JP6725249B2 - Method for manufacturing optical member with resin film - Google Patents

Description

The present invention relates to a method for producing an optical member with a resin film, which comprises laminating a resin film on an optical member via an adhesive layer, and also relates to a resin film with an adhesive layer.

Various optical members typified by a polarizing plate may be used by being attached to other members via an adhesive layer (for example, Patent Document 1). Therefore, the optical member may be marketed in the form of a pressure-sensitive adhesive layer-attached optical member in which a pressure-sensitive adhesive layer is provided in advance on one surface thereof. A peelable separate film (also referred to as “release film”) for protecting the pressure-sensitive adhesive layer is generally temporarily attached to the outer surface of the pressure-sensitive adhesive layer.

JP, 2008-275722, A

Good adhesiveness to the optical member is required for the pressure-sensitive adhesive layer used for bonding the optical member to another member. When the adhesiveness of the pressure-sensitive adhesive layer used for bonding the optical member to another member is not sufficient, the durability of the composite member obtained by bonding the optical member and the other member via the pressure-sensitive adhesive layer Reliability and reliability may be reduced.

An object of the present invention is an optical member with a resin film, which is obtained by laminating a resin film to an optical member via an adhesive layer, such as an optical member with an adhesive layer provided with the above-mentioned separate film. An object of the present invention is to provide a method for producing an optical member with a resin film, which has good adhesion between the agent layer and the optical member. Another object of the present invention is to provide a pressure-sensitive adhesive layer-carrying resin film having good adhesion to an optical member.

The present invention provides the following method for producing an optical member with a resin film.
[1] A coating step of coating a pressure-sensitive adhesive composition on a long resin film to form a coating layer,
A drying step of obtaining a resin film having a pressure-sensitive adhesive layer by introducing the drying step into a drying means while continuously transporting the film after the coating step, and drying the coating layer,
While continuously transporting the resin film having the pressure-sensitive adhesive layer, a groove groove forming step of pressing the uneven mold on the outer surface of the pressure-sensitive adhesive layer,
While continuously transporting the resin film after the groove groove forming step, a long optical member is laminated on the outer surface of the pressure-sensitive adhesive layer, and a laminating step of pressing the laminated body from above and below,
A method for producing an optical member with a resin film, comprising:

[2] The production method according to [1], further including a curing step of winding the optical member with a resin film obtained by the bonding step into a roll and curing the pressure-sensitive adhesive layer in a roll state.

[3] The production method according to [1] or [2], wherein in the groove-forming step, the temperature of the pressure-sensitive adhesive layer in contact with the uneven mold is lower than the glass transition temperature of the pressure-sensitive adhesive composition.

[4] The groove groove forming step is a step of forming a groove groove from the edge portion of the pressure-sensitive adhesive layer to the first end region of the width L ₁ .
The width L ₁ of the first end region satisfies the relationship of the following formula (1) when the length of the pressure-sensitive adhesive layer in the width direction is L _0, and is manufactured according to any one of [1] to [3]. Method.

[5] After the laminating step, the method further includes a cutting step of cutting the second end region having a width L ₂ from the end edge of the pressure-sensitive adhesive layer of the optical member with a resin film,
The manufacturing method according to [4], wherein the width L ₂ of the second end region satisfies the relationship of the following expression (2).

[6] The method according to any one of [1] to [5], further including a surface activation step of performing energy irradiation on a bonding surface of the optical member with the pressure-sensitive adhesive layer before the bonding step. Production method.

[7] The manufacturing method according to any one of [1] to [6], wherein the surface of the optical member that is in contact with the outer surface of the pressure-sensitive adhesive layer contains a (meth)acrylic resin.

[8] The manufacturing method according to any one of [1] to [7], wherein the optical member is a polarizing plate.
[9] The production method according to any one of [1] to [8], wherein the resin film is a separate film.

[10] A resin film and an adhesive layer formed on the resin film,
The pressure-sensitive adhesive layer-attached resin film, wherein the pressure-sensitive adhesive layer has a plurality of groove grooves on the outer surface thereof that reach the edge portions of the pressure-sensitive adhesive layer.

[11] The recessed groove is formed in a first end region having a width L ₁ from an end edge of the pressure-sensitive adhesive layer,
The width L ₁ of the first end region is the resin film with a pressure-sensitive adhesive layer according to [10], which satisfies the relationship of the following formula (1) when the length in the width direction of the pressure-sensitive adhesive layer is L ₀ .

According to the manufacturing method of the present invention, it is possible to provide an optical member with a resin film, which has good adhesion between the pressure-sensitive adhesive layer and the optical member. Further, according to the present invention, it is possible to provide a resin film with a pressure-sensitive adhesive layer, which has good adhesion to an optical member.

It is a schematic diagram showing an example of a manufacturing method and a manufacturing device used for the manufacturing method of an optical member with a resin film concerning the present invention. It is a schematic sectional drawing which shows an example of the resin film which has a coating layer (before drying). It is a schematic sectional drawing which shows an example of the resin film which has an adhesive layer (before forming a groove groove). It is a schematic sectional drawing which shows an example of the resin film with an adhesive layer. It is a schematic sectional drawing which shows an example of the optical member with a resin film. It is a top view which shows an example of the groove pattern in an adhesive layer.

The method for producing an optical member with a resin film according to the present invention includes the following steps:
A coating step of coating a pressure-sensitive adhesive composition on a long resin film to form a coating layer;
A drying step of obtaining a resin film having a pressure-sensitive adhesive layer by introducing the film after the coating step into a drying means while continuously conveying the film to dry the coating layer;
While continuously transporting the resin film having the pressure-sensitive adhesive layer, a groove groove forming treatment step of pressing an uneven mold on the outer surface of the pressure-sensitive adhesive layer; and continuously conveying the resin film after the groove groove forming step. However, a step of laminating a long optical member on the outer surface of the pressure-sensitive adhesive layer and pressing the laminated body from above and below;
including. The method for producing an optical member with a resin film according to the present invention may further include steps other than the above. Hereinafter, each step will be described with reference to FIGS. Moreover, below, the resin film which has a pressure sensitive adhesive layer which is a film intermediate stuck to an optical member is also called "a pressure sensitive adhesive layer-attached resin film".

[Coating process]
This step is a step of forming the coating layer 11 by coating the pressure-sensitive adhesive composition on the resin film 10 with the coating device 50 to obtain the resin film 15 having the coating layer 11 (FIG. 1). And FIG. 2).

(1) Resin Film The resin film 10 is usually a thermoplastic resin film, preferably a translucent (more preferably optically transparent) thermoplastic resin film. Specific examples of the thermoplastic resin include polyolefin resins such as chain polyolefin resins (polyethylene resin, polypropylene resin, etc.) and cyclic polyolefin resins (norbornene resin, etc.); polyvinyl fluoride, polyvinylidene fluoride, polyvinyl fluoride. Fluorinated polyolefin resin such as ethylene chloride; polyester resin such as polyethylene terephthalate resin and polyethylene naphthalate resin; (meth)acrylic resin such as methyl methacrylate resin; triacetyl cellulose [TAC], Cellulose-based resin such as cellulose acetate-based resin such as diacetyl cellulose; polycarbonate-based resin; polyvinyl alcohol-based resin; polyvinyl acetate-based resin; polyarylate-based resin; polyimide-based resin; polystyrene-based resin; polyamide-based resin; polyether Sulfone resins; polysulfone resins; and mixtures and copolymers thereof. In addition, in this specification, "(meth)acryl" means acryl and/or methacryl, and "(meth)" when referring to (meth)acrylate and the like has the same meaning.

The thickness of the resin film 10 is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The resin film with a pressure-sensitive adhesive layer, which is a film intermediate produced in the production method of the present invention, can be, for example, a separate film with a pressure-sensitive adhesive layer. In this case, the resin film 10 can be a separate film in which the surface on which the pressure-sensitive adhesive layer is laminated is subjected to a release treatment. Examples of the mold release treatment are silicone treatment, long-chain alkyl treatment, fluorine treatment and the like.

Further, the resin film 10 may be an optical member other than the separate film. The resin film 10, which is an optical member other than the separate film, may have a single-layer structure or a multi-layer structure. Specific examples of the resin film 10 which is an optical member include a polarizing film; an optical functional film such as an optical compensation film (retardation film or the like), a light diffusion film (sheet), a reflection film (sheet); a protective film for a polarizing film. Including a polarizing plate and the like.

