KR102436860B1 - Optical film set and manufacturing method thereof - Google Patents

Abstract

When bonding a thin optical function film to an optical cell, even if a roll-to-panel method and a sheet-to-panel method are used together, for the purpose of providing an optical film set capable of suitably manufacturing an optical display panel having the same configuration do. The present invention is an optical film set having an optical film on a roll and an optical film on a sheet, wherein the optical film (1) on a roll includes a release film (11), a pressure-sensitive adhesive layer (12), an optical function film (13) and a second film 1 surface protection film 14 is laminated in this order, and the said sheet-fed optical film 2 is the said release film 21, the said adhesive layer 22, the said optical function film 23; The first surface protection film 24 and the second surface protection film 25 are laminated in this order.

Description

Optical film set and manufacturing method thereof

The present invention relates to an optical film set having an optical film on a roll and an optical film on a sheet, and a method for producing the same.

An optical film in which a release film, an adhesive layer, an optical function film (typically, a polarizing film) and a surface protection film were laminated|stacked in this order is comprised in roll shape. The optical film fed out from the optical film on this roll is cut (half-cut) in the width direction while leaving the release film, and the release film is peeled from the optical film obtained by cutting, There is a method (hereinafter also referred to as a "roll-to-panel method") of bonding an optical film to an optical cell through the exposed pressure-sensitive adhesive layer (see, for example, Patent Documents 1 and 2).

On the other hand, as a bonding method of an optical film different from the roll-to-panel method, an optical film previously in a sheet state is bonded to an optical cell through a pressure-sensitive adhesive layer exposed by peeling the release film (hereinafter referred to as "sheet - also referred to as "two-panel system" (see, for example, Patent Document 3).

Japanese Patent Laid-Open No. 2011-123208 Japanese Patent Laid-Open No. 2015-049115 Japanese Patent Laid-Open No. 2006-039238

By the way, in the manufacturing site of optical display panels including a liquid crystal display panel, not only a roll-to-panel system but a sheet-to-panel system are used together, and the case of manufacturing the optical display panel of the same structure is newly generated. For example, in patent document 2, it manufactures continuously an optical display panel using the roll-to-panel system, and performing a rework process with respect to the optical display panel judged as a defective product is disclosed. When a new optical function film is bonded to an optical cell in such a rework process when many defective goods do not generate|occur|produce so much, it is considered to use a sheet-to-panel system. Moreover, for example, when mass production of the optical display panel of the same structure is required in a short period of time, it is impossible to procure all the supply quantity by a roll-to-panel system, and it is also conceivable to use a sheet-to-panel system together.

In recent years, as thickness reduction of an optical display panel progresses, the optical function film (for example, a polarizing film with a thickness of 60 micrometers or less) thinner than conventionally including a polarizing film has been developed. Such a thin optical function film is weak in elasticity (modulus of elasticity), and distortion, curl, etc. are easy to occur.

According to the roll-to-panel system, the thin optical function film is conveyed to the bonding position in the state laminated|stacked on the carrier film (release film), and the optical function film is peeled from the carrier film (release film) at the said bonding position, and optical In order to bond a functional film to an optical cell, a thin optically functional film can be continuously bonded to an optical cell, suppressing generation|occurrence|production of distortion, curl, etc. However, in the sheet-to-panel method, it is difficult to handle such as conveying the optical function film in a single-wafer state, peeling the release film, and bonding processing of the optical function film to the liquid crystal cell, and poor bonding occurs, resulting in a decrease in yield. concerned

The present invention relates to an optical film set capable of suitably manufacturing an optical display panel having the same configuration even when a roll-to-panel method and a sheet-to-panel method are used together when bonding a thin optical function film to an optical cell, and an optical film set thereof It aims at providing a manufacturing method.

The present invention is an optical film set having an optical film on a roll and an optical film on a sheet,

The optical film on the roll has a configuration in which a release film, an adhesive layer, an optical function film, and a first surface protection film are laminated in this order,

The said sheet-fed optical film is the structure by which the said release film, the said adhesive layer, the said optical function film, the said 1st surface protection film, and the 2nd surface protection film are laminated|stacked in this order.

Said invention WHEREIN: The same surface protection film as a 1st surface protection film may be sufficient as a said 2nd surface protection film, and the surface protection film different from a 1st surface protection film may be sufficient as it.

Said invention WHEREIN: The structure in which the peeling force between the layers of the said 1st surface protection film and the said optical function film is larger than the peeling force between the layers of a said 2nd surface protection film and the said 1st surface protection film may be sufficient.

According to the relationship of this peeling force, a 2nd surface protection film can be peeled more smoothly.

Said invention WHEREIN: A polarizing film may be sufficient as the said optical function film.

Said invention WHEREIN: The said polarizing film may be 60 micrometers or less in thickness.

Said invention WHEREIN: The structure which has a polarizer whose thickness is 10 micrometers or less may be sufficient as the said polarizing film.

Said invention WHEREIN: The said 1st surface protection film has a 1st base film and a 1st adhesive layer, and may be laminated|stacked on the said optical function film via the said 1st adhesive layer.

Said invention WHEREIN: The said 1st surface protection film may be a self-adhesive film.

Said invention WHEREIN: The said 2nd surface protection film has a 2nd base film and a 2nd adhesive layer, and may be laminated|stacked on the said 1st surface protection film via the said 2nd adhesive layer.

Said invention WHEREIN: The said 2nd surface protection film may be a self-adhesive film.

In the above invention, the roll-shaped optical film has a width corresponding to a set of sides that the optical cells face, and the single-leaf optical film has a set of sides that the optical cells face. It may have a configuration in which it has a length corresponding to one set of sides, and another set of opposite sides has a length corresponding to the other set of sides that the optical cell faces.

In the above invention, in the optical film on the roll and the optical film on the sheet, the pressure-sensitive adhesive layer, the optical function film, and the first surface protection film are laminated in this order on one side of the optical cell. It may be used to manufacture an optical display panel.

