JP6899721B2 - Polarizing plate manufacturing method and its manufacturing equipment - Google Patents

Description

The present invention relates to a method for producing a deformed polarizing plate and an apparatus for producing the same. More specifically, the present invention relates to a method for manufacturing a deformed polarizing plate having a concave R portion and / or a hole portion, and an apparatus for manufacturing the same. The present invention also relates to an optical film using the modified polarizing plate. Further, the present invention relates to an image display device such as the deformed polarizing plate, a liquid crystal display device using an optical film, an organic EL display device, and a PDP.

In recent years, it has been desired to use a polarizing plate in a meter display unit of an automobile, a smart watch, or the like. Further, from the viewpoint of the design of a smartphone, it has been desired to use a polarizing plate having a shape other than a rectangle, or to form a through hole in the polarizing plate. Furthermore, in irregular shape processing such as these, there is an increasing demand for more delicate and precise processing processing and more complicated processing processing, which have not been seen in the past, and small-diameter concave R processing. And small diameter holes may be machined.

Examples of processing the polarizing plate into a deformed shape include a punching process of forming a deformed blade shape and punching the polarizing plate, and a cutting process using laser irradiation. However, in the former punching process, it has been found that the polarizing plate is cracked or broken due to the damage of the pressing to the polarizing plate. Further, in the latter laser processing, it has been found that the polarizing plate is discolored by heat. In particular, in the examination by the applicants, it was found that cracks and breaks tend to occur in the concave processed portions such as the small diameter hole processing and the small diameter concave R processing.

Further, so far, proposals have been made regarding the finishing treatment of the end face of the polarizing plate (see, for example, Patent Documents 1 and 2). However, all of the above proposals relate only to the finishing treatment of the end portion of the cutting opening after cutting the polarizing plate into a rectangular shape, and are not a technique for concavely processing the polarizing plate itself. Further, in the above proposal, there is no disclosure about the problem that cracks and breaks occur when the polarizing plate is subjected to minute concave processing.

Japanese Unexamined Patent Publication No. 2004-148461 Japanese Unexamined Patent Publication No. 2004-148419

In light of these circumstances, the present invention is a method for manufacturing a deformed polarizing plate having a concave R portion and / or a hole portion having a particularly small diameter, and cracks, breaks, or discoloration that occur in the deformed polarizing plate during processing. It is an object of the present invention to provide a method for producing a deformed polarizing plate and an apparatus for producing the same.

As a result of diligent studies to solve the above problems, the present inventors have found that the above object can be achieved by the following manufacturing methods and the like, and have completed the present invention.

The method for producing a modified polarizing plate of the present invention is
A method for manufacturing a deformed polarizing plate having a concave R portion.
It is characterized by including a step of forming the concave R portion by using a cutting means in which the blade abuts on the cutting surface from the lateral direction to cut.

The method for producing a deformed polarizing plate of the present invention occurs during processing of a polarizing plate, which has been difficult to suppress until now, particularly by using a means in which the blade abuts on the cutting surface of the polarizing plate from the lateral direction. It is possible to suppress the occurrence of cracks and breaks and discoloration, and to manufacture a deformed polarizing plate having a concave R portion having a particularly small diameter.

Further, in the present invention, the concave R portion means a portion having a concave portion and a curved portion, and includes a portion in which the corner portion of the concave portion has a curved shape such as a circular shape, an elliptical shape, or a substantially circular shape. Further, the convex R portion refers to a portion having a convex portion and a curved portion, and includes a portion in which the corner portion of the convex portion has a curved shape such as a circular shape, an elliptical shape, or a substantially circular shape. For example, the concave R portion and the convex R portion shown in FIG. 1 can be mentioned.

Further, in the method for producing a deformed polarizing plate of the present invention, it is preferable that the radius of the concave R portion is 5 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the concave R portion is 5 mm or less. It is possible to manufacture a deformed polarizing plate having a concave R portion having a small diameter. The radius of the concave R portion means the radius of the circle when the R portion is circular, and the radius of curvature when the R portion is not circular such as an ellipse or a substantially circular shape.

Further, in the method for producing a deformed polarizing plate of the present invention, it is preferable that the cutting means is an end mill. By using the above manufacturing method, it is particularly suitable for small-diameter concave R processing.