(2) Adhesive composition The adhesive composition applied to the resin film 10 is, for example, a (meth)acrylic adhesive composition, a urethane adhesive composition, a silicone adhesive composition, a polyester adhesive composition. Examples thereof include a pressure-sensitive adhesive composition, a polyamide-based pressure-sensitive adhesive composition, a polyether-based pressure-sensitive adhesive composition, a fluorine-based pressure-sensitive adhesive composition, and a rubber-based pressure-sensitive adhesive composition. Among them, a (meth)acrylic pressure-sensitive adhesive having a (meth)acrylic resin as a base polymer is preferably used from the viewpoints of transparency, adhesive strength, reliability, reworkability, and the like.

(2-1) Base Polymer Specific examples of the (meth)acrylic resin that can be preferably used as the base polymer of the (meth)acrylic pressure-sensitive adhesive composition are represented by the following formula (I):

It is a (meth)acrylic resin (A-1) which is a polymer having (50% by weight or more) a structural unit derived from a (meth)acrylic acid ester as a main component.

In the above formula (I), R ¹ represents a hydrogen atom or a methyl group, R ² is an alkyl group having 1 to 14 carbon atoms which may be substituted with an alkoxy group having 1 to 10 carbon atoms, or 1 to 1 carbon atoms. It represents an aralkyl group having 7 to 21 carbon atoms which may be substituted with 10 alkoxy groups. R ² is preferably an alkyl group having 1 to 14 carbon atoms which may be substituted with an alkoxy group having 1 to 10 carbon atoms.

Specific examples of the (meth)acrylic acid ester represented by the formula (I) include methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, n-octyl acrylate, and lauryl acrylate. Chain-like alkyl acrylates; branched alkyl acrylates such as isobutyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate; methyl methacrylate, ethyl methacrylate, propyl methacrylate, n-butyl methacrylate , Linear alkyl methacrylates such as n-octyl methacrylate and lauryl methacrylate; isobutyl methacrylate, 2-ethylhexyl methacrylate, branched alkyl methacrylates such as isooctyl methacrylate, and the like.

When R ² is an alkyl group substituted with an alkoxy group, that is, when R ² is an alkoxyalkyl group, specific examples of the (meth)acrylic acid ester represented by the formula (I) include acrylic acid 2- Includes methoxyethyl, ethoxymethyl acrylate, 2-methoxyethyl methacrylate, ethoxymethyl methacrylate and the like. Specific examples of the (meth)acrylic acid ester represented by the formula (I) in the case where R ² is an aralkyl group having 7 to 21 carbon atoms include benzyl acrylate and benzyl methacrylate.

The (meth)acrylic acid ester represented by the formula (I) may be used alone or in combination of two or more. Among them, the (meth)acrylic acid ester preferably contains n-butyl acrylate. The (meth)acrylic resin (A-1) preferably contains n-butyl acrylate in an amount of 50% by weight or more based on all monomers constituting the (meth)acrylic resin. Of course, in addition to n-butyl acrylate, other (meth)acrylic acid ester represented by the formula (I) can be used together.

The (meth)acrylic resin (A-1) usually comprises a (meth)acrylic ester of the above formula (I) and at least one other monomer represented by a monomer having a polar functional group. It is a copolymer. The monomer having a polar functional group is preferably a (meth)acrylic acid compound having a polar functional group. Examples of polar functional groups include free carboxyl groups, hydroxyl groups, amino groups, and heterocyclic groups such as epoxy groups.

Specific examples of the monomer having a polar functional group include monomers having a free carboxyl group such as (meth)acrylic acid and β-carboxyethyl (meth)acrylate; 2-hydroxyethyl (meth)acrylate, ( 3-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-(2-hydroxyethoxy)ethyl (meth)acrylate, 2- or 3-chloro-2-hydroxypropyl (meth)acrylate A monomer having a hydroxyl group such as diethylene glycol mono(meth)acrylate; acryloylmorpholine, vinylcaprolactam, N-vinyl-2-pyrrolidone, vinylpyridine, tetrahydrofurfuryl(meth)acrylate, caprolactone-modified tetrahydrofurfuryl acrylate, 3 , 4-epoxycyclohexylmethyl (meth)acrylate, glycidyl (meth)acrylate, a monomer having a heterocyclic group such as 2,5-dihydrofuran; aminoethyl (meth)acrylate, N,N-dimethylaminoethyl ( For example, a monomer having an amino group different from a heterocycle such as (meth)acrylate and dimethylaminopropyl (meth)acrylate is included. As the monomer having a polar functional group, only one kind may be used alone, or two or more kinds may be used in combination.

Among the above, from the viewpoint of reactivity of the (meth)acrylic resin (A-1), a hydroxyl group is used as one of the polar functional group-containing monomers constituting the (meth)acrylic resin (A-1). It is preferable to use a monomer that has. In addition to the monomer having a hydroxyl group, it is also effective to use a monomer having another polar functional group, for example, a monomer having a free carboxyl group in combination.

The (meth)acrylic resin (A-1) is a monomer having one olefinic double bond and at least one aromatic ring in the molecule (provided that it is a monomer represented by the above formula (I). A monomer and a structural unit derived from the monomer having the polar functional group are excluded). A preferable example is a (meth)acrylic acid compound having an aromatic ring. A preferred example of the (meth)acrylic acid compound having an aromatic ring is represented by the following formula (II):

A (meth)acrylic acid ester having an aryloxyalkyl group such as a phenoxyethyl group-containing (meth)acrylic acid ester represented by

In the above formula (II), R ³ represents a hydrogen atom or a methyl group, n represents an integer of 1 to 8, and R ⁴ represents a hydrogen atom, an alkyl group, an aralkyl group or an aryl group. When R ⁴ is an alkyl group, it can have about 1 to 9 carbon atoms, when it is an aralkyl group, it has about 7 to 11 carbon atoms, and when it is an aryl group, it has 6 carbon atoms. It can be about 10 to 10.

Examples of the alkyl group having 1 to 9 carbon atoms which constitutes R ⁴ in the formula (II) include methyl, butyl and nonyl, and examples of the aralkyl group having 7 to 11 carbon atoms include benzyl, phenethyl and naphthylmethyl. Examples of the aryl group having 6 to 10 carbon atoms include phenyl, tolyl, naphthyl and the like.

Specific examples of the phenoxyethyl group-containing (meth)acrylic acid ester represented by the formula (II) include 2-phenoxyethyl (meth)acrylate, 2-(2-phenoxyethoxy)ethyl (meth)acrylate, and ethylene oxide. (Meth)acrylic acid ester of modified nonylphenol, 2-(o-phenylphenoxy)ethyl (meth)acrylate and the like are included. The phenoxyethyl group-containing (meth)acrylic acid ester may be used alone or in combination of two or more. Among them, the phenoxyethyl group-containing (meth)acrylic acid ester includes 2-phenoxyethyl (meth)acrylate, 2-(o-phenylphenoxy)ethyl (meth)acrylate and/or 2-(2)(meth)acrylic acid. -Phenoxyethoxy)ethyl is preferred.

The (meth)acrylic resin (A-1) has a structural unit derived from the (meth)acrylic ester represented by the above formula (I), preferably 60 to 99. 9% by weight, more preferably 80 to 99.6% by weight, and the structural unit derived from a monomer having a polar functional group is preferably 0.1 to 20% by weight, more preferably 0.1. 4 to 10% by weight, preferably 0 to 40% by weight of a structural unit derived from a monomer having one olefinic double bond and at least one aromatic ring in the molecule, More preferably, it can be contained in a proportion of 6 to 12% by weight.

The (meth)acrylic resin (A-1) includes a (meth)acrylic ester represented by the formula (I), a monomer having a polar functional group, and one olefinic double bond in the molecule. A structural unit derived from a monomer other than the monomer having at least one aromatic ring (hereinafter, also referred to as “other monomer”) may be included. Specific examples of other monomers are derived from a structural unit derived from a (meth)acrylic acid ester having an alicyclic structure in the molecule, a structural unit derived from a styrene-based monomer, and a vinyl-based monomer. It includes a structural unit, a structural unit derived from a monomer having a plurality of (meth)acryloyl groups in the molecule, a structural unit derived from a (meth)acrylamide monomer, and the like. The other monomers may be used alone or in combination of two or more.

The alicyclic structure has usually 5 or more carbon atoms, preferably about 5 to 7 carbon atoms. Specific examples of the (meth)acrylic acid ester having an alicyclic structure include isobornyl (meth)acrylate, cyclohexyl (meth)acrylate, dicyclopentanyl (meth)acrylate, cyclododecyl (meth)acrylate, ( Examples include methylcyclohexyl (meth)acrylate, trimethylcyclohexyl (meth)acrylate, tert-butylcyclohexyl (meth)acrylate, cyclohexylphenyl (meth)acrylate, and cyclohexyl α-ethoxyacrylate.