In the above invention, the optical film on the roll is used to manufacture the optical display panel by a roll-to-panel method, and the sheet-shaped optical film is manufactured by the sheet-to-panel method for the optical display panel may be used to

In the invention, the single-leaf optical film is determined to be defective among the optical display panels manufactured by the roll-to-panel method using the roll-shaped optical film, and the pressure-sensitive adhesive layer, the optical function film and Remanufacture of the optical display panel having a configuration in which a pressure-sensitive adhesive layer, an optical function film and a first surface protection film are laminated in this order on one side of the optical cell of the optical display panel from which the first surface protection film is peeled may be used for

A "roll-to-panel system" is a system which peels a release film from the optical film fed out from the optical film on a roll, and bonds the said optical film to an optical cell through the exposed adhesive layer. Here, by the time a release film peels, the perforation line of a predetermined space|interval should just leave a release film in the optical film in the width direction, and just to form. In addition, the perforation line may be formed in the width direction before the optical film is fed out from a roll, and after being fed, a perforation line may be formed in the width direction before peeling of a release film.

"The sheet-to-panel system" is a system which peels a release film from the optical film previously made into a sheet-wafer state, and bonds the said optical film to an optical cell through the exposed adhesive layer.

Another invention is the manufacturing method of the said optical film set,

The manufacturing method of the optical film on the said roll,

A step of preparing an optical film original fabric having a configuration in which the release film, the pressure-sensitive adhesive layer, the optical function film, and the first surface protection film are laminated in this order;

The optical film raw material is slitted and wound to produce an optical film on the roll,

The manufacturing method of the said sheet-fed optical film,

A step of bonding a second surface protection film original to the first surface protection film side of the optical film original fabric, and manufacturing an optical film original fabric on which a second surface protection film is laminated;

and cutting the optical film raw material on which the second surface protection film is laminated, and manufacturing a sheet-like optical film.

In the above invention, the "cutting processing" is not limited as long as the optical film raw material is processed into a single-leaf optical film through a cutting process, and the cross-section is processed after cutting into a sheet shape and cutting into a sheet shape. It means processing including cutting in the width direction after slitting the optical film original fabric to a predetermined width (however, not processing the cross section).

Another invention is a double-sided optical film set having a first optical film set and a second optical film set,

The first optical film set has a first optical film on a roll and a first optical film on a sheet,

The first optical film on the roll has a configuration in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are laminated in this order,

The sheet-like first optical film has a configuration in which the first release film, the first pressure-sensitive adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film are laminated in this order, ,

The second optical film set has a second optical film on a roll and a second optical film on a sheet,

The second optical film on the roll has a configuration in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are laminated in this order,

The said sheet-like 2nd optical film is a structure in which the said 2nd release film, the said 2nd adhesive layer, the said 2nd optical function film, the said 3rd surface protection film, and the 4th surface protection film are laminated|stacked in this order. .

In the above invention, the first optical film on the roll and the first optical film on the sheet and the second optical film on the roll and the second optical film on the sheet are the first adhesive on one side of the optical cell layer, the first optical function film and the first surface protection film are laminated in this order, and the second pressure-sensitive adhesive layer, the second optical function film and the third surface protection film on the other side of the optical cell It may be used for manufacturing the optical display panel of the structure laminated|stacked in this order.

Said invention WHEREIN: The said 1st optical function film and the said 2nd optical function film may have the same optical function, and may have another optical function.

A method for manufacturing the optical film set on both sides,

The manufacturing method of the 1st optical film on the said roll,

A step of preparing a first optical film raw material having a configuration in which the first release film, the first pressure-sensitive adhesive layer, the first optical function film, and the first surface protection film are laminated in this order;

The first optical film raw material may be slitted and wound to produce a first optical film on the roll,

The manufacturing method of the 1st optical film in the sheet form,

A step of bonding a second surface protection film original fabric to the first surface protection film side of the first optical film original fabric, and manufacturing a second optical film original fabric on which a second surface protection film is laminated;

The second optical film raw material on which the second surface protection film is laminated may be cut and processed to produce a sheet-like first optical film,

The manufacturing method of the 2nd optical film on the said roll,

A step of preparing a second optical film original fabric having a configuration in which the second release film, the second pressure-sensitive adhesive layer, the second optical function film, and the third surface protection film are laminated in this order;

The second optical film raw material may be slitted and wound to produce a second optical film on the roll,

The method for producing the sheet-like second optical film,

A step of bonding a fourth surface protection film original fabric to the third surface protection film side of the second optical film original fabric, and manufacturing a fourth optical film original fabric on which the fourth surface protection film is laminated;

The process of cutting and processing the 4th optical film original fabric on which the said 4th surface protection film was laminated|stacked, and manufacturing a sheet-like 2nd optical film may be included.

In the above invention, when a polarizing film is used as the optical function film (the first optical function film, the second optical function film) or when a polarizing film is included as one member of the configuration of the optical function film , in the roll- and sheetfed optical films (first optical film, second optical film) and optical film original (first optical film original, second optical film original), the absorption axis direction of the polarizing film is, in the present invention It is not particularly limited as long as it does not impair the achievement of the purpose of That is, even if a roll-to-panel system and a sheet-to-panel system are used together, as long as it becomes the combination which can manufacture the optical display panel of the same structure, the optical film (1st optical film, 2nd optical film) on a roll ) and the optical film raw material (first optical film raw material, second optical film raw material), in the polarizing film, the absorption axis direction may be parallel to, orthogonal to, the long side direction, and may be inclined (for example, long direction at an angle of 45° with respect to the side direction). In addition, the absorption axis direction of a rectangular single-leaf-shaped polarizing film may be parallel to the long side direction, may be orthogonal, and may be inclined (for example, the direction which makes an angle of 45 degrees with respect to a long side direction). In addition, the absorption axis direction of the square sheet-like polarizing film may be parallel to any one side, and may be inclined (for example, the direction which makes an angle of 45 degrees with respect to a side).

In the present invention, the optical film on a roll has an adhesive layer, an optical function film, and a surface protection film while leaving a release film, in a direction (width direction) orthogonal to the long side direction of the optical film, in which the optical cell faces another Incisions may be formed at intervals corresponding to a set of sides. According to this structure, it is not necessary to cut|disconnect (half-cut) an optical film in a roll-to-panel system.

Said invention WHEREIN: The liquid crystal cell or organic electroluminescent cell of VA mode or IPS mode may be sufficient as the said optical cell.