Further, in the method for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction and the blade surface of the blade is 60 ° or more. By using the above manufacturing method, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

Further, the apparatus for manufacturing a deformed polarizing plate of the present invention is
A device for manufacturing a deformed polarizing plate having a concave R portion.
It is characterized in that it is provided with a cutting means for cutting by contacting the blade from the lateral direction with respect to the cutting surface.

By using the above-mentioned manufacturing apparatus, it is possible to suppress the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate, and it is possible to easily manufacture a deformed polarizing plate having a concave R portion having a particularly small diameter.

Further, in the device for manufacturing a deformed polarizing plate of the present invention, it is preferable that the radius of the concave R portion is 5 mm or less. By using the above manufacturing apparatus, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate can be suppressed, and the radius of the concave R portion can be 5 mm or less. It is possible to easily manufacture a deformed polarizing plate having a concave R portion having a small diameter.

Further, in the apparatus for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting means is an end mill. By using the above-mentioned manufacturing apparatus, it is particularly suitable for small-diameter concave R processing.

Further, in the apparatus for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction by the cutting means and the blade surface of the blade is 60 ° or more. By using the above manufacturing apparatus, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

Further, the method for producing a deformed polarizing plate of the present invention is as follows.
A method for manufacturing a deformed polarizing plate having a hole.
It is characterized by including a step of forming the above-mentioned hole using an end mill.

In the above manufacturing method, in particular, by using a means in which the blade comes into contact with the cutting surface of the polarizing plate from the lateral direction, cracks and breaks that occur during the processing of the polarizing plate, which have been difficult to suppress until now, are generated. It is possible to suppress discoloration and to manufacture a deformed polarizing plate having a hole having a particularly small diameter.

Further, in the present invention, the hole portion refers to a portion having a hole such as a circular shape, an elliptical shape, a substantially circular shape, or a square shape, and means a portion penetrating the polarizing plate. For example, the hole shown in FIG. 1 can be mentioned.

Further, in the method for producing a deformed polarizing plate, the radius of the hole is preferably 5 mm or less. By using the above manufacturing method, even when the radius of the hole is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the hole is as small as 5 mm or less. It is possible to manufacture a deformed polarizing plate having a small-diameter hole. The radius of the hole is defined as the radius of the circle when the hole is circular, and the radius of curvature when the hole is not circular such as an ellipse or a substantially circular shape.

Further, in the method for manufacturing a deformed polarizing plate, it is preferable that the cutting angle formed by the processing direction and the blade surface of the end mill is 60 ° or more. By using the above manufacturing method, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

Further, the apparatus for manufacturing a deformed polarizing plate of the present invention is
A device for manufacturing a deformed polarizing plate having a hole.
It is characterized by being provided with an end mill.

By using the above-mentioned manufacturing apparatus, it is possible to suppress the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate, and it is possible to easily manufacture a deformed polarizing plate having a hole having a particularly small diameter.

Further, in the device for manufacturing a deformed polarizing plate of the present invention, it is preferable that the radius of the hole portion is 5 mm or less. By using the above manufacturing equipment, even when the radius of the hole is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the hole is as small as 5 mm or less. It is possible to easily manufacture a deformed polarizing plate having a small-diameter hole.

Further, in the device for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction and the blade surface of the end mill is 60 ° or more. By using the above manufacturing apparatus, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

An example of the deformed polarizing plate obtained by the method for producing a deformed polarizing plate of the present invention is shown. An example of the embodiment of the method for manufacturing a modified polarizing plate of the present invention is shown. An example of the embodiment of the method for manufacturing a modified polarizing plate of the present invention is shown. An example of an end mill in the method for manufacturing a shaped polarizing plate of the present invention is shown. An example of an end mill in the method for manufacturing a shaped polarizing plate of the present invention is shown. The processed shape carried out in the Example of this invention is shown. The processed shape carried out in the Example of this invention is shown.

Hereinafter, embodiments of the present invention will be described.

The method for producing a modified polarizing plate of the present invention is
A method for manufacturing a deformed polarizing plate having a concave R portion.
It is characterized by including a step of forming the concave R portion by using a cutting means in which the blade abuts on the cutting surface from the lateral direction to cut.

Further, the method for producing a deformed polarizing plate of the present invention is as follows.
A method for manufacturing a deformed polarizing plate having a hole.
It is characterized by including a step of forming the above-mentioned hole using an end mill.

