notched laminate 10b, the hole forming step can be efficiently performed.

In the manufacturing apparatus shown in FIG. 4, the pin 32 is provided on the upper portion of the transport belt 34, but the position is not particularly limited as long as the cutout piece 11a of the notched laminate 10b on the transport belt 34 can be pressed. For example, a pin may be provided at the lower part of the transport belt 34. When the pin is provided in the lower part of the transport belt 34, it is preferable that the pressing fixing portion is also provided in the lower part of the transport belt 34.

In the manufacturing apparatus shown in FIG. 4, a case where a pin capable of advancing and retreating is provided on the transport surface of the transport belt 34 has been described as an example, but the present invention is not limited to this, and for example, a pin having pins at predetermined intervals on the surface is provided. A roller with a roller may be used. Rotate the pinned roller while transporting the notched laminate so that the pin of the pinned roller and the cutout piece in the notched laminate come into contact, and the pin of the pinned roller contacts and presses the cutout piece. May remove the cutout pieces from the notched laminate.

In the manufacturing apparatus shown in FIG. 4, the case where two pressing rods are used as the pressing fixing portion 33 has been described as an example, but the number of pressing rods to be used as long as the periphery of the notch 11b can be pressed and fixed. The shape and shape are not particularly limited, and one pressing rod may be used, or a pressing fixing portion having a shape surrounding the periphery of the notch 11b may be provided.

Instead of the pressing fixing portion 33, a fixing portion capable of fixing the position of the notched laminate 10b may be used. For example, instead of the pressing fixing portion 33, a suction fixing portion (fixing portion) for suction-fixing the position of the notched laminate 10b may be provided. Further, if the position of the notched laminate 10b can be sufficiently fixed, the fixing portion may not be provided.

Even if the above-mentioned manufacturing apparatus for the perforated laminate 10c (FIG. 4) is provided with a punching blade for forming a notch 11b in the lamination direction of the material laminate 10a on the upstream side in the transport direction of the notched laminate 10b. Good. Thereby, the notched laminate 10b can be obtained from the material laminate 10a, and the obtained notched laminate 10b can be continuously or intermittently conveyed to perform the hole forming step.

The manufacturing apparatus shown in FIG. 4 may be provided with an accumulating portion for accumulating the cutout pieces 11a removed from the transport unit 31, and is provided with a cutout piece discharging portion for discharging the cutout pieces 11a to the outside of the manufacturing apparatus. You may.

[Embodiment 2]
Also in the present embodiment, the perforated laminate, the notched laminate, and the material laminate are polarizing plates, similarly to the perforated laminate, the notched laminate, and the material laminate described in the previous embodiment. A case will be described as an example. In the present embodiment, instead of the apparatus for manufacturing the perforated laminate shown in FIG. 4, the apparatus for producing the perforated laminate shown in FIG. 5 is used. In the following, the points different from those described in the previous embodiment will be mainly described, and the same points as those described in the previous embodiment will be omitted.

FIG. 5 is a schematic view schematically showing another example of the apparatus for manufacturing the perforated laminate of the present embodiment. In the manufacturing apparatus for the perforated laminate of the present embodiment, the hole forming step is performed by using the manufacturing apparatus (FIG. 5) provided with the suction unit 42 instead of the pin 32 (FIG. 4) used in the previous embodiment. Is different from the previous embodiment.

In the manufacturing apparatus shown in FIG. 5, a suction force (external force) is applied to the transport portion 41 for continuously or intermittently transporting the notched laminate 10b and the cutout piece 11a of the notched laminate 10b. A suction portion 42 for sucking and removing the cutout piece 11a from the notched laminate 10b is provided. The suction unit 42 is for forming a hole 11c by removing the cutout piece 11a from the notched laminate 10b transported by the transport unit 41. The suction unit 42 is provided at the lower part of the transport unit 41 so as to face the notched laminate 10b transported by the transport unit 41.

The transport unit 41 includes a transport belt 34, and a suction portion 42 is provided below the transport surface of the transport belt 34. The transport belt 34 is provided with a belt hole 34c through which the cutout piece 11a can pass at the position of the cutout piece 11a of the laminated body 10b with a notch so that the cutout piece 11a sucked by the suction portion 42 is sucked and removed. There is. Therefore, the laminated body 10b with a notch is placed on the transport belt 34 and conveyed so that the cutout piece 11a is arranged at the position of the belt hole 34c.

The suction unit 42 is, for example, a suction box, and is located at the lower part of the transport belt 34, and applies a suction force to the notched laminate 10b from the belt hole 34c of the transport belt 34. The suction unit 42 has, for example, a box shape as a whole, such as a rectangular parallelepiped, has an opening on the surface facing the transport belt 34, and exhausts the other surface to discharge the gas sucked into the suction box. Has a mouth.

In the hole forming step, the laminated body 10b with a notch is sequentially conveyed in the direction indicated by the single arrow in FIG. 5 by driving the conveying belt 34. When the cutout piece 11a portion of the laminated body 10b with a notch reaches the installation position of the suction portion 42 on the transport portion 41, it is removed from the belt hole 34c of the transport belt 34 to the outside of the transport portion 41 by the suction force of the suction portion 42. As a result, a perforated laminate 10c can be obtained. The obtained perforated laminate 10c (FIG. 5) is continuously or intermittently conveyed by the transfer belt 34.