The shape of the optical cell may be square or rectangular, and is not particularly limited as long as it is a shape having one set of opposite sides and another set of opposite sides. Further, one set of sides that the optical cell faces and the other set of sides are orthogonal to each other are usually orthogonal to each other.

The optical film set of this invention is used for manufacturing the optical display panel of the same structure. The roll-shaped optical film is used by a roll-to-panel system. The sheet-fed optical film is used in a sheet-to-panel method. The sheet-like optical film has the same laminated structure as the roll-like optical film except that the second surface protection film is provided. The optical film on a roll uses a roll-to-panel method to manufacture an optical display panel of a configuration in which an adhesive layer, an optical function film, and a first surface protection film are laminated in this order on one side of an optical cell. used In addition, the sheet-fed optical film provided with the second surface protection film is suitable for an optical cell by using a sheet-to-panel system while suppressing the occurrence of distortion, curl, etc., since handling properties are improved. can be tightly joined. And, by removing (eg, peeling) the second surface protection film from the sheet-like optical film bonded to the optical display panel, as a result, the same laminated configuration as that of the optical display panel manufactured by the roll-to-panel method An optical display panel can be manufactured. That is, according to the optical film set of this invention, when bonding an optical film to an optical cell, even when a roll-to-panel system and a sheet-to-panel system are used together, the optical display panel of the same structure is manufactured suitably can do.

BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic diagram which shows the optical film set of Embodiment 1. FIG.
It is a schematic diagram which shows the both-side optical film set of Embodiment 2. FIG.
Fig. 3A is a schematic view showing a method for manufacturing a first optical film on a roll;
Fig. 3B is a schematic diagram showing a method for manufacturing a sheet-like first optical film;
Fig. 4 is a schematic diagram of a system for continuous manufacturing of an optical display panel according to a fourth embodiment;
5 is a diagram showing a process of remanufacturing.
Fig. 6 is a schematic diagram of a continuous manufacturing system of an optical display panel according to a fifth embodiment;

(Embodiment 1: Optical Film Set)

BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic diagram which shows an optical film set. A side, planar and partial cross-sectional enlarged view of the first optical film 1 on a roll is shown in the upper part of FIG. 1 . The side, plan, and partial cross-sectional enlarged views of the sheet-like first optical film 2 are shown in the lower part of FIG. 1 . As for the first optical film 1 on a roll, the 1st release film 11, the 1st adhesive layer 12, the 1st optical function film 13, and the 1st surface protection film 14 are laminated|stacked in this order, have.

The roll-shaped 1st optical film 1 is used for manufacturing an optical display panel by a roll-to-panel system. In this case, the strip-shaped first optical film 10 of a width a fed out from the first optical film 1 on a roll is a release film 11 at a predetermined interval b in the cutting means C. is cut leaving a The code|symbol s is the cutout formed in the 1st optical film 30 by the said cutting|disconnection.

In addition, the sheet-like first optical film 2 includes a first release film 21 , a first pressure-sensitive adhesive layer 22 , a first optical function film 23 , a first surface protection film 24 , and a second surface protection film 24 . The surface protection films 25 are laminated in this order. The size of the sheet-like first optical film 2 is vertical a and horizontal b. The sheet-like first optical film 2 is used to manufacture an optical display panel by a sheet-to-panel system.

In this embodiment, the 1st release film 11 and the 1st release film 21 have the same structure. The first pressure-sensitive adhesive layer 12 and the first pressure-sensitive adhesive layer 22 have the same configuration. The first optical function film 13 and the first optical function film 23 have the same configuration. The 1st surface protection film 14, the 1st surface protection film 24, and the 2nd surface protection film 25 have the same structure. With "same structure", material, thickness, etc. not only correspond completely, but may be substantially the same (for example, it is the same in manufacturing quality).

In this embodiment, the 1st surface protection film 14 (or 24) has a 1st base film and a 1st adhesive layer, The 1st optical function film 13 ( or (23)). Moreover, as another embodiment, the 1st surface protection film 14 (or 24) may be a self-adhesive film.

In this embodiment, the 2nd surface protection film 25 has a 2nd base film and a 2nd adhesive layer, and is laminated|stacked on the 1st surface protection film 24 via the said 2nd adhesive layer. Moreover, as another embodiment, the 2nd surface protection film 25 may be a self-adhesive film.

(Relationship between phase separation force)

Moreover, the peeling force between the layers of the 1st surface protection film 24 and the 1st optical function film 23 is larger than the peeling force between the layers of the 2nd surface protection film 25 and the 1st surface protection film 24 is composition. According to this, the 2nd surface protection film 25 can be peeled more smoothly. As a measurement of peeling force, a tensile tester can be used, for example. As peeling conditions, it measures by 180 degree peeling of 0.3 m/min. Peeling force is controlled by the composition, thickness, etc. of an adhesive.

The magnitude relationship of the peeling force between each layer in the 1st optical film 2 of sheet-wafer shape is as follows.

Peeling force A between the first release film 21 and the first pressure-sensitive adhesive layer 22,

Peeling force B between the first adhesive layer 22 and the first optical function film 23,

Peeling force C between the first optical function film 23 and the first surface protection film 24 ,

When it is set as the interlayer peeling force D of the 1st surface protection film 24 and the 2nd surface protection film 25,

A<B, A<C, A<D.

Preferably, A<D<C≤B or A<D<B≤C.

More preferably, A<D<C<B.

According to the relationship of said interphase peeling force, when a 1st release film peels, it can suppress that a 2nd surface protection film peels.

<Optical function film>

The first optical function films 13 and 23 are not particularly limited as long as they are films having an optical function, and examples thereof include a polarizing film, a retardation film, a luminance enhancing film, and a diffusion film, but typically a polarizing film.

(polarizing film)

In this embodiment, from a viewpoint of thickness reduction, it is preferable to use the polarizing film whose thickness (total thickness) is 60 micrometers or less, It is more preferable that it is 55 micrometers or less, It is still more preferable that it is 50 micrometers or less. As a polarizing film, for example, (1) the structure in which the protective film (the "polarizer protective film" may be called) is laminated|stacked on both sides of the polarizer (it may be called a "both protective polarizing film"), (2) a polarizer The structure in which the protective film is laminated|stacked only on one side of (it may be called "one side protective polarizing film"), etc. are mentioned.