The method for manufacturing a deformed polarizing plate of the present invention is characterized by including a step of forming the concave R portion and / or a hole portion by using a cutting means in which a blade abuts on a cutting surface from the lateral direction to perform cutting. .. In particular, by using a means in which the blade comes into contact with the cutting surface of the polarizing plate from the lateral direction, it is possible to suppress the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate, which was difficult to suppress until now. In particular, it is possible to manufacture a deformed polarizing plate having a concave R portion and / or a hole portion having a small diameter. Further, the cutting means in which the blade abuts on the cutting surface from the lateral direction to cut is, for example, plane processing (processing in which the machined surface is scraped in parallel by a protruding blade having a rotation axis parallel to the machined surface). , A method using end milling or the like can be mentioned. In the method for producing a deformed polarizing plate of the present invention, it is particularly preferable that the cutting means is an end mill when performing small-diameter concave R processing or small-diameter hole processing. Further, in a method for manufacturing a deformed polarizing plate having a hole, an end mill is used as the cutting means.

An end mill is a type of cutting tool, and unlike a drill that only processes in the axial direction (dedicated to drilling only), it can also process in the direction orthogonal to the rotation axis.

Hereinafter, an embodiment using end milling will be described as an example with reference to FIG. While rotating the blade of the end mill, which is the blade in this case, the blade comes into contact with the cutting surface of the polarizing plate from the lateral direction and cuts against the target polarizing plate to form the concave R portion and / or the hole portion. To do. Then, while rotating the blade portion of the end mill and moving it in the processing direction, the cutting process of the polarizing plate is continued to process a predetermined deformed polarizing plate.

In the case of the end mill, the rotation of the cutting edge is, for example, as shown in FIG. 2, a rotation axis parallel to the cutting surface (for example, further, the rotation axis is in a direction perpendicular to the surface of the polarizing plate). ), And the plate plate can be cut by the end mill in the machining direction while performing the rotation continuously, stepwise, or intermittently. In this case, the cutting is performed in a state where the blade portion of the end mill is in contact with the cutting surface from the lateral direction. In the punching process of punching with a conventional blade mold, the blade hits and cuts from the upper surface of the polarizing plate (the direction parallel to the cutting surface in FIG. 2 and the direction perpendicular to the surface of the polarizing plate). It becomes.

Further, for example, when plane processing is used as the cutting means, instead of the blade portion of the end mill in FIG. 2, the blade portion of plane processing can be brought into contact with the cutting surface from the lateral direction for cutting.

Further, for example, in the case of drilling a hole, not only the hole is directly drilled by an end mill or the like, but also the end face is cut by a secondary or additional end mill or the like for a hole previously drilled by another punching or the like. A hole having a desired shape may be formed by expanding the hole.

Further, by using the method for producing a deformed polarizing plate of the present invention, even when the concave R portion has a small diameter or a fine diameter, cracks and breaks and discoloration that occur during processing are suppressed, and it is preferable. It can be manufactured and processed.

Therefore, in the method for manufacturing a deformed polarizing plate of the present invention, for example, even if the radius of the concave R portion is 5 mm or less, it can be easily manufactured and processed. Further, for example, the radius can be 1 mm or more and 5 mm or less, 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the concave R portion is 5 mm or less. It is possible to manufacture a deformed polarizing plate having a concave R portion having a small diameter.

Therefore, in the method for manufacturing a deformed polarizing plate of the present invention, for example, even if the radius of the hole is 5 mm or less, it can be easily manufactured and processed. Further, for example, the radius can be 1 mm or more and 5 mm or less, 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the hole is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the hole is as small as 5 mm or less. It is possible to manufacture a deformed polarizing plate having a small-diameter hole.

Further, in the method for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction and the blade surface of the blade is 60 ° or more. The cutting angle is preferably 60 ° to 90 °, may be 65 ° to 90 °, may be 70 ° to 85 °, or may be 70 ° to 80 °. By using the above manufacturing method, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

In the present invention, the cutting angle refers to the cutting angle formed by the cutting direction by the cutting means and the blade surface of the blade, and FIG. 3 shows an example of machining with an end mill. The angle between the rotation axis direction of the end mill and the blade is called the helix angle. When machining so that the rotation axis direction of the end mill is perpendicular to the machining direction as shown in Fig. 3, the helix angle of the end mill blade starts from 90 °. The angle obtained by subtracting is the cutting angle.

Further, the apparatus for manufacturing a deformed polarizing plate of the present invention is
A device for manufacturing a deformed polarizing plate having a concave R portion.
It is characterized in that it is provided with a cutting means for cutting by contacting the blade from the lateral direction with respect to the cutting surface.