The suction piece 11a may be sucked by the suction unit 42 while continuously transporting the notched laminate 10b, intermittently transporting the notched laminate 10b, and stopping the transport of the notched laminate 10b. It may be done during the suspension period. In order to efficiently suck the cutout piece 11a by the suction unit 42, the transfer belt 34 is continuously driven to continuously convey the notched laminate 10b while the suction by the suction unit 42 is activated. , It is preferable that the cutout piece 11a is removed by suction by passing through the position of the suction portion 42.

According to the present embodiment, as shown in FIG. 5, the cutout piece 11a is removed by an external force such as a suction force while transporting the laminated body 10b with a notch, so that the hole forming step can be efficiently performed.

In the manufacturing apparatus shown in FIG. 5, a suction portion 42 is provided at the lower part of the transport belt 34, but the position is not particularly limited as long as the cutout piece 11a of the notched laminate 10b on the transport belt 34 can be sucked. For example, a suction portion 42 may be provided on the upper portion of the transport belt 34.

In the manufacturing apparatus shown in FIG. 5, a case where a suction box is used as the suction unit 42 has been described as an example, but the present invention is not limited to this, and for example, a suction roller having a suction region having a predetermined length in the circumferential direction is used. May be good. When a suction roller is used, the suction roller is rotated while driving the conveyor belt so that the suction region of the suction roller and the position of the belt hole of the conveyor belt face each other, and the suction roller is sucked by the suction region of the suction roller. The cutout pieces may be removed by suction from the notched laminate on the belt.

As described in the previous embodiment, the manufacturing apparatus shown in FIG. 5 is provided with a punching blade for forming a notch 11b in the laminating direction of the material laminated body 10a on the upstream side in the transport direction of the laminated body 10b with a notch. You may. Thereby, the notched laminate 10b can be obtained from the material laminate 10a, and the obtained notched laminate 10b can be continuously or intermittently conveyed to perform the hole forming step.

The manufacturing apparatus shown in FIG. 5 may be provided with an accumulating portion for accumulating the cutout pieces 11a removed from the transport unit 41, and may be provided with a cutout piece discharging portion for discharging the cutout pieces 11a out of the manufacturing apparatus. You may. The collecting portion and the cutout piece discharging portion can be provided in, for example, the suction portion 42.

[Embodiment 3]
Also in the present embodiment, the perforated laminate, the notched laminate, and the material laminate are polarizing plates, similarly to the perforated laminate, the notched laminate, and the material laminate described in the previous embodiment. A case will be described as an example. In the present embodiment, the perforated laminate manufacturing apparatus shown in FIG. 6 is used instead of the perforated laminate manufacturing apparatus described above. In the following, the points different from those described in the previous embodiment will be mainly described, and the same points as those described in the previous embodiment will be omitted.

FIG. 6 is a schematic view schematically showing another example of the apparatus for manufacturing the perforated laminate of the present embodiment. In the manufacturing apparatus for the perforated laminate of the present embodiment, instead of the pin 32 (FIG. 4) and the suction portion 42 (FIG. 5) used in the previous embodiment, a spraying portion for spraying the fluid is provided. It differs from the previous embodiment in that the hole forming step is performed using the device (FIG. 6).

The manufacturing apparatus shown in FIG. 6 applies a force (external force) for blowing a fluid to a transport portion 51 for continuously or intermittently transporting the notched laminate 10b and a cutout piece 11a of the notched laminate 10b. In addition, a spraying portion 52 for spraying and removing the cutout piece 11a from the notched laminate 10b is provided. The spraying portion 52 is for forming a hole 11c by removing the cutout piece 11a from the notched laminate 10b conveyed by the conveying portion 51. The spraying portion 52 is provided on the upper portion of the conveying portion 51 so as to face the notched laminate 10b conveyed by the conveying portion 51. The manufacturing apparatus shown in FIG. 6 further has a pressing fixing portion 33 (fixing portion) for pressing and fixing the position of the notched laminate 10b when the spraying portion 52 sprays the fluid onto the cutout piece 11a. You may. The pressing fixing portion 33 is provided on the same side as the spraying portion 52, that is, on the upper portion of the conveying portion 51.

The transport unit 51 includes a transport belt 34, and a spray portion 52 is provided on the upper portion of the transport surface of the transport belt 34. The transport belt 34 is provided with a belt hole 34c through which the cutout piece 11a can pass at the position of the cutout piece 11a of the laminated body 10b with a notch so that the cutout piece 11a is removed by the spraying portion 52. Therefore, the laminated body 10b with a notch is placed on the transport belt 34 and conveyed so that the cutout piece 11a is arranged at the position of the belt hole 34c.

The spraying portion 52 is provided on the upper part of the transport belt 34, and blows a fluid such as a gas such as air, nitrogen, or noble gas or a liquid such as water onto the cutout piece 11a, and blows compressed air. Is preferable. The spraying portion 52 may be provided with, for example, a spraying nozzle, and by adjusting the size of the spraying nozzle or the like, the fluid may be sprayed only on the cutout piece 11a or only on the cutout piece 11a and its surroundings. Good.

The pressing fixing portion 33 is, for example, a pressing rod that presses the periphery of the notch 11b of the laminated body 10b with a notch. As a result, when the fluid is sprayed from the spraying portion 52, it is possible to suppress problems such as the transport position of the notched laminate 10b and the perforated laminate 10c being displaced. In the manufacturing apparatus shown in FIG. 6, an example is shown in which two holding rods are provided around the notch 11b in a direction orthogonal to the transport direction. As described in the previous embodiment, the pressing fixing portion 33 is preferably pressed at a position where it does not come into contact with the end portion of the product extending in the direction orthogonal to the conveying direction of the notched laminate 10b. For example, as shown by the double-headed arrow in FIG. 6, the pressing fixing portion 33 moves forward and backward in synchronization with the spraying of the fluid by the spraying portion 52, and at the timing when the spraying portion 52 sprays the fluid on the cutout piece 11a. At the same time, the notched laminate 10b can be pressed.