(polarizer)

As for the polarizer, the thing using polyvinyl alcohol-type resin is used. As the polarizer, for example, a dichroic substance such as iodine or a dichroic dye is adsorbed to a hydrophilic polymer film such as a polyvinyl alcohol-based film, a partially formalized polyvinyl alcohol-based film, or an ethylene/vinyl acetate copolymer-based partially saponified film. A polyene-type oriented film, such as a thing axially stretched, a dehydration-treated product of polyvinyl alcohol, and a dehydrochloric acid-treated product of polyvinyl chloride, etc. are mentioned. Among these, a polarizer made of a polyvinyl alcohol-based film and a dichroic substance such as iodine is suitable.

A polarizer obtained by uniaxially stretching a polyvinyl alcohol-based film by dyeing it with iodine can be produced by, for example, immersing polyvinyl alcohol in an aqueous solution of iodine, dyeing it, and stretching it to 3 to 7 times its original length. If necessary, boric acid, zinc sulfate, zinc chloride, etc. may be included, and it can also be immersed in aqueous solutions, such as potassium iodide. If necessary, the polyvinyl alcohol-based film may be immersed in water before dyeing and washed with water. By rinsing the polyvinyl alcohol-based film with water, it is possible not only to wash the surface of the polyvinyl alcohol-based film from stains and anti-blocking agents, but also to swell the polyvinyl alcohol-based film to prevent unevenness such as staining of dyeing. Extending|stretching may be performed after dyeing|staining with iodine, may be extended|stretched while dyeing|staining, and may dye|stain with iodine after extending|stretching. It can be extended also in aqueous solutions, such as boric acid and potassium iodide, and a water bath.

It is preferable that the thickness of a polarizer is 10 micrometers or less from a viewpoint of thickness reduction, Furthermore, it is 8 micrometers or less, Furthermore, it is preferable that it is 7 micrometers or less, Furthermore, it is preferable that it is 6 micrometers or less. On the other hand, it is preferable that the thickness of a polarizer is 2 micrometers or more, Furthermore, it is 3 micrometers or more. Such a thin polarizer has little thickness nonuniformity, is excellent in visibility, and since there are few dimensional changes, it is excellent in durability with respect to a thermal shock. On the other hand, in a polarizing film including a polarizer having a thickness of 10 µm or less, since the elasticity (modulus of elasticity) of the film is remarkably low, distortion, curl, etc. are highly likely to occur in the sheet-to-panel system. Therefore, this invention is especially suitable for the said polarizing film.

As a thin polarizer, typically,

Japanese Patent No. 4751486 specification,

Japanese Patent No. 4751481 specification,

Japanese Patent No. 4815544 specification,

Japanese Patent No. 5048120 specification,

International Publication No. 2014/077599 pamphlet,

International Publication No. 2014/077636 pamphlet,

The thin-shaped polarizer described in etc. or the thin-shaped polarizer obtained from the manufacturing method as described in these is mentioned.

The polarizer has an optical characteristic expressed by a single transmittance T and a degree of polarization P by the following formula

P>-(10 ^0.929T-42.4 -1)×100 (however, T<42.3), or

P≥99.9 (however, T≥42.3)

It is preferable that it is configured to satisfy the condition of The polarizer comprised so that the said condition may be satisfy|filled has the performance calculated|required as a display for liquid crystal TVs using a large-size display element uniquely. Specifically, the contrast ratio is 1000:1 or more, and the maximum luminance is 500 cd/m 2 or more. As another use, it is joined to the visual recognition side of an organic electroluminescent cell, for example.

Among the manufacturing methods including the process of extending|stretching and the process of dyeing as said thin-shaped polarizer in the state of a laminated body, from the point which can extend|stretch at a high magnification and can improve polarization performance, JP 4751486 specification, JP 4751481 It is preferably obtained by a manufacturing method including a step of stretching in an aqueous boric acid solution described in Japanese Patent No. 4815544 and Japanese Patent No. 4815544, and in particular, in an aqueous boric acid solution described in Japanese Patent No. 4751481 and Japanese Patent No. 4815544. It is preferable to obtain by the manufacturing method including the process of carrying out aerial stretching auxiliary before extending|stretching. These thin polarizers can be obtained by a manufacturing method including the process of extending|stretching a polyvinyl alcohol-type resin (henceforth PVA-type resin) layer and the resin base material for extending|stretching in the state of a laminated body, and the process of dyeing. If it is this manufacturing method, even if the PVA-type resin layer is thin, by being supported by the resin base material for extending|stretching, it becomes possible to extend|stretch without defects, such as a fracture|rupture by extending|stretching.

(Protective Film (Polarizer Protective Film))

As a material constituting the protective film, those having excellent transparency, mechanical strength, thermal stability, moisture barrier property, isotropy, and the like are preferable. For example, polyester polymers such as polyethylene terephthalate and polyethylene naphthalate, cellulose polymers such as diacetyl cellulose and triacetyl cellulose, acrylic polymers such as polymethyl methacrylate, polystyrene or acrylonitrile/styrene copolymer Styrenic polymers, such as (AS resin), polycarbonate-type polymer, etc. are mentioned. In addition, polyethylene, polypropylene, polyolefin having a cyclo or norbornene structure, polyolefin polymer such as ethylene/propylene copolymer, vinyl chloride polymer, amide polymer such as nylon or aromatic polyamide, imide polymer, alcohol Phone-based polymer, polyethersulfone-based polymer, polyetheretherketone-based polymer, polyphenylenesulfide-based polymer, vinyl alcohol-based polymer, vinylidene chloride-based polymer, vinyl butyral-based polymer, arylate-based polymer, polyoxymethylene-based polymer, Epoxy polymers or blends of the above polymers are also exemplified as examples of the polymer forming the above protective film.