In the apparatus for manufacturing a deformed polarizing plate having a concave R portion of the present invention, a cutting means for cutting by abutting the blade from the lateral direction with respect to the above-mentioned cutting surface, including an end mill, may be appropriately provided in the apparatus by a known method. it can.

Further, in the device for manufacturing a deformed polarizing plate of the present invention, for example, even if the radius of the concave R portion is 5 mm or less, it can be easily manufactured and processed. Further, for example, the radius can be 1 mm or more and 5 mm or less, 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the concave R portion is 5 mm or less. It is possible to manufacture a deformed polarizing plate having a concave R portion having a small diameter.

Further, in the apparatus for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction by the cutting means and the blade surface of the blade is 60 ° or more. The cutting angle is preferably 60 ° to 90 °, may be 65 ° to 90 °, may be 70 ° to 85 °, or may be 70 ° to 80 °. By using the above manufacturing apparatus, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

Further, the apparatus for manufacturing a deformed polarizing plate of the present invention is
A device for manufacturing a deformed polarizing plate having a hole.
It is characterized by being provided with an end mill.

Further, in the apparatus for manufacturing a deformed polarizing plate having a hole portion of the present invention, the above-mentioned end mill can be appropriately provided in the apparatus by a known method.

Further, in the device for manufacturing a deformed polarizing plate of the present invention, for example, even if the radius of the hole is 5 mm or less, it can be easily manufactured and processed. Further, for example, the radius can be 1 mm or more and 5 mm or less, 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the hole is 5 mm or less, the occurrence of cracks and breaks and discoloration that occur during the processing of the polarizing plate are suppressed, and the radius of the hole is as small as 5 mm or less. It is possible to manufacture a deformed polarizing plate having a small-diameter hole.

Further, in the apparatus for manufacturing a deformed polarizing plate of the present invention, it is preferable that the cutting angle formed by the processing direction by the cutting means and the blade surface of the blade is 60 ° or more. The cutting angle is preferably 60 ° to 90 °, may be 65 ° to 90 °, may be 70 ° to 85 °, or may be 70 ° to 80 °. By using the above manufacturing apparatus, it is possible to suppress the occurrence of delamination of the deformed polarizing plate.

Further, as the above-mentioned end mill, for example, those shown in FIGS. 4 and 5 can be appropriately used. Note that FIG. 5 shows an example in which the number of blades is 2, 3, 4, or 6.

The shape of the end mill is preferably 1 to 6 blades, and may be 1 to 4 blades.

Further, the rake angle of the blade portion of the end mill is preferably less than 0 to 15 °, and may be 3 to 12 °. If the rake angle is 15 ° or more, the blade is likely to be chipped.

Further, the clearance angle of the blade portion of the end mill is preferably larger than 0 ° and less than 20 °, and may be 3 to 15 °. If the clearance angle is 0 °, it will rub against the film, and if it is 20 ° or more, the blade will be easily chipped.

Further, the helix angle of the blade portion of the end mill is preferably −75 ° to 75 °, and may be −65 ° to 65 °. If the helix angle exceeds the above range, shavings are likely to be discharged poorly.

Further, the blade diameter (outer diameter) φ of the blade portion of the end mill is preferably 3 to 30 mm, and may be 5 to 25 mm. If the blade diameter φ is smaller than 3 mm, it is easy to break, and if it is larger than 30 mm, it becomes difficult to perform fine irregular shape processing.

Further, as a manufacturing condition when manufacturing using the end mill, the feed rate of the blade portion of the end mill is preferably 100 to 10000 mm / min, and may be 200 to 8000 mm / min.

Further, the rotation speed of the blade portion of the end mill is preferably 1000 to 120,000 rpm, and may be 2000 to 60,000 rpm or 3,000 to 50,000 rpm. If the rotation speed is slower than 1000 rpm, it may cause cracks, while if it is faster than 60,000 rpm, it may generate heat and damage the polarizing plate or the like.

The polarizing plate used in the present invention is not particularly limited, and a known polarizing plate can be appropriately used. Examples of the polarizing plate include a polarizing plate manufactured by stretch molding and a polarizing plate manufactured by coating molding.