In the hole forming step, the laminated body 10b with a notch is sequentially conveyed in the direction indicated by the single arrow in FIG. 6 by driving the conveying belt 34. When the cutout piece 11a portion of the notched laminate 10b reaches the installation position of the spraying portion 52, the pressing fixing portion 33 advances toward the transport belt 34. As a result, the pressing fixing portion 33 presses the periphery of the notch 11b of the notched laminate 10b to fix the position of the notched laminate 10b, and in this state, the spraying portion 52 directs the fluid toward the cutout piece 11a. Spray. The cutout piece 11a to which the fluid is sprayed is removed from the belt hole 34c of the transport belt 34 to the outside of the transport portion 51, whereby the perforated laminate 10c is obtained. The obtained perforated laminate 10c (FIG. 6) is continuously or intermittently conveyed by the transfer belt 34.

The cutout piece 11a may be sprayed by the spraying portion 52 while continuously transporting the notched laminate 10b, or intermittently transporting the notched laminate 10b to transport the notched laminate 10b. It may be done during the suspension period. When the notched laminate 10b is intermittently pressed and fixed when the fluid is sprayed onto the cutout piece 11a by the spraying portion 52, the position of the notched laminate 10b is appropriately fixed by the pressing fixing portion 33. The laminated body 10b with a notch is intermittently transported so that the fluid is appropriately sprayed on the cutout piece 11a, and during the stop period in which the transport is temporarily stopped, the pressing fixing portion 33 presses and fixes and blows. It is preferable to spray the fluid by the attachment portion 52. In this case, it is preferable that the notched laminate 10b and the perforated laminate 10c are conveyed when the pressing fixing portion 33 does not press or the spraying portion 52 does not spray the fluid.

According to the present embodiment, as shown in FIG. 6, since the cutout piece 11a is removed by spraying the fluid while transporting the notched laminate 10b, the hole forming step can be efficiently performed.

In the manufacturing apparatus shown in FIG. 6, a spraying portion 52 is provided on the upper portion of the transport belt 34, but the position is not particularly limited as long as the cutout piece 11a of the notched laminate 10b on the transport belt 34 can be pressed. .. For example, a spraying portion may be provided at the lower part of the transport belt 34. When the spraying portion is provided at the lower part of the transport belt 34, it is preferable that the pressing fixing portion is also provided at the lower part of the transport belt.

In the manufacturing apparatus shown in FIG. 6, a spraying portion 52 for spraying a fluid is particularly provided on the cutout piece 11a, but the present invention is not limited to this as long as an external force capable of removing the cutout piece 11a can be applied from the notched laminate 10b. .. For example, a spraying portion capable of spraying the fluid may be provided on a line along a direction orthogonal to the transport direction of the notched laminate 10b, and the fluid may be sprayed on the cutout piece 11a and its periphery. In the manufacturing apparatus shown in FIG. 6, the case where the spraying portion is provided at a specific position on the transport belt 34 has been described as an example, but the spraying portion can move in synchronization with the transport of the notched laminate 10b. It may be provided in.

In the manufacturing apparatus shown in FIG. 6, a case where two pressing rods are used as the pressing fixing portion 33 has been described as an example, but as described in the previous embodiment, the periphery of the notch 11b can be pressed and fixed. As long as it is used, the number and shape of the pressing rods to be used are not particularly limited, and one pressing rod may be used, or a pressing fixing portion having a shape surrounding the periphery of the notch 11b may be provided.

Instead of the pressing fixing portion 33, a fixing portion capable of fixing the position of the notched laminate 10b may be used. For example, instead of the pressing fixing portion 33, a suction fixing portion (fixing portion) for suction-fixing the position of the notched laminate 10b may be provided. Further, if the position of the notched laminate 10b can be sufficiently fixed, the fixing portion may not be provided.

As described in the previous embodiment, the manufacturing apparatus shown in FIG. 6 is provided with a punching blade for forming a notch 11b in the laminating direction of the material laminated body 10a on the upstream side in the transport direction of the laminated body 10b with a notch. You may. Thereby, the notched laminate 10b can be obtained from the material laminate 10a, and the obtained notched laminate 10b can be continuously or intermittently conveyed to perform the hole forming step.

The manufacturing apparatus shown in FIG. 6 may be provided with an accumulating portion for accumulating the cutout pieces 11a removed from the transport unit 51, and may be provided with a cutout piece discharging portion for discharging the cutout pieces 11a out of the manufacturing apparatus. You may.

[Embodiment 4]
Also in the present embodiment, the perforated laminate, the notched laminate, and the material laminate are polarizing plates, similarly to the perforated laminate, the notched laminate, and the material laminate described in the previous embodiment. A case will be described as an example. In the following, the points different from those described in the previous embodiment will be mainly described, and the same points as those described in the previous embodiment will be omitted.

FIG. 7 is a schematic view schematically showing another example of the apparatus for manufacturing the perforated laminate of the present embodiment. In the manufacturing apparatus for the perforated laminate of the present embodiment, instead of the manufacturing apparatus (FIG. 6) in which the spraying portion 52 is provided on the transport belt 34 in the previous embodiment, spraying is performed between a set of nip rollers. It differs from the previous embodiment in that the hole forming step is performed by using the manufacturing apparatus (FIG. 7) provided with the portion.