In addition, one or more types of arbitrary appropriate additives may be contained in a protective film. As an additive, a ultraviolet absorber, antioxidant, a lubricant, a plasticizer, a mold release agent, a coloring inhibitor, a flame retardant, a nucleating agent, antistatic agent, a pigment, a coloring agent etc. are mentioned, for example. Content of the said thermoplastic resin in a transparent protective film becomes like this. Preferably it is 50 to 100 weight%, More preferably, it is 50 to 99 weight%, More preferably, it is 60 to 98 weight%, Especially preferably, it is 70 to 97 weight%. to be. When content of the said thermoplastic resin in a transparent protective film is 50 weight% or less, there exists a possibility that the high transparency etc. which a thermoplastic resin originally has may not fully express.

As said protective film, retardation film, a brightness improving film, a diffusion film, etc. can also be used.

Functional layers, such as a hard coat layer, an antireflection layer, a sticking prevention layer, a diffusion layer thru|or an anti-glare layer, can be formed on the surface to which the polarizer is not adhere|attached of the said protective film. In addition, the functional layers such as the hard coat layer, the antireflection layer, the anti-sticking layer, the diffusion layer and the anti-glare layer can be provided on the transparent protective film itself, and can also be installed separately from the transparent protective film. have.

(Intervening layer)

The protective film and the polarizer are laminated with intervening layers such as an adhesive layer, an adhesive layer, and an undercoat layer (primer layer) interposed therebetween. At this time, it is preferable to laminate both without an air gap by an intervening layer.

The adhesive layer is formed by an adhesive. The type of adhesive is not particularly limited, and various types of adhesive may be used. The adhesive layer is not particularly limited as long as it is optically transparent, and various types of adhesives such as water-based, solvent-based, hot-melt-based and active energy ray-curable adhesives are used, but water-based adhesives or active energy ray-curable adhesives are suitable.

Examples of the water-based adhesive include an isocyanate-based adhesive, a polyvinyl alcohol-based adhesive, a gelatin-based adhesive, a vinyl-based latex-based adhesive, and a water-based polyester. A water-based adhesive agent is normally used as an adhesive agent containing aqueous solution, and contains 0.5 to 60weight% of solid content normally.

An active energy ray-curable adhesive is an adhesive which hardening advances by active energy rays, such as an electron beam and an ultraviolet-ray (radical hardening type, cation curing type), For example, it can be used in the form of an electron beam curing type and an ultraviolet curable type. As an active energy ray hardening-type adhesive agent, an optical radical hardening-type adhesive agent can be used, for example. When using an active energy ray hardening-type adhesive agent of an optical radical curing type as an ultraviolet curing type, the said adhesive agent contains a radically polymerizable compound and a photoinitiator.

Moreover, lamination|stacking of a polarizer and a protective film WHEREIN: An easily bonding layer can be provided between a transparent protective film and an adhesive bond layer. The easily-adhesive layer can be formed of various resins having, for example, a polyester skeleton, a polyether skeleton, a polycarbonate skeleton, a polyurethane skeleton, a silicone-based skeleton, a polyamide skeleton, a polyimide skeleton, and a polyvinyl alcohol skeleton. have. These polymer resins can be used individually by 1 type or in combination of 2 or more type. Moreover, you may add another additive to formation of an easily bonding layer. Specifically, you may further use stabilizers, such as a tackifier, a ultraviolet absorber, antioxidant, and a heat-resistant stabilizer.

An adhesive layer is formed from an adhesive. Various pressure-sensitive adhesives can be used as the pressure-sensitive adhesive, for example, a rubber pressure-sensitive adhesive, an acrylic pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, a urethane pressure-sensitive adhesive, a vinyl alkyl ether-based pressure-sensitive adhesive, a polyvinylpyrrolidone pressure-sensitive adhesive, a polyacrylamide-based pressure-sensitive adhesive, a cellulose pressure-sensitive adhesive, etc. have. The adhesive base polymer is selected according to the type of the adhesive. Among the above-mentioned pressure-sensitive adhesives, acrylic pressure-sensitive adhesives are preferably used from the viewpoints of excellent optical transparency, moderate wettability, cohesiveness and adhesive properties, and excellent weather resistance and heat resistance.

The undercoat layer (primer layer) is formed in order to improve the adhesiveness of a polarizer and a protective film. As a material which comprises a primer layer, if it is a material which exhibits strong adhesive force to some extent to both of a base film and a polyvinyl alcohol-type resin layer, it will not specifically limit. For example, a thermoplastic resin excellent in transparency, thermal stability, stretchability, etc. is used. Examples of the thermoplastic resin include an acrylic resin, a polyolefin resin, a polyester resin, a polyvinyl alcohol resin, or a mixture thereof.

(surface protection film)

A 1st, 2nd surface protection film is an optical film. WHEREIN: It is provided in the single side|surface (surface on which the adhesive layer is not laminated|stacked) of a polarizing film, and protects optical function films, such as a polarizing film.

As a base film of a 1st, 2nd surface protection film, the film material which has an isotropy from viewpoints, such as a test|inspection property, manageability, or isotropy, is selected. Examples of the film material include polyester-based resins such as polyethylene terephthalate films, cellulose-based resins, acetate-based resins, polyethersulfone-based resins, polycarbonate-based resins, polyamide-based resins, polyimide-based resins, and transparent polymers such as polyolefin resins and acrylic resins. Among these, polyester-type resin is preferable. A base film can also be used as a laminated body of 1 type, or 2 or more types of film materials, and also the stretched material of the said film can also be used. It is preferable that the thickness of a base film film is 10 micrometers - 150 micrometers or less, Furthermore, it is preferable that they are 20-100 micrometers.

The 1st, 2nd surface protection film can use the thing which has the said base film and an adhesive layer besides being able to use the said base film as a self-adhesive film. It is preferable to use what has an adhesive layer from a viewpoint of protecting optical function films, such as a polarizing film, for a 1st, 2nd surface protection film.

As the pressure-sensitive adhesive layer used for lamination of the first and second surface protection films, for example, a (meth)acrylic polymer, silicone polymer, polyester, polyurethane, polyamide, polyether, fluorine-based or rubber-based polymer is used as a base polymer. It can be used by appropriately selecting the pressure-sensitive adhesive. From viewpoints of transparency, weather resistance, heat resistance, etc., the acrylic adhesive which uses an acrylic polymer as a base polymer is preferable. The thickness (dry film thickness) of an adhesive layer is determined with the required adhesive force. It is about 1-100 micrometers normally, Preferably it is 5-50 micrometers.