Specific examples of the styrene-based monomer are styrene; alkylstyrene such as methylstyrene, dimethylstyrene, trimethylstyrene, ethylstyrene, diethylstyrene, triethylstyrene, propylstyrene, butylstyrene, hexylstyrene, heptylstyrene and octylstyrene; Included are halogenated styrenes such as fluorostyrene, chlorostyrene, bromostyrene, dibromostyrene, iodostyrene; nitrostyrene, acetylstyrene, methoxystyrene, divinylbenzene and the like.

Specific examples of the vinyl-based monomer include fatty acid vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate and vinyl laurate; vinyl halides such as vinyl chloride and vinyl bromide; Vinylidene halides such as vinylidene chloride; nitrogen-containing aromatic vinyls such as vinylpyridine, vinylpyrrolidone and vinylcarbazole; conjugated diene monomers such as butadiene, isoprene and chloroprene; acrylonitrile and methacrylonitrile.

Specific examples of the monomer having a plurality of (meth)acryloyl groups in the molecule include 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, and 1,9-nonanediol. Two (meth) in the molecule such as di(meth)acrylate, ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate Monomers having an acryloyl group; including monomers having three (meth)acryloyl groups in the molecule such as trimethylolpropane tri(meth)acrylate.

Specific examples of the (meth)acrylamide compound include N-methylol(meth)acrylamide, N-(2-hydroxyethyl)(meth)acrylamide, N-(3-hydroxypropyl)(meth)acrylamide, N-(4-hydroxy). Butyl)(meth)acrylamide, N-(5-hydroxypentyl)(meth)acrylamide, N-(6-hydroxyhexyl)(meth)acrylamide, N,N-dimethyl(meth)acrylamide, N,N-diethyl(meth) ) Acrylamide, N-isopropyl(meth)acrylamide, N-(3-dimethylaminopropyl)(meth)acrylamide, N-(1,1-dimethyl-3-oxobutyl)(meth)acrylamide, N-[2-(2 -Oxo-1-imidazolidinyl)ethyl](meth)acrylamide, 2-acryloylamino-2-methyl-1-propanesulfonic acid, N-(methoxymethyl)acrylamide, N-(ethoxymethyl)(meth)acrylamide, N- (Propoxymethyl)(meth)acrylamide, N-(1-methylethoxymethyl)(meth)acrylamide, N-(1-methylpropoxymethyl)(meth)acrylamide, N-(2-methylpropoxymethyl)(meth)acrylamide [Alias: N-(isobutoxymethyl)(meth)acrylamide], N-(butoxymethyl)(meth)acrylamide, N-(1,1-dimethylethoxymethyl)(meth)acrylamide, N-(2-methoxyethyl) )(Meth)acrylamide, N-(2-ethoxyethyl)(meth)acrylamide, N-(2-propoxyethyl)(meth)acrylamide, N-[2-(1-methylethoxy)ethyl](meth)acrylamide, N-[2-(1-methylpropoxy)ethyl](meth)acrylamide, N-[2-(2-methylpropoxy)ethyl](meth)acrylamide [alias: N-(2-isobutoxyethyl)(meth)] Acrylamide], N-(2-butoxyethyl)(meth)acrylamide, N-[2-(1,1-dimethylethoxy)ethyl](meth)acrylamide and the like.

The (meth)acrylic resin (A-1) contains the other monomer in an amount of usually 0 to 20% by weight, preferably 0 to 10% by weight, based on the total solid content.

From the viewpoint of adhesiveness between the pressure-sensitive adhesive layer and the optical member, the (meth)acrylic resin (A-1) has a weight average molecular weight (Mw) of 500,000 in terms of standard polystyrene measured by gel permeation chromatography (GPC). It is preferably at least 600,000, and more preferably at least 600,000. The Mw of the (meth)acrylic resin (A-1) is usually 1.7 million or less.

The base polymer of the (meth)acrylic pressure-sensitive adhesive composition may include two or more types of (meth)acrylic resin (A-1). The base polymer is a structural unit derived from a (meth)acrylic resin (A-1) and a different (meth)acrylic resin, for example, a (meth)acrylic ester of the formula (I). And a structural unit derived from a (meth)acrylic resin (A-2) having no and a polar functional group or a (meth)acrylic ester represented by the above formula (I) as a main component, and Mw Can be included in the range of 50,000 to 120,000 (meth)acrylic resin (A-3).

(2-2) Crosslinking agent The pressure-sensitive adhesive composition may further contain a crosslinking agent (B). The crosslinking agent is a compound that reacts with a structural unit derived from a monomer having a polar functional group in a base polymer such as a (meth)acrylic resin to crosslink the base polymer. Specific examples include isocyanate compounds, epoxy compounds, aziridine compounds, metal chelate compounds and the like. Among these, the isocyanate compound, the epoxy compound, and the aziridine compound have at least two functional groups capable of reacting with the polar functional group in the base polymer in the molecule. As the crosslinking agent (B), one type may be used alone, or two or more types may be used in combination.

The isocyanate compound is a compound having at least two isocyanato groups (-NCO) in the molecule. Specific examples of the isocyanate compound include tolylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, diphenylmethane diisocyanate, hydrogenated diphenylmethane diisocyanate, naphthalene diisocyanate, and triphenylmethane triisocyanate. Further, an adduct body obtained by reacting these isocyanate compounds with a polyol such as glycerol or trimethylolpropane, or a dimer or trimer of an isocyanate compound can also be the crosslinking agent (B).

The epoxy compound is a compound having at least two epoxy groups in the molecule. Specific examples of the epoxy compound include bisphenol A type epoxy resin, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerin diglycidyl ether, glycerin triglycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane. Including triglycidyl ether, N,N-diglycidylaniline, N,N,N',N'-tetraglycidyl-m-xylenediamine, 1,3-bis(N,N'-diglycidylaminomethyl)cyclohexane ..

The aziridine compound is a compound having at least two 3-membered ring skeletons each having one nitrogen atom and two carbon atoms, which is also called ethyleneimine, in the molecule. Specific examples of the aziridine compound include diphenylmethane-4,4′-bis(1-aziridinecarboxamide), toluene-2,4-bis(1-aziridinecarboxamide), triethylenemelamine, isophthaloylbis-1-(2. -Methylaziridine), tris-1-aziridinylphosphine oxide, hexamethylene-1,6-bis(1-aziridinecarboxamide), trimethylolpropane-tris-β-aziridinylpropionate, tetramethylolmethane-tris -Β-aziridinyl propionate and the like are included.

Specific examples of the metal chelate compound include a compound in which acetylacetone or ethyl acetoacetate is coordinated to a polyvalent metal such as aluminum, iron, copper, zinc, tin, titanium, nickel, antimony, magnesium, vanadium, chromium and zirconium. Including.

The cross-linking agent (B) is in a proportion of usually 0.05 to 5 parts by weight, preferably 0.1 to 5 parts by weight, based on 100 parts by weight of the solid content of the base polymer (when two or more kinds are used, the total amount thereof). Contained in. When the content of the crosslinking agent (B) is 0.05 parts by weight or more, the durability of the pressure-sensitive adhesive layer tends to be improved.

(2-3) Ionic Compound The pressure-sensitive adhesive composition may further contain an ionic compound (C) as an antistatic agent. The ionic compound (C) is, for example, a compound having an inorganic cation or an organic cation and an inorganic anion or an organic anion.

Examples of the inorganic cations include alkali metal ions such as lithium cations [Li ⁺ ], sodium cations [Na ⁺ ] and potassium cations [K ⁺ ], beryllium cations [Be ²⁺ ], magnesium cations [Mg ²⁺ ]. , Alkaline earth metal ions such as calcium cation [Ca ²⁺ ] and the like.

Examples of the organic cation include an imidazolium cation, a pyridinium cation, a pyrrolidinium cation, an ammonium cation, a sulfonium cation, and a phosphonium cation.

Among the above-mentioned cation components, the organic cation component has excellent compatibility in the pressure-sensitive adhesive composition. Among the organic cation components, the pyridinium cation and the imidazolium cation are advantageous in terms of antistatic property.