The manufacturing apparatus shown in FIG. 7 applies a force (external force) for blowing a fluid to the transport portion 61 for continuously or intermittently transporting the notched laminate 10b and the cutout piece 11a of the notched laminate 10b. In addition, a spraying portion 52 for spraying and removing the cutout piece 11a from the notched laminate 10b is provided. The spraying portion 52 is for forming a hole 11c by removing the cutout piece 11a from the notched laminate 10b conveyed by the conveying portion 61. The spraying portion 52 is provided on the upper portion of the conveying portion 61 so as to face the notched laminate 10b conveyed by the conveying portion 61.

The transport unit 61 includes a first transport belt 62a (convey belt), a set of nip rollers 63a and 63b (convey rollers), and a second transport belt 62b (convey belt) from the upstream side of the notched laminate 10b in the transport direction. And are prepared in this order. The first transport belt 62a transports the notched laminate 10b, and the second transport belt 62b has the cutout piece 11a removed from the notched laminate 10b or the notched laminate 10b that has passed through a set of nip rollers 63a, 63b. The perforated laminate 10c (FIG. 7) is conveyed.

Each of the pair of nip rollers 63a and 63b has a pair of rollers, and the laminated body 10b with a notch is conveyed between the pair of rollers in a nip state, and the spraying portion 52 fluidizes the cutout piece 11a. Can also function as a fixing portion for fixing the position of the notched laminate 10b when spraying. The set of nip rollers 63a and 63b are constant in the axial direction of the nip rollers 63a and 63b (direction orthogonal to the conveying direction of the notched laminate 10b) so as not to press the notch 11b of the notched laminate 10b to be conveyed. They are juxtaposed at intervals (Fig. 7). It is preferable that a driving force is applied to at least one of the pair of rollers to the nip rollers 63a and 63b.

As shown in FIG. 7, for example, the spraying portion 52 is a set of nip rollers so that a fluid can be sprayed on the cutout piece 11a of the notched laminate 10b that passes between the set of nip rollers 63a and 63b. It is provided in the upper part between 63a and 63b. The spraying unit 52 blows a fluid such as a gas such as air, nitrogen, or noble gas, or a liquid such as water onto the cutout piece 11a, and preferably blows compressed air. The spraying portion 52 may be provided with, for example, a spraying nozzle, and by adjusting the size of the spraying nozzle or the like, the fluid may be sprayed only on the cutout piece 11a or only on the cutout piece 11a and its surroundings. Good.

In the hole forming step, the notched laminate 10b is sequentially conveyed in the direction indicated by the single arrow in FIG. 7 by driving the first conveying belt 62a. When the notched laminate 10b reaches the positions of the set of nip rollers 63a and 63b, it is conveyed by the first transfer belt 62a and the set of nip rollers 63a and 63b. By this transfer, when the cutout piece 11a portion of the notched laminate 10b reaches the installation position of the spraying portion 52 between the set of nip rollers 63a and 63b, the fluid spraying force from the spraying portion 52 causes one As a result of being removed from between the nip rollers 63a and 63b of the set to the outside of the transport portion 61, a perforated laminated body 10c is obtained. The obtained perforated laminate 10c (FIG. 7) is continuously or intermittently transported by a set of nip rollers 63a and 63b and a second transport belt 62b.

The fluid may be sprayed onto the cutout piece 11a by the spraying portion 52 while continuously transporting the notched laminate 10b, or intermittently transporting the notched laminate 10b to the notched laminate 10b. May be carried out during the suspension period during which the transport of the fluid is stopped. In the manufacturing apparatus shown in FIG. 7, since a set of nip rollers 63a and 63b can carry the laminated body 10b with a notch while sandwiching the laminated body 10b and fixing the position, the laminated body 10b with a notch can be continuously conveyed while being conveyed. The fluid can be sprayed by the spraying unit 52. As described above, in the hole forming step, the cutout piece 11a can be removed while continuously or intermittently transporting the notched laminate 10b using a set of nip rollers 63a and 63b.

According to the present embodiment, as shown in FIG. 7, since the cutout piece 11a is removed by spraying the fluid while transporting the notched laminate 10b, the hole forming step can be efficiently performed.

In the manufacturing apparatus shown in FIG. 7, the spraying portion 52 is provided in the upper part between the set of nip rollers 63a and 63b, but the spraying portion may be provided in the lower part between the set of nip rollers 63a and 63b.

As described in the previous embodiment, the manufacturing apparatus shown in FIG. 7 is provided with a punching blade for forming a notch 11b in the laminating direction of the material laminated body 10a on the upstream side in the transport direction of the laminated body 10b with a notch. You may. Thereby, the notched laminate 10b can be obtained from the material laminate 10a, and the obtained notched laminate 10b can be continuously or intermittently conveyed to perform the hole forming step.

As described in the previous embodiment, the manufacturing apparatus shown in FIG. 7 may be provided with an accumulating portion for accumulating the cutout pieces 11a removed from the transport portion 61, and the cutout pieces 11a may be provided outside the manufacturing apparatus. A cutout piece discharging portion for discharging may be provided. The accumulating portion and the cutout piece discharging portion can be provided, for example, between a set of nip rollers 63a and 63b.

Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and for example, each structure and each step of each of the above embodiments can be combined and implemented. Hereinafter, each item common to all the embodiments, a modification of the above-described embodiment, and the like will be described in detail.