The polarizer is not particularly limited, and various polarizers can be used. As the polarizer, for example, a hydrophilic polymer film such as a polyvinyl alcohol-based film, a partially formalized polyvinyl alcohol-based film, an ethylene / vinyl acetate copolymerization system partially saponified film, and two colors such as iodine and a bicolor dye are used. Examples thereof include a uniaxially stretched film obtained by adsorbing a sex material, a polyene-based oriented film such as a dehydrated product of polyvinyl alcohol and a dehydrogenated product of polyvinyl chloride. Among these, a polarizer made of a polyvinyl alcohol-based film and a dichroic substance such as iodine is preferable.

Polyvinyl alcohol or a derivative thereof is used as the material of the polyvinyl alcohol-based film applied to the polarizer. Examples of polyvinyl alcohol derivatives include polyvinyl formal, polyvinyl acetal, and the like, olefins such as ethylene and propylene, unsaturated carboxylic acids such as acrylic acid, methacrylic acid, and crotonic acid, and alkyl esters thereof, and those modified with acrylamide and the like. can give. A polyvinyl alcohol having a degree of polymerization of about 1000 to 10000 and a degree of saponification of about 80 to 100 mol% is generally used.

The polyvinyl alcohol-based film (unstretched film) is subjected to at least uniaxial stretching treatment and iodine dyeing treatment according to a conventional method. Further, boric acid treatment and iodine ion treatment can be performed. Further, the polyvinyl alcohol-based film (stretched film) subjected to the above treatment is dried according to a conventional method to become a polarizer.

The polarizing plate used in the present invention may be one in which a protective film is attached to at least one side of the polarizer via an adhesive. The protective film may be attached to one side or both sides of the polarizer. The protective film may have other optical functions at the same time, and may be formed by laminating other layers.

When the polarizing plate has protective films on both sides of the polarizer, the protective film on one side and the protective film on the other side may be the same or different. Further, at least one protective film may be used per one side, or a laminate having two or more layers may be used.

The thickness of the protective film can be appropriately determined, but is generally about 1 to 500 μm in terms of workability such as strength and handleability, and thin layer property. In particular, 1 to 300 μm is preferable, and 5 to 200 μm is more preferable.

Examples of the material constituting the protective film include a thermoplastic resin having excellent transparency, mechanical strength, thermal stability, and moisture blocking property. When the protective film is required to have optical isotropic properties, it is preferable to select a resin having a small intrinsic birefringence. Specific examples of such thermoplastic resins include polyester resins, polyether sulfone resins, polysulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, and (meth) acrylic resins. , Norbornen-based resins, polyarylate-based resins, and mixtures thereof. Further, a thermosetting resin such as (meth) acrylic or an ultraviolet curable resin can also be used. Of the above, from the viewpoint of moisture permeability and optical properties, it is preferable to use a (meth) acrylic resin, a polyimide resin, or a norbornene resin.

As the protective film, the protective film on the cell side may have a phase difference function for viewing angle compensation, and the protective film on the cell side may or may not have a phase difference.

The surface of the protective film that adheres to the polarizer can be easily adhered. Examples of the easy-adhesion treatment include plasma treatment, dry treatment such as corona treatment, chemical treatment such as alkali treatment (saponification treatment), and coating treatment for forming an easy-adhesion layer. Among these, a coating treatment or an alkali treatment for forming an adhesive layer is preferable. Various easy-adhesive materials such as polyol resin, polycarboxylic acid resin, and polyester resin can be used for forming the easy-adhesion layer. The thickness of the easy-adhesion layer is usually about 0.001 to 10 μm, more preferably about 0.001 to 5 μm, and particularly preferably about 0.001 to 1 μm.

The surface of the protective film to which the polarizer is not adhered may be subjected to a hard coat layer, antireflection treatment, anti-sticking treatment, or treatment for the purpose of diffusion or anti-glare.

The adhesive constituting the above-mentioned polarizing plate is not particularly limited as long as it is optically transparent, and various forms such as water-based, solvent-based, hot-melt-based, and radical-curing type are used. Mold adhesives are suitable.

The water-based adhesive forming the adhesive layer is not particularly limited, and examples thereof include vinyl polymer-based, gelatin-based, vinyl-based latex-based, polyurethane-based, isocyanate-based, polyester-based, and epoxy-based adhesives.

Examples of the radical curable adhesive include various types such as an electron beam curable type, an active energy ray curable type such as an ultraviolet curable type, and a thermosetting type. preferable.