Examples of the inorganic anion include chloride anion [Cl ^- ], bromide anion [Br ^- ], iodide anion [I ^- ], tetrachloroaluminate anion [AlCl ₄ ^- ], heptachlorodialuminate anion [Al ₂ Cl ₇ ^- ], tetrafluoroborate anion [BF ₄ ^- ], hexafluorophosphate anion [PF ₆ ^- ], perchlorate anion [ClO ₄ ^- ], nitrate anion [NO ₃ ^- ], hexafluoroarsenate anion [AsF ₆ ^- ], hexafluoroantimonate anion [SbF ₆ ^- ], hexafluoroniobate anion [NbF ₆ ^- ], hexafluorotantalate anion [TaF ₆ ^- ], dicyanamide anion [(CN) ₂ N ^- ], and the like. To be

Examples of the organic anion include acetate anion [CH ₃ COO ⁻ ], trifluoroacetate anion [CF ₃ COO ⁻ ], methanesulfonate anion [CH ₃ SO ₃ ⁻ ], trifluoromethanesulfonate anion [CF ₃ SO ₃ ⁻ ], p- toluenesulfonate anion _{[p-CH 3 C 6 H 4} SO 3 - ], bis (fluorosulfonyl) imide anion [(FSO _{2) 2} N ^-], bis (trifluoromethanesulfonyl) imide anion [(CF ₃ SO ₂ ) ₂ N ^-], tris (trifluoromethanesulfonyl) meth acetonide anion _{[(CF 3 SO 2) 3 C} - ], dimethyl phosphinate anion [(CH _{3) 2} POO ^-], (poly) hydrofluoroether fluoride anion [ F(HF) _n ^- ] (n is about 1 to 3), thiocyanate anion [SCN ^- ], perfluorobutane sulfonate anion [C ₄ F ₉ SO ₃ ^- ], bis(pentafluoroethanesulfonyl)imide anion [(C ₂ F ₅ SO ₂ ) ₂ N ⁻ ], perfluorobutanoate anion [C ₃ F ₇ COO ⁻ ], (trifluoromethanesulfonyl)(trifluoromethanecarbonyl)imide anion [(CF ₃ SO ₂ )(CF ₃ CO) N ^-], perfluoro-1,3-disulfonate anion ^{_{[- O 3 S (CF 2)}} 3 SO 3 - ], carbonate anions [CO ₃ ^2-], and the like. Among the above-mentioned anion components, the anion component containing a fluorine atom is advantageous in terms of antistatic property.

Specific examples of the ionic compound (C) can be appropriately selected from the combination of the above cation component and anion component. When the examples of the ionic compound (C) having an organic cation are listed according to the structure of the organic cation, the following can be mentioned.

Pyridinium salt:
N-hexylpyridinium hexafluorophosphate,
N-octylpyridinium hexafluorophosphate,
N-octyl-4-methylpyridinium hexafluorophosphate,
N-butyl-4-methylrupyridinium hexafluorophosphate,
Tetrabutylammonium hexafluorophosphate,
N-decylpyridinium bis(fluorosulfonyl)imide,
N-dodecylpyridinium bis(fluorosulfonyl)imide,
N-tetradecylpyridinium bis(fluorosulfonyl)imide,
N-hexadecylpyridinium bis(fluorosulfonyl)imide,
N-dodecyl-4-methylpyridinium bis(fluorosulfonyl)imide,
N-tetradecyl-4-methylpyridinium bis(fluorosulfonyl)imide,
N-hexadecyl-4-methylpyridinium bis(fluorosulfonyl)imide,
N-benzyl-2-methylpyridinium bis(fluorosulfonyl)imide,
N-benzyl-4-methylpyridinium bis(fluorosulfonyl)imide N-hexylpyridinium bis(trifluoromethanesulfonyl)imide,
N-octylpyridinium bis(trifluoromethanesulfonyl)imide,
N-octyl-4-methylpyridinium bis(trifluoromethanesulfonyl)imide,
N-butyl-4-methyl rupyridinium bis(trifluoromethanesulfonyl)imide.

Imidazolium salt:
1-ethyl-3-methylimidazolium hexafluorophosphate,
1-ethyl-3-methylimidazolium p-toluenesulfonate,
1-ethyl-3-methylimidazolium bis(fluorosulfonyl)imide 1-ethyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imide 1-butyl-3-methylimidazolium methanesulfonate,
1-Butyl-3-methylimidazolium bis(fluorosulfonyl)imide.

Pyrrolidinium salt:
N-butyl-N-methylpyrrolidinium hexafluorophosphate,
N-butyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide N-butyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide.

Quaternary ammonium salt:
Tetrabutylammonium p-toluenesulfonate,
(2-hydroxyethyl)trimethylammonium bis(trifluoromethanesulfonyl)imide,
(2-Hydroxyethyl)trimethylammonium dimethylphosphinate.

Examples of the ionic compound (C) having an inorganic cation include the following.
Lithium bromide,
Lithium iodide,
Lithium tetrafluoroborate,
Lithium hexafluorophosphate,
Lithium thiocyanate,
Lithium perchlorate,
Lithium trifluoromethanesulfonate,
Lithium bis(fluorosulfonyl)imide lithium bis(trifluoromethanesulfonyl)imide,
Lithium bis(pentafluoroethanesulfonyl)imide,
Lithium tris(trifluoromethanesulfonyl)methanide,
Lithium p-toluenesulfonate,
Sodium hexafluorophosphate,
Sodium bis(fluorosulfonyl)imide,
Sodium bis(trifluoromethanesulfonyl)imide,
Sodium p-toluenesulfonate,
Potassium hexafluorophosphate,
Potassium bis(fluorosulfonyl)imide,
Potassium bis(trifluoromethanesulfonyl)imide,
Potassium p-toluene sulfonate.

The ionic compound (C) preferably has a melting point of 30° C. or higher, more preferably 35° C. or higher, from the viewpoint of antistatic durability. On the other hand, the ionic compound (C) preferably has a melting point of 90° C. or lower, more preferably 70° C. or lower, and further preferably less than 50° C. from the viewpoint of compatibility with the base polymer.

The ionic compound (C) is preferably 0.2 to 8 parts by weight, more preferably 0.2 to 5 parts by weight, based on 100 parts by weight of the solid content of the base polymer (when two or more kinds are used, the total thereof). It is mixed in the ratio of parts. The content of the ionic compound (C) of 0.2 parts by weight or more is advantageous for improving the antistatic property, and the content of 8 parts by weight or less is advantageous for improving the durability of the pressure-sensitive adhesive layer. is there.

(2-4) Silane compound The pressure-sensitive adhesive composition improves the adhesiveness between the pressure-sensitive adhesive layer and the glass when the pressure-sensitive adhesive layer of the resin film with the pressure-sensitive adhesive layer is attached to an optical member made of glass. Can further contain a silane compound (D).

Examples of the silane compound (D) include vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, and N-(2. -Aminoethyl)-3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl) ) Ethyltrimethoxysilane, 3-chloropropylmethyldimethoxysilane, 3-chloropropyltrimethoxysilane, 3-methacryloyloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3 -Glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethoxymethylsilane, 3-glycidoxypropylethoxydimethylsilane and the like. You may use 2 or more types of silane compounds.

The silane compound (D) may be of a silicone oligomer type. Examples of the silicone oligomer include the following.