(Manufacturing method of perforated laminate)
As described above, the production method of the present invention includes a step of preparing a laminated body with a notch and a step of forming a hole.
The step of preparing may include an operation of forming a notch by cutting a punching blade in the laminating direction of the material laminate as an operation of obtaining a laminated body with a notch.
In the step of forming the hole, the hole is usually formed by applying an external force to the cutout piece. The external force is at least one of a force for pressing the cutout piece by a pressing member, a force for sucking the cutout piece, and a force for blowing a fluid on the cutout piece.
In the step of forming the holes, the notched laminate is typically conveyed by at least one of a transfer belt, a transfer roller, and a rotary table.
In the step of forming the holes, the cut-out laminate can be intermittently transported, and the cutout pieces can be removed while the transport of the notched laminate is stopped.
The step of forming the holes may further include an operation of removing the cutout pieces from the notched laminate and then transporting the perforated laminate obtained by the removal operation.

(Manufacturing equipment for perforated laminates)
The apparatus for manufacturing a perforated laminate of the present invention has a transport section for continuously or intermittently transporting the laminated body 10b with a notch, and a notch 11b from the laminate 10b with a notch conveyed by the transport section. It is provided with a hole forming portion for forming the hole 11c by removing the cutout piece 11a formed by the above.

As described in the previous embodiment, the manufacturing apparatus of the present invention may be provided with a mechanism for obtaining the notched laminate 10b from the material laminate 10a on the upstream side in the transport direction of the notched laminate 10b. The mechanism may include a punching blade for forming a notch 11b in the laminating direction of the material laminate 10a.

The transport section is typically provided with at least one of a transport belt, a transport roller, and a rotary table for transporting the notched laminate 10b.
In the manufacturing apparatus for the perforated laminate (perforated laminate) of the above-described embodiment, there are cases where a transport belt is provided in the transport portion (FIGS. 4 to 6) and a case where a transport belt and a transport roller are provided (FIG. 7). The explanation has been given as an example, but the present invention is not limited to this. Instead of the transport belt, a transport roller or a rotary table may be used, or any combination thereof may be used.
Further, even if a fixed table and a transport arm are provided in the transport unit, the notched laminate or the perforated laminate placed on the fixed table is lifted by the transport arm and transported to another fixed table. Good.

The notched laminate or the perforated laminate to be conveyed in the conveying portion may be conveyed alone or in a state where two or more are laminated. When transporting a laminated body with a notch or a laminated body with holes in a state where two or more are laminated, the above-mentioned hole forming step may be performed in the state where these are laminated.

The hole forming portion is, for example, at least one of a pressing portion for pressing the cutout piece with a pressing member such as a pin, a suction portion for sucking the cutout piece, and a spraying portion for spraying a fluid on the cutout piece. Including one.

In the manufacturing apparatus of the above-described embodiment, a cutting tool such as an end mill for polishing the holes of the perforated laminate may be provided on the downstream side in the transport direction of the perforated laminate from which the cutout pieces have been removed from the notched laminate. Good. In this case, after the hole forming step, the hole of the perforated laminate in which the cutout portion is removed from the notched laminate is polished with a cutting tool, so that the processing quality and dimensional accuracy of the hole can be improved. ..

Even if the manufacturing apparatus of the above-described embodiment is provided with an inspection unit for inspecting whether or not the cutout pieces have been removed, on the downstream side in the transport direction of the perforated laminate in which the cutout pieces have been removed from the notched laminate. Good. For example, the inspection unit can take an image of the hole state of the perforated laminate with a camera or the like, and inspect the removed state of the cutout piece based on the captured image. The inspection unit may be performed before polishing with the cutting tool described above, or may be performed after polishing.

The manufacturing apparatus of the above-described embodiment is an apparatus for removing foreign matter adhering to the surface of the perforated laminate on the downstream side in the transport direction of the perforated laminate from which the cutout pieces have been removed from the notched laminate. (Adhesive rubber roll, etc.) may be provided. The device may be provided on the downstream side of the inspection unit in the transport direction of the perforated laminate, or may be provided on the upstream side in the transport direction.

(Material laminate)
In the above-described embodiment, the case where the material laminate is a linear polarizing plate has been described as an example, but the present invention is not limited to this. As long as the material laminate has one or more resin film layers and one or more bonded layers, the layer structure and the number of layers are not particularly limited, but resin film layers are provided on both sides of the bonded layers. It is preferable that the film is used. For example, the material laminate may be a laminate of an optical layer (resin film layer) and a bonding layer, or may be a lamination of a resin film layer other than the optical layer and a bonding layer. , A resin film layer other than the optical layer, an optical layer, and a bonding layer may be laminated.

Examples of the optical layer used in the material laminate include a linear polarizer (polarizer), a retardation film, a brightness improving film, an antiglare film, an antireflection film, a diffusion film, and a light collecting film. Only one type of these optical layers may be used, or two or more types may be used in combination. Examples of the material laminate having an optical layer include a linear polarizing plate having a protective film on one or both sides of a linear polarizing element via a bonding layer. The material laminate including the optical layer further has a bonding layer for bonding to other members such as a display panel and a display element, and a release film (resin film layer) for coating and protecting the bonding layer. You may be doing it.

Examples of the material laminate having no optical layer include a protective film (surface protective film) laminated on the outer surface of an optical film such as a polarizing plate. The protective film is, for example, a base film (resin film layer), a bonding layer, and a release film (resin film layer) laminated in this order.