In addition, a peeling process layer can be formed in the 1st, 2nd surface protection film with low adhesive materials, such as silicone treatment, a long-chain alkyl treatment, and a fluorine treatment, on the opposite surface of the surface on which the adhesive layer was formed.

<Adhesive layer>

A suitable adhesive can be used for formation of the 1st adhesive layers 12 and 22, and there is no restriction|limiting in particular about the kind. Examples of the pressure-sensitive adhesive include a rubber pressure-sensitive adhesive, an acrylic pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, a urethane pressure-sensitive adhesive, a vinyl alkyl ether pressure-sensitive adhesive, a polyvinyl alcohol-based pressure-sensitive adhesive, a polyvinylpyrrolidone pressure-sensitive adhesive, a polyacrylamide pressure-sensitive adhesive, and a cellulose pressure-sensitive adhesive.

Among these pressure-sensitive adhesives, those which are excellent in optical transparency, exhibit moderate wettability, cohesiveness, and adhesive properties, and are excellent in weather resistance, heat resistance, and the like are preferably used. As what shows these characteristics, an acrylic adhesive is used preferably.

As a method of forming the first pressure-sensitive adhesive layers 12 and 22, for example, after the pressure-sensitive adhesive is applied to a release film (separator, etc.) subjected to peeling treatment, the polymerization solvent is dried and removed to form the pressure-sensitive adhesive layer, a polarizer (or It is produced by a method of transferring to a transparent protective film) or a method of applying the adhesive to a polarizer (or transparent protective film), drying and removing a polymerization solvent, etc. to form an adhesive layer on the polarizer, etc. In addition, in application of the adhesive, , suitably, one or more solvents other than the polymerization solvent may be newly added.

As the release film subjected to the release treatment, a silicone release liner is preferably used. In the step of forming the pressure-sensitive adhesive layer by applying and drying the pressure-sensitive adhesive of the present invention on such a liner, as a method of drying the pressure-sensitive adhesive, an appropriate and appropriate method may be employed depending on the purpose. Preferably, a method of overheating and drying the coating film is used. The heat drying temperature is preferably 40°C to 200°C, more preferably 50°C to 180°C, and particularly preferably 70°C to 170°C. By making heating temperature into the said range, the adhesive which has the outstanding adhesive characteristic can be obtained.

As for the drying time, an appropriate, appropriate time may be employed. The drying time is preferably 5 seconds to 20 minutes, more preferably 5 seconds to 10 minutes, particularly preferably 10 seconds to 5 minutes.

As a formation method of the 1st adhesive layers 12 and 22, various methods are used. Specifically, for example, roll coating, kiss roll coating, gravure coating, reverse coating, roll brush, spray coating, dip roll coating, bar coating, knife coating, air knife coating, curtain coating, lip coating, die coater, etc. Methods, such as an extrusion coating method, are mentioned.

The thickness in particular of the 1st adhesive layers 12 and 22 is not restrict|limited, For example, it is about 1-100 micrometers. Preferably, it is 2-50 micrometers, More preferably, it is 2-40 micrometers, More preferably, it is 5-35 micrometers.

<Release film>

The first release films 11 and 21 protect the pressure-sensitive adhesive layer until put into practical use. As a constituent material of the release film, for example, plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and nonwoven fabrics, nets, foam sheets, metal foils, and laminates thereof, etc. Although thin leaf body etc. are mentioned, A plastic film is used suitably at the point which is excellent in surface smoothness.

The plastic film is not particularly limited as long as it is a film capable of protecting the pressure-sensitive adhesive layer, and for example, a polyethylene film, a polypropylene film, a polybutene film, a polybutadiene film, a polymethylpentene film, a polyvinyl chloride film, and a vinyl chloride film. A copolymer film, a polyethylene terephthalate film, a polybutylene terephthalate film, a polyurethane film, an ethylene-vinyl acetate copolymer film, etc. are mentioned.

The thickness of the 1st release films 11 and 21 is 5-200 micrometers normally, Preferably it is about 5-100 micrometers. If necessary, the separator may be subjected to mold release and antifouling treatment with a silicone-based, fluorine-based, long-chain alkyl- or fatty acid amide-based release agent, silica powder, or the like, or antistatic treatment such as coating type, mixing type or vapor deposition type. In particular, by appropriately performing peeling treatment such as silicone treatment, long-chain alkyl treatment, and fluorine treatment on the surface of the release film, the releasability from the pressure-sensitive adhesive layer can be further improved.

(Embodiment 2: Double-sided optical film set)

The both-side optical film set of Embodiment 2 is comprised with a 1st optical film set and a 2nd optical film set. Since the 1st optical film set is the same as that of the 1st optical film set of Embodiment 1, description is abbreviate|omitted. The second optical film set will be described with reference to FIG. 2 . The second optical film set has a roll-shaped second optical film 3 and a sheet-shaped second optical film 4 .

The upper part of FIG. 2 shows a side view, a plan view and a partial cross-sectional enlarged view of the second optical film 3 on a roll. In the lower part of FIG. 2, a side view, a plan view, and a partial cross-sectional enlarged view of the sheet-like second optical film 4 are shown. As for the second optical film 3 on a roll, the 2nd release film 31, the 2nd adhesive layer 32, the 2nd optical function film 33, and the 3rd surface protection film 34 are laminated|stacked in this order, have. The strip|belt-shaped optical film 30 of the width b fed out from the 2nd optical film 3 on a roll is cut|disconnected leaving the 2nd release film 31 at the predetermined space|interval a by the cutting means C. The code|symbol s is the cut formed by the said cutting|disconnection in the optical film 30.

Moreover, the sheet-like 2nd optical film 4 is the 2nd release film 41, the 2nd adhesive layer 42, the 2nd optical function film 43, the 3rd surface protection film 44, and the 4th The surface protection films 45 are laminated in this order. The size of the 2nd optical film 4 of a single-wafer state is a horizontal a and a vertical b.