3-mercaptopropyltrimethoxysilane-tetramethoxysilane copolymer,
3-mercaptopropyltrimethoxysilane-tetraethoxysilane copolymer,
3-mercaptopropyltriethoxysilane-tetramethoxysilane copolymer,
Copolymers containing mercaptopropyl groups, such as 3-mercaptopropyltriethoxysilane-tetraethoxysilane copolymers;
Mercaptomethyltrimethoxysilane-tetramethoxysilane copolymer,
Mercaptomethyltrimethoxysilane-tetraethoxysilane copolymer,
Mercaptomethyltriethoxysilane-tetramethoxysilane copolymer,
Copolymers containing mercaptomethyl groups such as mercaptomethyltriethoxysilane-tetraethoxysilane copolymers;
3-glydidoxypropyltrimethoxysilane-tetramethoxysilane copolymer,
3-glycidoxypropyltrimethoxysilane-tetraethoxysilane copolymer,
3-glycidoxypropyltriethoxysilane-tetramethoxysilane copolymer,
3-glycidoxypropyltriethoxysilane-tetraethoxysilane copolymer,
3-glydidoxypropylmethyldimethoxysilane-tetramethoxysilane copolymer,
3-glycidoxypropylmethyldimethoxysilane-tetraethoxysilane copolymer,
3-glydidoxypropylmethyldiethoxysilane-tetramethoxysilane copolymer,
Copolymers containing 3-glycidoxypropyl groups such as 3-glydidoxypropylmethyldiethoxysilane-tetraethoxysilane copolymers;
3-methacryloyloxypropyltrimethoxysilane-tetramethoxysilane copolymer,
3-methacryloyloxypropyltrimethoxysilane-tetraethoxysilane copolymer,
3-methacryloyloxypropyltriethoxysilane-tetramethoxysilane copolymer,
3-methacryloyloxypropyltriethoxysilane-tetraethoxysilane copolymer,
3-methacryloyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer,
3-methacryloyloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer,
3-methacryloyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer,
Copolymers containing methacryloyloxypropyl groups such as 3-methacryloyloxypropyl methyldiethoxysilane-tetraethoxysilane copolymers;
3-acryloyloxypropyltrimethoxysilane-tetramethoxysilane copolymer,
3-acryloyloxypropyltrimethoxysilane-tetraethoxysilane copolymer,
3-acryloyloxypropyltriethoxysilane-tetramethoxysilane copolymer,
3-acryloyloxypropyltriethoxysilane-tetraethoxysilane copolymer,
3-acryloyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer,
3-acryloyloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer,
3-acryloyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer,
Acryloyloxypropyl group-containing copolymers such as 3-acryloyloxypropylmethyldiethoxysilane-tetraethoxysilane copolymers;
Vinyltrimethoxysilane-tetramethoxysilane copolymer,
Vinyltrimethoxysilane-tetraethoxysilane copolymer,
Vinyltriethoxysilane-tetramethoxysilane copolymer,
Vinyltriethoxysilane-tetraethoxysilane copolymer,
Vinylmethyldimethoxysilane-tetramethoxysilane copolymer,
Vinylmethyldimethoxysilane-tetraethoxysilane copolymer,
Vinylmethyldiethoxysilane-tetramethoxysilane copolymer,
Copolymers containing vinyl groups such as vinylmethyldiethoxysilane-tetraethoxysilane copolymers;
3-aminopropyltrimethoxysilane-tetramethoxysilane copolymer,
3-aminopropyltrimethoxysilane-tetraethoxysilane copolymer,
3-aminopropyltriethoxysilane-tetramethoxysilane copolymer,
3-aminopropyltriethoxysilane-tetraethoxysilane copolymer,
3-aminopropylmethyldimethoxysilane-tetramethoxysilane copolymer,
3-aminopropylmethyldimethoxysilane-tetraethoxysilane copolymer,
3-aminopropylmethyldiethoxysilane-tetramethoxysilane copolymer,
Copolymers containing amino groups, such as 3-aminopropylmethyldiethoxysilane-tetraethoxysilane copolymers.

The silane compound (D) is in a proportion of usually 0.01 to 10 parts by weight, preferably 0.05 to 5 parts by weight, based on 100 parts by weight of the solid content of the base polymer (when two or more kinds are used, the total amount thereof). Contained in. When the content of the silane compound (D) is 0.01 parts by weight or more, the effect of improving the adhesiveness between the pressure-sensitive adhesive layer and the glass can be easily obtained. When the content is 10 parts by weight or less, bleed-out of the silane compound (D) from the pressure-sensitive adhesive layer can be suppressed.

(2-5) Other Components The pressure-sensitive adhesive composition contains additives such as a crosslinking catalyst, a weather resistance stabilizer, a tackifier, a plasticizer, a softening agent, a dye, a pigment, an inorganic filler, light scattering particles, and a tackifier. Can be included. In addition, it is also possible to add a UV-curable compound to the pressure-sensitive adhesive composition, form a pressure-sensitive adhesive layer, and then irradiate it with ultraviolet rays to cure it, thereby forming a harder pressure-sensitive adhesive layer.

The pressure-sensitive adhesive composition is usually prepared as a pressure-sensitive adhesive liquid in which the ingredients are dissolved or dispersed by containing an organic solvent. The organic solvent is preferably selected according to the type of base polymer. Specific examples of organic solvents include aromatic hydrocarbons such as toluene and xylene; aliphatic hydrocarbons such as hexane, heptane, and pentane; ketones such as methyl ethyl ketone and methyl isobutyl ketone; ethyl acetate and butyl acetate. Including various esters. The concentration of the base polymer in the pressure-sensitive adhesive liquid is usually 3 to 20% by weight.

(3) Coating of pressure-sensitive adhesive composition The method for coating the pressure-sensitive adhesive composition on the resin film 10 using the coating device 50 is not particularly limited, and examples thereof include a slot die method, a reverse gravure coating method, and a microgravure method. The dipping method, the roll coating method, the flexographic printing method and the like can be used. The thickness of the coating layer 11 made of the pressure-sensitive adhesive composition is adjusted so that the thickness of the pressure-sensitive adhesive layer 13 of the resin film 25 with a pressure-sensitive adhesive layer falls within the range described later.

As shown in FIG. 1, in the coating step, more specifically, the pressure-sensitive adhesive composition is continuously coated on one surface of the long resin film 10 that is continuously unwound from the first feeding roll 1. Can be the step of doing. At this time, as shown in FIG. 1, the pressure-sensitive adhesive composition may be applied while the resin film 10 is wound around the application roll 60.

For the purpose of improving the adhesion between the resin film 10 and the pressure-sensitive adhesive layer, such as corona treatment, plasma treatment, ultraviolet irradiation treatment, flame (flame) treatment, saponification treatment, and primer layer formation treatment on the coated surface of the resin film 10. You may give surface treatment.

[Drying process]
This step is a step of drying the coating layer 11 of the resin film 15 having the coating layer 11 (solvent volatilization) to obtain the resin film 20 having the adhesive layer 12 (see FIGS. 1 and 3 ). The drying step can be performed by continuously conveying the long resin film 15 having the coating layer 11 obtained by the coating step and passing through (introducing) the drying means 70 with reference to FIG. 1.

The drying means 70 is not particularly limited as long as it can volatilize the solvent, and is, for example, a drying furnace (heating furnace). The drying oven may further include decompression means in addition to the heating means. For the drying conditions such as the amount of hot air supplied to the drying oven, the temperature and pressure in the drying oven, etc., consider the type of solvent contained in the coating layer 11 and the surface state after drying such as smoothness and dew condensation. Be set appropriately. The drying temperature (for example, the temperature in the drying oven) is usually 50 to 120°C, preferably 60 to 110°C.

[Recessed groove forming process]
This step is a step of forming a concave groove 14 on the outer surface of the adhesive layer 12 of the resin film 20 having the adhesive layer 12 by pressing a concave-convex mold on the surface (see FIGS. 1 and 4). Through this step, the resin film 25 with the pressure-sensitive adhesive layer, which has the pressure-sensitive adhesive layer 13 (after the groove is formed), which is an intermediate body of the optical member with the resin film, is continuously manufactured. The groove groove 14 formed in this groove groove forming step functions as a groove for removing air when the pressure-sensitive adhesive layer 13 is bonded to the optical member, and improves the adhesiveness of the pressure-sensitive adhesive layer 13 to the optical member. Can be improved. It is preferable that a plurality of the groove grooves 14 are formed so as to reach the end edge portion 13a of the pressure-sensitive adhesive layer 13, since the function as a groove for removing air is further enhanced. One of the features of the present invention is a groove forming step without subjecting the adhesive layer 12 obtained by drying the coating layer 11 to a curing step (without sufficiently proceeding the curing reaction of the adhesive). It is in the point of offering. This makes it possible to obtain a more remarkable adhesion improving effect.

The groove forming step can be carried out by continuously conveying the long resin film 20 having the pressure-sensitive adhesive layer 12 obtained through the drying step and passing it through the groove forming device 80. In the groove forming device 80, the concave-convex mold is pressed against the outer surface of the adhesive layer 12. At this time, the temperature of the pressure-sensitive adhesive layer 12 in contact with the uneven mold is preferably lower than the glass transition temperature of the pressure-sensitive adhesive layer composition. When the temperature is lower than the glass transition temperature, it is possible to prevent the pressure-sensitive adhesive composition from adhering to the surface of the uneven mold when the pressure-sensitive adhesive layer 12 is peeled from the uneven mold. The temperature of the pressure-sensitive adhesive layer 12 can be adjusted by controlling the ambient temperature in the groove forming device 80 or the surface temperature of the uneven mold. In order to prevent dew condensation on the surface of the pressure-sensitive adhesive layer and the surface of the concave-convex mold, it is preferable to keep the inside of the groove forming device 80 in an atmosphere containing no moisture such as dry air or nitrogen. The pressing strength of the concavo-convex mold is not particularly limited as long as the surface shape of the concavo-convex mold is transferred, and can be appropriately adjusted according to the degree of curing of the pressure-sensitive adhesive layer 12.