Specific examples of the material laminate include, in addition to the above-mentioned polarizing plate and protective film, a polarizing plate with a protective film having a polarizing plate and a protective film, a circular polarizing plate having a linear polarizing plate and a retardation film, and the like. Can be done. Examples of the retardation film used for the circular polarizing plate include a λ / 2 layer, a λ / 4 layer, a λ / 4 layer having an inverse wavelength dispersion, and a positive C layer. The layer structure of the circularly polarizing plate includes, for example, a linear polarizing plate, a bonded layer, a λ / 2 layer, a bonded layer, and a λ / 4 layer laminated in this order, a linear polarizing plate, a bonded layer, and an inverse wavelength. Dispersible λ / 4 layer, bonded layer, and positive C layer laminated in this order, linear polarizing plate, bonded layer, positive C layer, bonded layer, and inverse wavelength dispersive λ / 4 layer. Examples include those laminated in this order. The retardation film may be a resin film or a cured film of a polymerizable liquid crystal compound.

(Laminate with notch)
In the above-described embodiment, the case where the notched laminate is a linear polarizing plate has been described as an example, but the present invention is not limited to this. Examples of the layer structure of the notched laminate include those having the same layer structure as the above-mentioned material laminate. A laminated body with a notch can be obtained by forming a notch penetrating the material laminated body in the laminating direction in the above-mentioned material laminated body.

The notched laminate is not particularly limited, and examples thereof include a laminate that is a single-wafer.
As an example of the notched laminate, a laminate in which the base film, the bonding layer, and the release film are laminated in this order, or a polarizing plate having the protective film on one or both sides of a linear polarizer is laminated. The laminated body is mentioned.

(Perforated laminate)
In the above-described embodiment, the case where the perforated laminate is a polarizing plate has been described as an example, but the present invention is not limited to this. Examples of the layer structure of the perforated laminate include those having the same layer structure as the above-mentioned material laminate and the above-mentioned notched laminate. By removing the cutout pieces from the above-mentioned notched laminate, a perforated laminate can be obtained.

The diameter of the hole is preferably 1 mm or more, preferably 3 mm or more, 5 mm or more, 7 mm or more, 20 mm or less, and 18 mm or less. It may be 15 mm or less, or 12 mm or less.

The perforated laminate can be applied to a display device such as a liquid crystal display device or an organic electroluminescence (EL) display device, for example, when a linear polarizer is provided as an optical layer. By arranging holes in the perforated laminate in the area where the camera lens of the display device such as a smartphone or tablet terminal is placed or in the area where icons, logos, etc. are printed, a linear polarizer can be placed in these areas. It can be prevented from being placed.

(Linear polarizer)
A linear polarized light is a layer or film having a function of selectively transmitting linearly polarized light in a certain direction from natural light. Examples of the linear polarizer include a film in which a dichroic dye is adsorbed and oriented on a uniaxially or biaxially stretched polyvinyl alcohol-based resin film. Examples of the dichroic dye include iodine and a dichroic organic dye. Further, the linear polarizing element may be a coating type polarizing film in which a dichroic dye in a Riotrovic liquid crystal state is coated on a base film and oriented and immobilized.

The thickness of the linear polarizer can be 40 μm or less, preferably 30 μm or less (for example, 20 μm or less, further 15 μm or less, and further 10 μm or less or 8 μm or less). The thickness of the linear polarizer is usually 2 μm or more.

(Protective film)
The protective film provided on one side or both sides of the linear polarizing element is not limited as long as it is a resin film capable of transmitting light. Examples of the resin film include a cyclic polyolefin resin film, a cellulose acetate resin film made of a resin such as triacetyl cellulose and diacetyl cellulose, and a polyester resin film made of a resin such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate. , Polycarbonate resin film, (meth) acrylic resin film, polypropylene resin film and the like, which are known in the art. From the viewpoint of thinning, the thickness of the protective film is usually 300 μm or less, preferably 200 μm or less, more preferably 100 μm or less, and usually 5 μm or more, preferably 20 μm or more. .. The protective film may or may not have optical functions such as a phase difference characteristic and a brightness improving function. The protective film having retardation characteristics can be obtained at an arbitrary position by, for example, stretching a transparent resin film made of the above material (uniaxial stretching or biaxial stretching, etc.) or forming a liquid crystal layer or the like on the film. It can be obtained by giving a phase difference value.

The protective film may have a hard coat layer formed therein. The hard coat layer may be formed on one surface of the transparent resin film made of the above material, or may be formed on both surfaces. By providing the hard coat layer, a protective film having improved hardness and scratch resistance can be obtained. The hard coat layer is, for example, a cured layer of an ultraviolet curable resin. Examples of the ultraviolet curable resin include acrylic resin, silicone resin, polyester resin, urethane resin, amide resin, epoxy resin and the like. The hard coat layer may contain additives to improve strength. Additives are not limited, and examples thereof include inorganic fine particles, organic fine particles, and mixtures thereof.

(Protect film)
As described above, the protective film has a base film, a bonding layer, and a release film. The resin constituting the base film is not particularly limited, and for example, heat of a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, a polyester resin such as polyethylene terephthalate or polyethylene naphthalate, or a polycarbonate resin. It can be a plastic resin. Preferably, a polyester resin such as polyethylene terephthalate can be used.

Examples of the release film include a film made of a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, and a polyester resin such as polyethylene terephthalate, which has been subjected to a mold release treatment by a silicone coating or the like.

(Lated layer)
The bonding layer may be an adhesive layer formed by an adhesive, or may be an adhesive layer formed by an adhesive. As described above, when the adhesive layer is included as the bonding layer, the cutout piece 11a tends to remain in the notched laminate 10b. Therefore, the manufacturing method and manufacturing apparatus of each of the above-described embodiments can be preferably used when the material laminate, the notched laminate, and the perforated laminate have an adhesive layer as a bonding layer. it can.