The method for manufacturing a deformed polarizing plate of the present invention is a method for manufacturing a deformed polarizing plate having a concave R portion and / or a hole portion, and is a cutting means for cutting by a blade contacting a cutting surface such as an end mill from the lateral direction. It is characterized by including a step of forming the concave R portion using the above.

The production of the polarizing plate itself in the pre-stage of forming the concave R portion and / or the hole portion used in the present invention can be appropriately used with a known method. Further, in the manufacturing method of the present invention, the step of forming the concave R portion by using a cutting means in which the blade abuts on the cutting surface such as an end mill from the lateral direction to cut the concave R portion may be performed after the polarizing plate itself is manufactured. Often, in some cases, this may be done during the manufacturing process of the polarizing plate itself.

In the manufacturing stage of the polarizing plate itself before forming the concave R portion and / or the hole portion, a known method may be appropriately used for cutting the polarizing plate itself. For example, in the stage of making a certain size before microfabrication, a rectangular shape or the like is made by a method using a conventional laser or the like, and in the stage of forming a fine concave R portion and / or a hole portion, the present invention It can also be appropriately used as a manufacturing method or the like. In the former stage, the shape of the polarizing plate at the time of the cutting is not particularly limited, but it is generally a quadrangle, and the polarizing plate may be cut in the absorption axis direction and the transmission axis direction. Further, in the former stage, for example, cutting by a laser may be performed on at least one end edge, but it is preferable to perform cutting in the absorption axis direction, the transmission axis direction, or both.

The polarizing plate itself can be manufactured, for example, by laminating the polarizing element and the protective film with the adhesive. In the obtained polarizing plate, a protective film can be provided on one side or both sides of the polarizing element via an adhesive layer formed by the above-mentioned polarizing plate adhesive.

Further, the polarizing plate can be used as an optical film laminated with another optical layer in practical use. The deformed polarizing plate in the method for producing a deformed polarizing plate of the present invention includes a deformed polarizing plate and a deformed optical film or the like in which at least one layer of the polarizing plate is laminated. In the production method of the present invention, the polarizing plate itself may be first subjected to a processing step of deforming the polarizing plate itself and then an optical film, or an optical film may be first subjected to a processing step of deforming the polarizing plate itself, and both may be used in combination as appropriate. You may.

The optical layer is not particularly limited, but is used for forming, for example, a reflector, a transflective plate, a retardation plate (including a wave plate such as 1/2 or 1/4), a liquid crystal display device such as a viewing angle compensation film, or the like. One or two or more optical layers that may be used can be used. In particular, a reflective polarizing plate or a semi-transmissive polarizing plate in which a reflecting plate or a semi-transmissive polarizing plate is further laminated on the above-mentioned polarizing plate, an elliptical polarizing plate or a circular polarizing plate in which a retardation plate is further laminated on the polarizing plate, A wide viewing angle polarizing plate in which a viewing angle compensating film is further laminated on the polarizing plate, or a polarizing plate in which a brightness improving film is further laminated on the polarizing plate is preferable.

An adhesive layer for adhering to other members such as a liquid crystal cell may be provided on the above-mentioned polarizing plate or an optical film in which at least one layer of the polarizing plates is laminated. The pressure-sensitive adhesive forming the pressure-sensitive adhesive layer is not particularly limited, and for example, a polymer based on an acrylic polymer, a silicone-based polymer, a polyester, a polyurethane, a polyamide, a polyether, a fluorine-based polymer, a rubber-based polymer, or the like is appropriately selected. Can be used. In particular, an acrylic pressure-sensitive adhesive that is excellent in optical transparency, exhibits appropriate wettability, cohesiveness, and adhesiveness, and is excellent in weather resistance, heat resistance, and the like can be preferably used.

The adhesive layer can be attached to one or both sides of the polarizing plate or the optical film by an appropriate method. As an example, a pressure-sensitive adhesive solution of about 10 to 40% by weight is prepared by dissolving or dispersing the base polymer or its composition in a solvent composed of a single solvent or a mixture of appropriate solvents such as toluene and ethyl acetate. It is directly attached on the polarizing plate or the optical film by an appropriate developing method such as a casting method or a coating method, or an adhesive layer is formed on the separator according to the above and the adhesive layer is formed on the polarizing plate or the optical film. There is a method of transferring to the top.

The adhesive layer may be provided on one side or both sides of a polarizing plate or an optical film as a superimposing layer having a different composition or type. Further, when provided on both sides, adhesive layers having different compositions, types and thicknesses can be formed on the front and back surfaces of the polarizing plate and the optical film. The thickness of the adhesive layer can be appropriately determined according to the purpose of use, adhesive strength, etc., and is generally 1 to 500 μm, preferably 5 to 200 μm, and particularly preferably 10 to 100 μm.