The concave-convex mold is not particularly limited in its overall shape as long as it has concaves and convexes in the surface shape, and may be a flat plate shape, or a cylindrical or cylindrical roll. From the viewpoint of continuous productivity, the embossing roll, which is a cylindrical or cylindrical mold, is preferable. The embossing roll is preferably a roll with a cooling mechanism whose surface temperature can be controlled by the refrigerant inside the roll.

The material of the base material of the concavo-convex mold is not particularly limited, and can be appropriately selected from metal, glass, carbon, resin, or a composite thereof. A metal is preferably used in terms of workability. From the viewpoint of cost, aluminum, iron, an alloy mainly composed of aluminum or iron, and the like can be cited as the metal material preferably used. From the viewpoint of releasability from the pressure-sensitive adhesive layer, a fluororesin is preferably used.

The surface of the concavo-convex mold may be subjected to a release treatment in order to facilitate the separation from the pressure-sensitive adhesive layer. An example of the mold release treatment is fluorine treatment or the like. The pressing strength of the concave-convex mold to the pressure-sensitive adhesive layer 12 is not particularly limited as long as the surface shape of the concave-convex mold is transferred to the pressure-sensitive adhesive layer 12.

As a method for obtaining a concavo-convex mold, for example, a method in which a base material is polished, sandblasted, and then electroless nickel plated to form a roll mold (Japanese Patent Laid-Open No. 2006-53371); A method in which copper plating or nickel plating is performed, followed by polishing, sandblasting, and then chromium plating (JP 2007-187952A); copper plating or nickel plating is performed, followed by polishing, and sandblasting. After performing the etching, a method of performing an etching step or a copper plating step, and then performing a chromium plating (JP 2007-237541A); after performing copper plating or nickel plating on the surface of the die base material, polishing , A photosensitive resin film is formed by coating on the polished surface, a pattern is exposed on the photosensitive resin film, then developed, and an etching process is performed using the developed photosensitive resin film as a mask, A method in which the resin film is peeled off, etching is further performed to dull the uneven surface, and then the formed uneven surface is plated with chrome; and a machine tool such as a lathe is used as a template by a cutting tool. And a method of cutting (Pamphlet of International Publication No. 2007/077892) and the like.

In the groove groove forming device 80, after the surface shape of the concave-convex mold is transferred to the outer surface of the pressure-sensitive adhesive layer 12, the concave-convex mold is peeled from the resin film 25 having the pressure-sensitive adhesive layer 13. The peeling method is not particularly limited, for example, when the concave-convex mold is an embossing roll, a pressure bonding device such as a nip roll is installed at the separation point between the resin film 25 having the pressure-sensitive adhesive layer 13 and the concave-convex mold. A method of peeling off the resin film 25 having the pressure-sensitive adhesive layer 13 from the concavo-convex mold using the pressure bonding device as a fulcrum is preferably used. As a result, the resin film 25 reaching the fulcrum can be efficiently and stably peeled off.

The pressure-sensitive adhesive layer 13 included in the pressure-sensitive adhesive layer-attached resin film 25 obtained through the groove formation step is, for example, 10 to 45 μm, and preferably 10 to 35 μm. When the thickness of the pressure-sensitive adhesive layer 13 is 45 μm or less, it is advantageous for the adhesiveness with the optical member. When the thickness is 10 μm or more, the pressure-sensitive adhesive layer 13 has good followability with respect to dimensional changes of the optical member.

(Recessed groove)
The concave groove 14 formed on the surface of the pressure-sensitive adhesive layer 13 is formed so as to reach the end edge portion 13a of the pressure-sensitive adhesive layer 13 (see FIG. 4 ). A pool of air generated at the boundary surface of (1) is discharged to the outside from the end edge portion 13a via the groove groove 14. In particular, when the area of the resin film with an adhesive is large to some extent, or when a long resin film with an adhesive is continuously attached to an optical member, air trapping is likely to occur. Air can be discharged to the outside by the groove 14, and the adhesiveness can be remarkably improved.

The upper surface shape of the groove groove 14 may be linear or curved, and a plurality of groove grooves 14 may be independent without being connected or may be connected. May be. As a mode in which the plurality of groove grooves 14 are not connected and are independent, a mode in which the upper surface shape of each groove groove 14 is a straight line and the plurality of groove grooves 14 are formed to be parallel to each other is possible. Can be mentioned. As a mode in which the plurality of groove grooves 14 are connected, the shape of the upper surface of each groove groove 14 is a linear shape, and the plurality of groove grooves 14 are formed in a lattice shape intersecting each other. Are listed. The width of each groove 14 is, for example, 0.1 mm to 50 mm, preferably 1 mm to 20 mm, more preferably 5 mm to 10 mm. The depth of each groove 14 is, for example, 0.5 μm to 20 μm, preferably 1 μm to 10 μm. The interval between the grooved grooves 14 adjacent to each other is, for example, 0.1 mm to 50 mm, preferably 1 mm to 20 mm, and more preferably 5 mm to 10 mm. The ratio of the width of the groove groove 14 to the distance between the adjacent groove grooves 14 is usually 1:3 to 3:1 and preferably 1:2 to 2:1. From the viewpoint that the groove groove is less likely to be crushed and the shape is easily maintained, the closer the ratio of “width of the groove groove to the space” is to 1:2, the more preferable it is from the viewpoint that air is easily released. The closer it is to 1, the better.

In FIG. 4, the case where the cross-sectional shape of the groove groove 14 is a rectangular shape is shown, but the cross-sectional shape of the groove groove 14 is not limited to a rectangular shape, and another cross-sectional shape is V-shaped. , U-shaped, etc. are exemplified.

FIG. 6 shows an example of the pattern of the groove grooves 14 on the surface of the adhesive layer 13. As shown in FIG. 6, the groove groove 14 may be formed in an area 13b having a width L ₁ from the edge portion 13a of the adhesive layer (hereinafter, referred to as “first edge area”) 13b. The width L ₁ of the first end region 13b preferably satisfies the relationship of the following formula (1) when the length of the pressure-sensitive adhesive layer in the width direction is L ₀ .

Furthermore, it is preferable to satisfy the relationship of the following formula (1').

Further, it is preferable that the relationship of the following expression (3) is satisfied.

In the aspect in which the groove 14 is formed in the first end region 13b, after the outer surface of the pressure-sensitive adhesive layer 13 is attached to the optical member, the resin film with the pressure-sensitive adhesive layer-attached resin film and the optical member is attached. A cutting step of cutting a region including the first end region 13b (hereinafter, referred to as “second end region”) from the optical member may be included. The excision step is preferable because the groove 14 can be configured not to remain in the final product.

The second end region is a region having a width L ₂ from the end edge of the pressure-sensitive adhesive layer in the resin film-attached optical member. Since the second end region includes the first end region 13b, the relationship of the following expression (2) is satisfied.

From the point that the second end region to be cut is determined to include the first end region, the width L ₁ of the first end region is calculated by formula so that the part to be cut does not become too large. It is preferable to satisfy the relationship of (1), and it is more preferable to satisfy the relationship of formula (1′).

The method of cutting the second end region in the cutting step is not particularly limited, but for example, a method generally called a slitter can be preferably used.

An example of the slitter is a method using a razor blade called a leather blade. Even with the method using the same leather blade, hollow cutting that slits in the air without providing a backup guide, or the groove roll method that stabilizes the meandering of the slit by inserting the blade into a grooved roll as a backup guide, etc. is there. In addition, a method of using two circular blades called shear blades to make a slit by applying contact pressure to the lower blade with the upper blade while rotating according to the transport of the film, and a blade called shear blade or score blade It is possible to use a method of pressing by pressing on a quenching roll or the like, and a method of combining two shear blades and slitting while cutting like scissors. Among them, the “groove roll method using a leather blade”, which is a method in which the slit position of the film can be easily changed and the traveling is easily stabilized, is preferably used.