In this embodiment, the 2nd release film 31 and the 2nd release film 41 have the same structure. The second pressure-sensitive adhesive layer 32 and the second pressure-sensitive adhesive layer 42 have the same configuration. The second optical function film 33 and the second optical function film 43 have the same configuration. The 3rd surface protection film 34, the 3rd surface protection film 44, and the 4th surface protection film 45 have the same structure. With "same structure", material, thickness, etc. not only correspond completely, but may be substantially the same (for example, it is the same in manufacturing quality).

In this embodiment, the 3rd surface protection film 34 (or 44) has a 3rd base film and a 3rd adhesive layer, and the 2nd optical function film 33 ( or (43)). Moreover, as another embodiment, the 3rd surface protection film 34 (or 44) may be a self-adhesive film.

In this embodiment, the 4th surface protection film 45 has a 4th base film and a 4th adhesive layer, and is laminated|stacked on the 3rd surface protection film 34 via the said 4th adhesive layer. In another embodiment, the fourth surface protection film 45 may be a self-adhesive film.

(Relationship between phase separation force)

Moreover, the peeling force between the layers of the 3rd surface protection film 34 and the 2nd optical function film 33 is larger than the peeling force between the layers of the 4th surface protection film 45 and the 3rd surface protection film 44 is composition. According to this, the 4th surface protection film 45 can be peeled more smoothly.

The magnitude relationship of the peeling force between each layer in the sheet-like 2nd optical film 4 is as follows.

The interlayer peeling force A1 of the second release film 41 and the second pressure-sensitive adhesive layer 42 ,

Peeling force B1 between the second pressure-sensitive adhesive layer 42 and the second optical function film 43 ,

Interlayer peeling force C1 of the second optical function film 43 and the third surface protection film 44;

When it is set as the interlayer peeling force D1 of the 3rd surface protection film 44 and the 4th surface protection film 45,

A1<B1, A1<C1, A<D1.

Preferably, A1<D1<C1≤B1 or A1<D1<B1≤C1.

More preferably, A1<D1<C1<B1.

According to the relationship of said interphase peeling force, when a 2nd release film peels, it can suppress that a 4th surface protection film peels.

Each member constituting the roll-shaped second optical film and the sheet-leaf-shaped second optical film in the second optical film set is the same as the optical function film, the release film, the pressure-sensitive adhesive layer, and the surface protection film according to the first embodiment. configuration may be sufficient.

(Embodiment 3: Preparation of optical film set)

Next, the manufacturing method of a 1st optical film set and a 2nd optical film set is demonstrated. 3A is a schematic diagram showing a method of manufacturing the first optical film 1 on a roll. 3B is a schematic diagram showing a method of manufacturing the sheet-like first optical film 2 .

In FIG. 3A, the 1st optical film original fabric 5 on the roll of the structure in which the 1st release film, the 1st adhesive layer, the 1st optical function film, and the 1st surface protection film is laminated|stacked in this order is prepared. Then, from the 1st optical film original fabric 5, a 1st optical film is fed out, and it slit-processes to three strip|belt-shaped optical films with predetermined width a using the slit cut part sc. The slit-processed three strip|belt-shaped optical films are wound, respectively, and manufacture the 1st optical film on a roll.

In this embodiment, although the slit process is carried out in three strip|belt-shaped optical films, it is not restrict|limited to this. In addition, although the both ends e1 and e2 are trimmed (end trimming) in this embodiment, either end may be trimmed, and neither end part does not need to be trimmed.

In FIG. 3B, the 2nd surface fed out from the 2nd surface protection film original fabric S25 to the 1st surface protection film 14 side of the 1st optical film 1 (corresponding to the 1st optical film original fabric) on a roll. The protective film 25 is bonded by a bonding means (a pair of bonding rolls R1, R2), and optical film original fabric S2 in which the 2nd surface protection film 25 was laminated|stacked is manufactured. Then, all the optical film original fabric S2 on which the 2nd surface protection film 25 was laminated|stacked is cut-processed at predetermined intervals (b) using the cutting means FC, and the 1st optical film 2 of a sheet shape is cut manufacture The sheet-like 1st optical film 2 may be accommodated in a predetermined|prescribed accommodation part, and may be laminated|stacked on a carrier film. By the above method, a 1st optical film set can be manufactured.

As another embodiment, the process of winding optical film original fabric S2, and a strip|belt-shaped 1st optical film may be fed out from optical film original fabric S2, and you may cut and process by predetermined space|interval b using the cutting means FC.

In the process similar to FIG. 3A, FIG. 3B, you may manufacture a 2nd optical film set.

Moreover, as another embodiment, the adhesive layer 12, the 1st optical function film, and the 1st surface protection film are cut|disconnected at predetermined intervals by leaving the strip|belt-shaped 1st release film 11 after a slit process (half-cut). and forming a plurality of perforated lines may be further included.

(liquid crystal cell, liquid crystal display panel)

The liquid crystal cell has a configuration in which a liquid crystal layer is sealed between a pair of opposing substrates (a first substrate (viewable side) Pa and a second substrate (rear side) Pb). Although any type of liquid crystal cell can be used, in order to implement|achieve high contrast, it is preferable to use the liquid crystal cell of a vertical alignment (VA) mode, and in-plane switching (IPS) mode. A liquid crystal display panel is a thing by which the polarizing film was bonded on the single side|surface or both surfaces of a liquid crystal cell, and a drive circuit is built-in as needed.

(organic EL cell, organic EL display panel)

The organic EL cell has a structure in which an electroluminescent layer is sandwiched between a pair of electrodes. The organic EL cell can use arbitrary types, such as a top emission system, a bottom emission system, and a double emission system, for example. The organic EL display panel has a polarizing film bonded to one or both surfaces of an organic EL cell, and a driving circuit is incorporated as necessary.

(Embodiment 4: Remanufacturing Using First Optical Film Set)

4 is a schematic diagram of a continuous manufacturing system of an optical display panel. In this embodiment, the 1st optical film 1 on a roll is used for manufacturing an optical display panel by a roll-to-panel system. The sheet-like first optical film 2 is judged to be defective among the optical display panels manufactured using the roll-shaped first optical film 1, and the first pressure-sensitive adhesive layer, the first optical function film, and the first surface Used for remanufacturing an optical display panel having a configuration in which a first pressure-sensitive adhesive layer, a first optical function film, and a first surface protection film are laminated in this order on one side of an optical cell of an optical display panel from which a protective film is peeled off do. Specifically, on one side of the optical cell from which the 1st adhesive layer 22, the 1st optical function film 23, and the 1st surface protection film 24 peeled, it is sheet-fed by a sheet-to-panel system. Peeling the first release film 21 from the first optical film 2 of After bonding the film 25 in this order, the 2nd surface protection film 25 is peeled. In this embodiment, a liquid crystal cell is mentioned as an example as an optical cell, and a liquid crystal display panel is demonstrated as an optical display panel.