The exposed surface of the adhesive layer is temporarily covered with a separator for the purpose of preventing contamination or the like until it is put into practical use. As a result, it is possible to prevent the adhesive layer from coming into contact with the adhesive layer in the usual handling state. As the separator, except for the above-mentioned thickness condition, for example, a plastic film, a rubber sheet, a paper, a cloth, a non-woven fabric, a net, a foam sheet or a metal foil, an appropriate thin leaf body such as a laminate thereof, etc. It is possible to use an appropriate one according to the conventional one, such as one coated with an appropriate release agent such as a long-chain alkyl type, a fluorine type or molybdenum sulfide.

The above-mentioned polarizing plate or optical film can be preferably used for forming various devices such as a liquid crystal display device.

Hereinafter, examples and the like that specifically show the configuration and effects of the present invention will be described.

[Example, Comparative Example]
The processing in Examples 1 and 2 and Comparative Examples 1 to 3 was carried out by processing under the conditions shown in Table 1 below and the processing shape shown in FIG. Further, a laminated body in which a surface protection film (PPF-100T) manufactured by Nitto Denko Co., Ltd. was laminated on a polarizing plate manufactured by Nitto Denko Co., Ltd. (NPF-CWQ1463VDUAG380-ACJ) was used as a work piece. The unit in FIG. 6 is mm.

(Measurement / evaluation of shape freedom)
The degree of freedom in shape of each variant polarizing plate processed and manufactured according to Examples and Comparative Examples was measured and evaluated as follows. In each of the examples and comparative examples, the convex R portion, the concave R portion, and the deformed portion of the hole portion as shown in FIG. 1 were processed and manufactured into a polarizing plate, and as a result, the processed portion could be formed. If it was impossible, it was evaluated as "○", and if it was impossible, it was evaluated as "×". When the processed portion could be formed, the minimum value that could be formed was measured using a three-dimensional dimensional measuring device QV-Apex606 manufactured by Mitutoyo.

(Measurement of dimensional accuracy and squareness accuracy)
The dimensional accuracy and squareness accuracy of each variant polarizing plate processed and manufactured according to Examples and Comparative Examples were measured as follows. Each dimensional accuracy was calculated by observing with an optical microscope BX51 manufactured by OLIMPUS and a three-dimensional dimensional measuring instrument QV-Apex606 manufactured by Mitutoyo. The results were the same in both cases.

(Measurement / evaluation of end parts)
The end component positions of the irregularly shaped polarizing plates processed and manufactured according to Examples and Comparative Examples were measured and evaluated as follows. In each of the examples and comparative examples, "○" if cracks, breaks, or discoloration did not occur at each end after processing and manufacturing, and "x" if cracks, breaks, or discoloration occurred. Evaluated as. In addition, when cracks, breaks, or discoloration occurred, the magnitude of those defects was measured using a microscope (optical microscope BX51 manufactured by OLIMPUS).

The obtained results are shown in Table 2 below.

In Example 1, the minimum value of R was 3 mm in the concave R. Further, in Example 2, the minimum value of R was 62.5 mm in the concave R. On the other hand, in Comparative Examples 1 and 2, cracks having a maximum of 100 μm were generated. Further, in Comparative Examples 1 and 2, a maximum breakage of 1000 μm occurred. Further, in Comparative Example 3, discoloration of a maximum of 50 μm occurred.

As described above, when the manufacturing method in the examples of the present application is used, a deformed polarizing plate having a concave R portion and / or a hole portion having a small diameter can be easily suppressed from cracking, breaking, and discoloration. I was able to get it. On the other hand, when the production method in the comparative example was used, cracks, breaks, or discoloration occurred.

Further, the processing in Examples 3 to 5 and Comparative Examples 4 to 5 was carried out by processing under the conditions shown in Table 3 below and the processing shape shown in FIG. 7. Further, a laminated body in which a surface protection film (RP296C) manufactured by Nitto Denko Co., Ltd. was laminated on a polarizing plate (APCFU4MS) manufactured by Nitto Denko Co., Ltd. was used as a work piece. The processing conditions for the Thomson type in Comparative Example 5 are the same as those in Comparative Example 1. The radius of the recess in FIG. 7 is 3 mm.