In the pattern of the groove grooves 14 shown in FIG. 6, a plurality of groove grooves 14 are formed in the first end regions 13b at both ends in parallel with the arrow B, respectively. In the pattern shown in FIG. 6, when the laminating direction when laminating the resin film with the pressure-sensitive adhesive layer to the optical member is the direction of arrow A, the angle between arrow A and arrow B may be less than 90°. preferable. Since the angle formed by the bonding direction (arrow A) and the direction in which the groove 14 extends from the inner side toward the end edge portion 13a (arrow B) is less than 90°, air bleeding is performed in a direction close to the bonding direction. Therefore, it is possible to more efficiently perform air bleeding at the time of bonding using the concave groove 14.

[Laminating process]
This step is a step of bonding the optical member 30 to the outer surface of the adhesive layer 13 of the adhesive layer-attached resin film 25 to obtain the resin film-attached optical member 40 (see FIGS. 1 and 5 ). As shown in FIG. 5, the resin film-attached optical member 40 is obtained by laminating and bonding the adhesive layer-attached resin film 25 on the surface of the optical member 30 via the adhesive layer 13. According to the present invention, the resin film-attached optical member 40 having good adhesiveness between the pressure-sensitive adhesive layer 13 and the optical member 30 can be manufactured.

The laminating step can be specifically carried out as follows. The long adhesive film with a pressure-sensitive adhesive layer 25 obtained through the groove forming step is continuously conveyed, and the long optical member 30 is continuously conveyed while being unwound from the second feeding roll 2 to form a pressure-sensitive adhesive layer. The optical member 30 is laminated on the outer surface (groove forming surface) of the pressure-sensitive adhesive layer 13 of the attached resin film 25 to form a laminated body. By pressing this laminated body from above and below using a pair of bonding rolls 90 etc., the resin film-attached optical member 40 is continuously manufactured. From the viewpoint of the adhesiveness between the pressure-sensitive adhesive layer 13 and the optical member 30, the resin film 25 with a pressure-sensitive adhesive layer obtained through the groove groove forming step is not wound once in a roll shape or subjected to other treatment. It is preferable to supply it as it is to the bonding step with the optical member 30.

Although FIG. 1 shows an example in which the adhesive layer-attached resin film 25 is attached to one side of the optical member 30, the adhesive layer-attached resin film 25 may be attached to both sides of the optical member 30. When the adhesive layer-attached resin films 25 are attached to both surfaces of the optical member 30, the adhesive layer-attached resin films 25 on both sides may be attached at the same time or may be attached stepwise.

The optical member 30 may be a single-layer or multi-layer optical film or the like. Specific examples of the optical film include a polarizing film; an optical functional film such as an optical compensation film (retardation film), a light diffusion film (sheet), a reflection film (sheet); a protective film for a polarizing film; a polarizing plate; a glass film. (Including a glass sheet or a glass substrate); a separate film; a base film for a protect film and the like. The optical member 30 is preferably a polarizing plate. When the resin film 25 with a pressure-sensitive adhesive layer is a separate film with a pressure-sensitive adhesive layer, and the optical member 30 is a separate film, as the optical member 40 with a resin film, a pressure-sensitive adhesive layer with a double-sided separate film (pressure-sensitive adhesive sheet). Is obtained. Further, when the adhesive layer-attached resin film 25 is the adhesive layer-attached separate film and the optical member 30 is the base film for the protect film, the resin film-attached optical member 40 is a protect film-attached protect film. To be

The protect film (also called “surface protection film”) is a peelable film that is temporarily attached to the optical member for the purpose of protecting the surface of the optical member from scratches and dirt, and is usually made of a thermoplastic resin. It is composed of a base film and an adhesive layer laminated on the base film.

The material of the surface of the optical member 30 which is in contact with the outer surface of the pressure-sensitive adhesive layer 13 is not particularly limited, but the pressure-sensitive adhesive layer 13 and the optical member 30 are still subjected to energy irradiation treatment such as corona treatment which is usually performed on the surface. The manufacturing method according to the present invention is particularly effective when the surface material is such that sufficient adhesion between the and is not obtained. The surface of the optical member 30 in which sufficient adhesion to the pressure-sensitive adhesive layer 13 is difficult to obtain without the groove-forming step is, for example, a surface containing (typically consisting of) a (meth)acrylic resin. And so on. When the optical member 30 is a polarizing plate, such a surface is often formed by a protective film attached to the polarizing film, an optical compensation film (such as a retardation film), or the like.

The polarizing plate may be one in which a protective film is attached to at least one surface of a polarizing film via an adhesive layer. This protective film may also have a function as an optical compensation film such as a retardation film. The polarizing plate may be one in which a cured resin layer formed of a curable resin is laminated on at least one surface of a polarizing film. Further, another optically functional film such as a retardation film or a brightness enhancement film may be laminated on the polarizing film or the protective film or the cured resin layer via an adhesive layer or an adhesive layer. ..

The polarizing film is a film having a function of extracting linearly polarized light from incident natural light, and a preferable example is a dichroic dye such as iodine or a dichroic dye adsorbed and oriented on a uniaxially stretched polyvinyl alcohol-based resin film. Is what The thickness of the polarizing film is not particularly limited, but is usually 2 to 35 μm.

The protective film can be a translucent (preferably optically transparent) thermoplastic resin film. Specific examples of the thermoplastic resin include polyolefin resins such as chain polyolefin resins (polypropylene resin, etc.) and cyclic polyolefin resins (norbornene resin, etc.); polyester resins (polyethylene terephthalate resin, etc.); ) Acrylic resin (methyl methacrylate resin, etc.); Cellulose resin (cellulose acetate resin such as triacetyl cellulose, diacetyl cellulose, etc.); Polycarbonate resin; Polyvinyl alcohol resin; Polyvinyl acetate resin; Polyarylate Resins; polystyrene resins; polyether sulfone resins; polysulfone resins; polyamide resins; polyimide resins; and mixtures and copolymers thereof. The thickness of the protective film is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The cured resin layer is formed of a curable resin such as a thermosetting resin or an active energy ray curable resin. The curable resin may contain a thermopolymerizable compound, may contain a cationically polymerizable compound, may contain a radically polymerizable compound, these plural types May be included. The thickness of the cured resin layer is, for example, about 0.1 to 10 μm, preferably 1 to 5 μm.

When protective films are attached to both surfaces of the polarizing film, these protective films may be composed of the same thermoplastic resin or different thermoplastic resins. Further, the thickness may be the same or different. When the cured resin layers are laminated on both sides of the polarizing film, these cured resin layers may be formed of the same curable resin or different curable resins. Further, the thickness may be the same or different. The protective film or the cured resin layer may have a surface treatment layer (coating layer) such as a hard coat layer, an antiglare layer, an antireflection layer, a light diffusion layer, an antistatic layer, an antifouling layer, and a conductive layer. Good. When the protective film is attached to one surface of the polarizing film or the cured resin layer is laminated, the adhesive layer 13 of the adhesive layer-attached resin film 25 may be directly attached to the polarizing film surface.

The retardation film is an optical film exhibiting optical anisotropy, a uniaxially or biaxially stretched film of a thermoplastic resin film composed of a resin or the like that can be used for the protective film, or a liquid crystal for the thermoplastic resin film. The film may be a film that exhibits optical anisotropy by coating and orienting a polar compound, a film that exhibits optical anisotropy by coating an inorganic layered compound on a thermoplastic resin film, and the like.

The protective film (or retardation film or the like) can be attached to the polarizing film via the adhesive layer. As the adhesive forming the adhesive layer, a water-based adhesive, an active energy ray-curable adhesive or a thermosetting adhesive can be used, and preferably a water-based adhesive or an active energy ray-curable adhesive.

Examples of the water-based adhesive include an adhesive composed of a polyvinyl alcohol-based resin aqueous solution and a water-based two-component urethane-based emulsion adhesive. Above all, a water-based adhesive composed of a polyvinyl alcohol-based resin aqueous solution is preferably used. The polyvinyl alcohol-based resin may be a vinyl alcohol homopolymer obtained by saponifying polyvinyl acetate, which is a homopolymer of vinyl acetate, or a copolymer of vinyl acetate and another monomer copolymerizable therewith. A polyvinyl alcohol-based copolymer obtained by saponifying a polymer, a modified polyvinyl alcohol-based polymer obtained by partially modifying a hydroxyl group thereof, or the like can be used. The water-based adhesive can contain a crosslinking agent such as an aldehyde compound (glyoxal or the like), an epoxy compound, a melamine compound, a methylol compound, an isocyanate compound, an amine compound, a polyvalent metal salt or the like.

When a water-based adhesive is used, it is preferable to carry out a drying step for removing water contained in the water-based adhesive after the polarizing film and the protective film are bonded together. After the drying step, for example, a curing step of curing at a temperature of about 20 to 45° C. may be provided.