As the pressure-sensitive adhesive used for the pressure-sensitive adhesive layer, a (meth) acrylic resin, a silicone-based resin, a polyester-based resin, a polyurethane-based resin, a polyether resin, or the like as a base polymer can be used. Among them, a (meth) acrylic pressure-sensitive adhesive is preferable from the viewpoints of transparency, adhesive strength, reliability, weather resistance, heat resistance, reworkability and the like. The (meth) acrylic pressure-sensitive adhesive includes a (meth) acrylic acid alkyl ester having an alkyl group having 20 or less carbon atoms such as a methyl group, an ethyl group, an n-, i- or t-butyl group, and (meth). A weight average molecular weight of a functional group-containing (meth) acrylic monomer such as acrylic acid or hydroxyethyl (meth) acrylic acid blended so that the glass transition temperature is preferably 25 ° C. or lower, more preferably 0 ° C. or lower. A (meth) acrylic resin having a value of 100,000 or more is useful as a base polymer.

The thickness of the pressure-sensitive adhesive layer is determined according to the adhesive strength and the like, but a range of 1 μm or more and 50 μm or less is appropriate, and preferably 2 μm or more and 40 μm or less.

As the adhesive layer used for the adhesive layer, a known water-based composition (including a water-based adhesive) in which a curable resin component is dissolved or dispersed in water, and a known active energy ray-curable compound are contained. Examples thereof include an active energy ray-curable composition (including an active energy ray-curable adhesive).

Examples of the resin component contained in the aqueous composition include polyvinyl alcohol-based resin and urethane resin. The active energy ray-curable composition is a composition that is cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. The composition that is cured by irradiation with active energy rays is preferably an ultraviolet curable composition, and more preferably contains an epoxy compound that is cured by cationic polymerization as a curable component.

The thickness of the adhesive layer is not particularly limited, but a range of 1 μm or more and 50 μm or less is suitable, and preferably 2 μm or more and 40 μm or less.

The above-mentioned perforated laminate can be applied to, for example, a display device. When the perforated laminate is applied to the display device, the perforated laminate can be applied to the display device alone or as an optical laminate in which the perforated laminate and the front plate or the back plate are laminated.

When the optical laminate has a front plate and a back plate and the perforated laminate includes an optical layer such as a linear polarizer or a retardation film, the optical laminate includes the front plate, the perforated laminate, and the back plate. It can be held in this order.

(Front plate)
The front plate constitutes the outermost surface of the display device on the visual side, and can have a function of protecting the front surface (screen) of the display device. The front plate is preferably a plate-like body capable of transmitting light. The front plate may be composed of only one layer, or may be composed of two or more layers. The front plate may have a blue light cut function, a viewing angle adjustment function, and the like.
Examples of the front plate include a glass plate-like body (glass plate, flexible thin-walled glass, etc.), a resin plate-like body (resin plate, resin sheet, resin film (sometimes referred to as a window film), etc.). ), And it is preferable that the plate-like body exhibits flexibility. Among the above, a plate-like body made of resin such as a resin film is preferable.

Examples of the resin plate-like body include a resin film made of a thermoplastic resin. As the thermoplastic resin, a polyolefin resin such as a chain polyolefin resin (polyethylene resin, polypropylene resin, polymethylpentene resin, etc.), a cyclic polyolefin resin (norbornen resin, etc.); cellulose such as triacetyl cellulose Based resin; Polyester based resin such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate; Polycarbonate resin; Ethylene-vinyl acetate resin; Polystyrene resin; Polyamide resin; Polyetherimide resin; Polymethyl (meth) acrylate resin Etc. (Meta) acrylic resin; polyimide resin; polyether sulfone resin; polysulfone resin; polyvinyl chloride resin; polyvinylidene chloride resin; polyvinyl alcohol resin; polyvinyl acetal resin; polyether ketone resin ; Polyether ether ketone resin; polyether sulfone resin; polyamideimide resin and the like.
The thermoplastic resin can be used alone or in combination of two or more.
Above all, from the viewpoint of flexibility, strength and transparency, a polyimide resin, a polyamide resin and a polyamide imide resin are preferably used as the thermoplastic resin constituting the front plate.

The front plate may be a film having a hard coat layer provided on at least one surface of the base film to further improve the hardness. As the base film, the above-mentioned resin film can be used.

The hard coat layer may be formed on one surface of the base film, or may be formed on both surfaces. By providing the hard coat layer, hardness and scratch resistance can be improved. The thickness of the hard coat layer may be, for example, 0.1 μm or more and 30 μm or less, preferably 1 μm or more and 20 μm or less, and more preferably 5 μm or more and 15 μm or less.

The hard coat layer is, for example, a cured layer of an ultraviolet curable resin. Examples of the ultraviolet curable resin include (meth) acrylic resin, silicone resin, polyester resin, urethane resin, amide resin, epoxy resin and the like. The hard coat layer may contain additives to improve strength. The additive is not limited, and examples thereof include inorganic fine particles, organic fine particles, and a mixture thereof.

The thickness of the front plate may be, for example, 20 μm or more and 2000 μm or less, preferably 25 μm or more and 1500 μm or less, more preferably 30 μm or more and 1000 μm or less, still more preferably 40 μm or more and 500 μm or less, particularly preferably 40 μm or more and 200 μm or less, and further preferably. It may be 40 μm or more and 100 μm or less.