(Measurement of delamination amount)
The amount of delamination of each variant polarizing plate processed and manufactured according to Examples and Comparative Examples was measured as follows. The obtained irregularly shaped polarizing plates were observed under a microscope, and the distances at which delamination occurred deepest from the ends at the corners, straight lines, and recesses were measured.

The obtained results are shown in Table 3 below.

In Examples 3 to 5, the maximum value of the delamination amount was less than 0 μm at any of the corner portion, the straight portion, and the concave portion. On the other hand, in Comparative Examples 4 to 5, the maximum value of the delamination amount was 60 μm or more at any of the corner portion, the straight portion, and the concave portion.

When processing was performed at a cutting angle of 60 ° or more as described above, the occurrence of delamination of the deformed polarizing plate could be suppressed more preferably.

Claims (16)

A method for manufacturing a deformed polarizing plate for an image display device having a concave R portion.
Including a step of forming the concave R portion by using a cutting means in which the blade abuts on the cutting surface from the lateral direction and cuts.
The radius of the concave R portion is 5 mm or less, and the radius is 5 mm or less.
The cutting means is an end mill.
The deformed polarizing plate includes a polarizer and a protective film arranged on at least one of the polarizers.
A method for manufacturing a deformed polarizing plate, wherein the cutting angle formed by the processing direction and the blade surface of the blade is 60 ° or more. The method for producing a deformed polarizing plate according to claim 1, wherein the protective film is an acrylic resin or a norbornene resin. The method for manufacturing a deformed polarizing plate according to claim 1, wherein the cutting angle formed by the processing direction and the blade surface of the blade is 65 ° to 90 °. The method for manufacturing a deformed polarizing plate according to claim 1, wherein the cutting angle formed by the processing direction and the blade surface of the blade is 90 °. A device for manufacturing a deformed polarizing plate for an image display device having a concave R portion.
Equipped with a cutting means that allows the blade to come into contact with the cutting surface from the lateral direction and cut.
The radius of the concave R portion is 5 mm or less, and the radius is 5 mm or less.
The cutting means is an end mill.
The deformed polarizing plate includes a polarizer and a protective film arranged on at least one of the polarizers.
A device for manufacturing a deformed polarizing plate in which the cutting angle formed by the processing direction and the blade surface of the blade is 60 ° or more. The apparatus for producing a deformed polarizing plate according to claim 5, wherein the protective film is an acrylic resin or a norbornene resin. The apparatus for manufacturing a deformed polarizing plate according to claim 5, wherein the cutting angle formed by the machining direction by the cutting means and the blade surface of the blade is 65 ° to 90 °. The apparatus for manufacturing a deformed polarizing plate according to claim 5, wherein the cutting angle formed by the machining direction by the cutting means and the blade surface of the blade is 90 °. A method for manufacturing a deformed polarizing plate for an image display device having a hole.
Including the step of forming the hole using an end mill.
The radius of the hole is 5 mm or less,
The deformed polarizing plate includes a polarizer and a protective film arranged on at least one of the polarizers.
A method for manufacturing a deformed polarizing plate, wherein the cutting angle formed by the processing direction and the blade surface of the end mill is 60 ° or more. The method for producing a deformed polarizing plate according to claim 9, wherein the protective film is an acrylic resin or a norbornene resin. The method for manufacturing a deformed polarizing plate according to claim 9, wherein the cutting angle formed by the processing direction and the blade surface of the end mill is 65 ° to 90 °. The method for manufacturing a deformed polarizing plate according to claim 9, wherein the cutting angle formed by the processing direction and the blade surface of the end mill is 90 °. A device for manufacturing a deformed polarizing plate for an image display device having a hole.
Equipped with an end mill
The radius of the hole is 5 mm or less,
The deformed polarizing plate includes a polarizer and a protective film arranged on at least one of the polarizers.
A device for manufacturing a deformed polarizing plate in which the cutting angle formed by the processing direction and the blade surface of the end mill is 60 ° or more. The apparatus for producing a deformed polarizing plate according to claim 13, wherein the protective film is an acrylic resin or a norbornene resin. The apparatus for manufacturing a deformed polarizing plate according to claim 13, wherein the cutting angle formed by the processing direction and the blade surface of the end mill is 65 ° to 90 °. The apparatus for manufacturing a deformed polarizing plate according to claim 13, wherein the cutting angle formed by the processing direction and the blade surface of the end mill is 90 °.

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