The active energy ray-curable adhesive refers to an adhesive that is cured by irradiation with active energy rays such as ultraviolet rays, visible rays, X-rays, and electron beams, and examples thereof include a polymerizable compound and a photopolymerization initiator. Examples thereof include a curable composition containing the same, a curable composition containing a photoreactive resin, a curable composition containing a binder resin and a photoreactive crosslinking agent, and the like. UV curable adhesives are preferred. Examples of the polymerizable compound include a photopolymerizable monomer such as a photocurable epoxy monomer, a photocurable (meth)acrylic monomer, and a photocurable urethane monomer, and an oligomer derived from the photopolymerizable monomer. it can. Examples of the photopolymerization initiator include those containing a substance that generates active species such as neutral radicals, anion radicals, and cation radicals upon irradiation with active energy rays. As an active energy ray curable adhesive containing a polymerizable compound and a photopolymerization initiator, a curable composition containing a photocurable epoxy monomer and a photocationic polymerization initiator, a photocurable (meth)acrylic monomer, and a photocurable composition A curable composition containing a radical polymerization initiator, a photocurable epoxy monomer, a photocurable (meth)acrylic monomer, a photocationic polymerization initiator and a curable composition containing a photoradical polymerization initiator are preferably used. it can.

When using an active energy ray-curable adhesive, after laminating the polarizing film and the protective film, a drying step is performed as necessary (however, the active energy ray-curable adhesive is substantially a solvent component It may be a solvent-free adhesive that does not contain the active energy ray), and then undergoes a curing step of curing the active energy ray-curable adhesive by irradiating the active energy ray. The light source of the active energy rays is not particularly limited, but ultraviolet rays having a light emission distribution at a wavelength of 400 nm or less are preferable, and specifically, low-pressure mercury lamp, medium-pressure mercury lamp, high-pressure mercury lamp, ultra-high-pressure mercury lamp, chemical lamp, black light lamp, micro A wave excitation mercury lamp, a metal halide lamp, etc. can be used.

Prior to laminating the protective film, in order to improve the adhesiveness, at least one of the polarizing film and the protective film is subjected to corona treatment, plasma treatment, ultraviolet irradiation treatment, flame (flame) treatment, saponification treatment, Surface activation treatment such as primer layer formation treatment may be performed.

When the protective films are attached to both surfaces of the polarizing film, the adhesive for attaching these protective films may be the same kind of adhesive or different kinds of adhesives.

[Other processes]
The manufacturing method of the present invention can further include a surface activation step of irradiating energy to the bonding surface of the optical member 30 with the pressure-sensitive adhesive layer 13. The energy irradiation treatment can be, for example, corona treatment, plasma treatment, ultraviolet ray irradiation treatment, or the like. Among them, the corona treatment is preferably used because of the effect of improving the adhesiveness and the facility simplicity.

The manufacturing method of the present invention includes a winding step of winding the long resin film-attached optical member 40 obtained through the laminating step on the winding roll 3 to form a film roll. (See FIG. 1). Further, the production method of the present invention may include a curing step of curing (aging) the pressure-sensitive adhesive layer 13 in a roll state after the winding step. By carrying out the curing step, the curing reaction of the pressure-sensitive adhesive layer 13 is promoted, and the pressure-sensitive adhesive force of the pressure-sensitive adhesive layer 13 can be increased. Further, by performing curing (curing reaction of the pressure-sensitive adhesive) with the pressure-sensitive adhesive layer 13 in close contact with the optical member 30, the interaction with the optical member 30 (including chemical reaction) and the pressure-sensitive adhesive for the optical member 30. Since the wettability is improved, the adhesiveness between the pressure-sensitive adhesive layer 13 and the optical member 30 can be further enhanced. The curing temperature is, for example, 20 to 45°C.

Moreover, the manufacturing method of this invention WHEREIN: The optical member 30 (this optical member is also called a "1st optical member") bonded to the adhesive layer 13 of the resin film 25 with an adhesive layer in the bonding process. A substituting step of substituting another optical member (this optical member is also referred to as a “second optical member”) can be included.

Specifically, for example, when the adhesive layer-attached resin film 25 is an adhesive layer-attached separate film and the first optical member is a separate film, the replacing step peels and removes the first optical member separate film. A peeling step and, subsequently, a bonding step (a second bonding step) of bonding a second optical member such as a polarizing plate to the pressure-sensitive adhesive layer 13 of the resin film with a pressure-sensitive adhesive layer 25 may be included. .. After the peeling process and before the second bonding process, at least one of the bonding surface of the adhesive layer 13 and the second optical member is subjected to corona treatment, plasma treatment, ultraviolet irradiation treatment, flame (flame) treatment, saponification. Surface treatment such as treatment or primer layer forming treatment may be performed.

As described above, according to the present invention, the adhesion between the pressure-sensitive adhesive layer 13 of the resin film with pressure-sensitive adhesive layer 25 and the optical member 30 (first optical member) can be improved. Due to performing the groove formation step in a state where the curing reaction of the agent layer 12 has not progressed sufficiently, the adhesiveness between the second optical member replacing the first optical member and the adhesive layer 13 is improved. Can be increased.

Further, the production method of the present invention peels and removes the resin film 10 of the optical member 40 with a resin film obtained through the laminating step so that the resin film 10 is a separate film, and the exposed adhesive layer A step of bonding an optical member different from the optical member 30 to the outer surface of 13 can be included. For example, when the pressure-sensitive adhesive layer-attached resin film 25 is a pressure-sensitive adhesive layer-attached separate film and the optical member 30 is a base film for a protect film, a resin film-attached optical member 40 is a protect film with a separate film. However, a separate film is peeled off from the separated film, and a polarizing plate is attached to the exposed outer surface of the pressure-sensitive adhesive layer 13, whereby a protective film-attached polarizing plate can be obtained.

1 1st feeding roll, 2 2nd feeding roll, 3 winding roll, 10 resin film, 11 coating layer, 12 adhesive layer (before energy irradiation), 13 adhesive layer (after forming groove groove), 13a adhesive Edge portion of the agent layer, 13b first end region, 14 groove groove, 15 resin film having coating layer, 20 resin film having adhesive layer (before groove groove formation), 25 adhesive layer resin Film, 30 optical member, 40 resin film-attached optical member, 50 coating device, 60 coating roll, 70 drying means, 80 concave groove forming device, 90 laminating roll.

Claims (8)

A coating step of forming a coating layer by coating a pressure-sensitive adhesive composition on a long resin film,
A drying step of obtaining a resin film having a pressure-sensitive adhesive layer by introducing the drying step into a drying means while continuously transporting the film after the coating step, and drying the coating layer,
While continuously transporting the resin film having the pressure-sensitive adhesive layer, a groove groove forming step of pressing the uneven mold on the outer surface of the pressure-sensitive adhesive layer,
While continuously transporting the resin film after the groove groove forming step, a long optical member is laminated on the outer surface of the pressure-sensitive adhesive layer, and a laminating step of pressing the laminated body from above and below,
Including
A method for producing an optical member with a resin film, wherein the resin film is a separate film. The manufacturing method according to claim 1, further comprising a curing step of winding the optical member with a resin film obtained by the bonding step into a roll shape, and curing the pressure-sensitive adhesive layer in a roll state. The manufacturing method according to claim 1 or 2, wherein in the groove-forming step, the temperature of the pressure-sensitive adhesive layer in contact with the uneven mold is lower than the glass transition temperature of the pressure-sensitive adhesive composition. The groove groove forming step is a step of forming a groove groove from the edge portion of the pressure-sensitive adhesive layer to the first end region of the width L ₁ .
The width L ₁ of the first end region satisfies the relationship of the following formula (1) when the length of the pressure-sensitive adhesive layer in the width direction is L ₀ , the production according to any one of claims 1 to 3. Method.

After the laminating step, the method further includes a cutting step of cutting the second end region of the width L ₂ from the end edge of the pressure-sensitive adhesive layer of the resin film-attached optical member,
The manufacturing method according to claim 4, wherein the width L ₂ of the second end region satisfies the relationship of the following expression (2).

The manufacturing method according to any one of claims 1 to 5, further comprising a surface activation step of performing energy irradiation on a bonding surface of the optical member with the pressure-sensitive adhesive layer before the bonding step. The manufacturing method according to claim 1, wherein a surface of the optical member in contact with the outer surface of the pressure-sensitive adhesive layer contains a (meth)acrylic resin. The manufacturing method according to claim 1, wherein the optical member is a polarizing plate.

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