(Back plate)
The back plate is preferably a plate-like body capable of transmitting light. The back plate may be composed of only one layer, or may be composed of two or more layers.
The back plate can form, for example, an image display element layer such as a liquid crystal panel of a display device or an organic display element.
Similar to the front plate, the back plate includes, for example, a glass plate-like body (for example, a glass plate, a glass film, etc.) and a resin plate-like body (for example, a resin plate, a resin sheet, a resin film, etc.). Can be mentioned.
Specific examples of the thermoplastic resin constituting the resin plate-like body include the thermoplastic resin exemplified in the front plate. The thermoplastic resin is preferably a cellulose-based resin, a (meth) acrylic-based resin, a cyclic polyolefin-based resin, a polyester-based resin, a polycarbonate-based resin, or the like.

From the viewpoint of thinning, the thickness of the back plate is preferably 15 μm or more and 200 μm or less, more preferably 20 μm or more and 150 μm or less, and further preferably 30 μm or more and 130 μm or less.

(Display device)
When the perforated laminate includes an optical layer such as a linear polarizer or a retardation film, it can be suitably used for a display device. The display device is not particularly limited, and examples thereof include a liquid crystal display device and an organic EL display device.
The display device may be a display device having flexibility that can be repeatedly folded, bent, or wound.

10a Material Laminate, 10b Laminate with Notch, 10c Perforated Laminate, 11a Cutout, 11b Notch, 11c Hole, 12a-12c Linear Polarizer, 13a-13c Laminated Layer, 14a-14c Protective Film, 31 Conveyor , 32 pins (pressing member, pressing part), 33 pressing fixing part, 34 transport belt, 34c belt hole, 41 transport part, 42 suction part, 51 transport part, 52 spraying part, 61 transport part, 62a 1st transport belt (Convey belt), 62b Second transport belt (convey belt), 63a, 63b Nip roller.

Claims (15)

A method for manufacturing a perforated laminate having holes penetrating in the stacking direction.
A step of preparing a notched laminate having one or more resin film layers and one or more laminating layers laminated, and having a notch penetrating in the laminating direction and a cutout piece formed by the notch.
Including a step of forming the hole by removing the cutout piece from the notched laminate while continuously or intermittently transporting the notched laminate.
In the step of forming the hole, the hole is formed by applying an external force to the cutout piece.
The external force is at least one of a force for pressing the cutout piece by a pressing member, a force for sucking the cutout piece, and a force for blowing a fluid on the cutout piece.
A method for producing a perforated laminate including an optical layer as the resin film layer. The preparation step includes an operation of forming the notch by cutting a punching blade in the laminating direction of the material laminate in which the one or more resin film layers and the one or more laminating layers are laminated. The method for producing a perforated laminate according to claim 1. The method for producing a perforated laminate according to claim 1 or 2, wherein the hole diameter is 1 mm or more and 20 mm or less. The perforated laminate according to any one of claims 1 to 3, wherein in the step of forming the hole, the laminate with a notch is conveyed by at least one of a transfer belt, a transfer roller, and a rotary table. How to make a body. The step according to any one of claims 1 to 4, wherein in the step of forming the hole, the notched laminate is intermittently conveyed, and the cutout piece is removed while the notched laminate is stopped. The method for manufacturing a perforated laminate according to the description. Any one of claims 1 to 5, wherein the step of forming the hole further includes an operation of removing the cutout piece from the notched laminate and then transporting the perforated laminate obtained by the removal operation. The method for producing a perforated laminate according to item 1. The method for producing a perforated laminate according to any one of claims 1 to 6, wherein the notched laminate is a single-wafer. The notched laminate further contains a base film and a release film as the resin film layer.
The method for producing a perforated laminate according to any one of claims 1 to 7, wherein the base film, the bonding layer, and the release film are laminated in this order. The notched laminate contains a linear polarizer and a protective film as the resin film layer.
The method for producing a perforated laminate according to any one of claims 1 to 8, wherein the protective film is laminated on one side or both sides of the linear polarizer. The method for producing a perforated laminate according to any one of claims 1 to 9, wherein the bonding layer is an adhesive layer or an adhesive layer. A device for manufacturing a perforated laminate having holes penetrating in the stacking direction.
A notched laminate having one or more resin film layers and one or more laminating layers laminated and having a notch penetrating in the laminating direction and a cutout piece formed by the notch is continuously or. A transport unit for intermittent transport and
A hole forming portion for forming the hole by removing the cutout piece from the notched laminate that is continuously or intermittently conveyed by the conveying portion is provided.
The hole forming portion is at least one of a pressing portion for pressing the cutout piece with a pressing member, a suction portion for sucking the cutout piece, and a spraying portion for spraying a fluid on the cutout piece. Including
An apparatus for manufacturing a perforated laminate including an optical layer as the resin film layer. The perforated laminate according to claim 11, further provided with a mechanism for obtaining the notched laminate from the material laminate in which the one or more resin film layers and the one or more bonded layers are laminated. Manufacturing equipment. The apparatus for producing a perforated laminate according to claim 12, wherein the mechanism for obtaining the notched laminate from the material laminate includes a punching blade for forming the notch in the stacking direction of the material laminate. The hole according to any one of claims 11 to 13, wherein the transport unit is provided with at least one of a transport belt, a transport roller, and a rotary table for transporting the notched laminate. Manufacturing equipment for open laminates. The apparatus for manufacturing a perforated laminate according to any one of claims 11 to 14, wherein the transport unit can transport the perforated laminate immediately after removing the cutout piece.

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