As for the first optical film 1 on a roll, the 1st release film 11, the 1st adhesive layer 12, the 1st optical function film 13, and the 1st surface protection film 14 are laminated|stacked in this order, have. As shown in FIG. 1 , the first optical film 1 on the roll has a width a, and has a width corresponding to the long side of the liquid crystal panel (a width substantially shorter than the long side of the liquid crystal cell P).

The manufacturing system of the liquid crystal display panel which concerns on this embodiment, as shown in FIG. 4, the 1st conveyance part 81 which conveys the liquid crystal cell P to the 1st attachment part 64, The liquid crystal cell P It has the 2nd conveyance part 82 which conveys the liquid crystal cell P after affixing an optical film using the 1st optical film 1 on a roll on the 1st surface P1. Each conveyance part has several conveyance roller R for conveying liquid crystal cell P by rotating centering around the rotation axis parallel to the direction orthogonal to a conveyance direction, and is comprised. Moreover, you may have an adsorption|suction plate etc. other than a conveyance roller, and may be comprised.

(Liquid crystal cell transfer process)

From the accommodating part 91 which accommodates the liquid crystal cell P, the liquid crystal cell P is arrange|positioned in the 1st conveyance part 81 so that the 1st surface P1 may become a ceiling surface, and the conveyance roller R It is conveyed to the 1st attachment part 64 by rotation.

(1st optical film feeding process, 1st optical film cutting process)

The strip-shaped first optical film 10 fed out from the first optical film 1 on a roll adsorbs and fixes the first release film 11 side, and the first release film 11 is removed by the cut portion 61 . The strip-shaped pressure-sensitive adhesive layer 12, the strip-shaped first optical function film 13, and the strip-shaped first surface protection film 14 were left uncut to a predetermined size (according to the short side of the liquid crystal cell P). It is cut to length (length substantially shorter than the short side), and the cut-out part s is formed. As for the cutting|disconnection by the cutting|disconnection part 61, the cutting|disconnection using a blade (cutting by the blade|wing to pull and cut|disconnect), and the cutting|disconnection by a laser device are mentioned, for example. Although an example of the cut-out part s after cut|disconnection is shown with the arrow of FIG. 4, in order to make description easy, the cut-out is drawn large on purpose. A nip roller (not shown) may be disposed on the upstream or downstream side of the cut portion 61 , and may be configured to convey the strip-shaped first optical film 10 . Further, nip rollers may be disposed on the upstream side and downstream side of the cut portion 61 .

(Tension control process)

In the cutting treatment of the strip-shaped first optical film 10 and the attaching treatment at the rear end, in order to enable continuous treatment so that the treatment is not interrupted over a long period of time, and to adjust the relaxation of the film, the first tension An adjustment unit 62 is provided. The 1st tension|tensile_strength adjustment part 62 has a dancer mechanism using weights, and is comprised, for example. A nip roller (not shown) may be arranged on the upstream or downstream side of the first tension adjustment unit 62 , and may be configured to convey the first optical film 10 . Moreover, nip rollers may be arrange|positioned upstream and downstream of the 1st tension|tensile_strength adjustment part 62. As shown in FIG.

(Peeling process)

The 1st optical film 10 is wound around the 1st peeling part 63, and is inverted, and the 1st optical film 10 is peeled from the 1st release film 11. The 1st release film 11 is wound up by the 1st winding-up part 65 on a roll. The 1st winding-up part 65 has a roll and a rotation drive part, The 1st release film 11 is wound on a roll by a rotation drive part rotating a roll. Moreover, the nip roller which is not shown in figure is arrange|positioned at the upstream or downstream of the peeling part 63, and the structure which conveys the 1st optical film 10 or the 1st release film 11 may be sufficient. Moreover, nip rollers may be arrange|positioned at the upstream and downstream of the peeling part 63. As shown in FIG.

(1st attachment process)

The 1st attachment part 64 conveys the liquid crystal cell P, the 1st optical film 10 from which the 1st release film 11 peeled to the 1st surface P1 of the liquid crystal cell P , attached through the first pressure-sensitive adhesive layer 12 . The first attachment portion 64 is composed of a pair of first rollers 64a and second rollers 64b. Either one may be a drive roller, the other may be a driven roller, and both rollers may be a drive roller. By sending the first optical film 10 and the liquid crystal cell P downstream with a pair of first rollers 64a and second rollers 64b sandwiching the liquid crystal cell P, the first optical film 10 is transferred to the liquid crystal cell. It is attached to the first surface (P1) of (P). Liquid crystal cell P after sheet-fed 1st optical film 10 is affixed to 1st surface P1 of liquid crystal cell P is conveyed downstream by the 2nd conveyance part 82.

(1st inspection process)

The first inspection unit 70 optically inspects the liquid crystal cell P. The first inspection unit 70 is disposed on one side of the liquid crystal cell P, and a light source 71 that transmits light to the liquid crystal cell P, and the liquid crystal cell P is disposed on the opposite side of the light source, It has the 1st imaging part 72 which picks up the transmitted light image of the liquid crystal cell P. An area sensor may be sufficient as the 1st imaging part 72, and a line sensor may be sufficient as it. Moreover, the 1st inspection part 70 may have a 2nd imaging part (not shown) which picks up the reflected light image for test|inspecting the attachment position of the 1st optical film 10. The image captured by the first inspection unit 70 is image-analyzed by the first image analysis unit 51 . The control unit 50 controls the operation timing of each configuration of the continuous manufacturing system, and the like.

(1st judgment process)

Based on the result of having analyzed the image by the 1st image analysis part 51, the 1st determination part 52 determines whether liquid crystal cell P is a good product or a defective product. Examples of defective products include misalignment of adhesion and mixing of air bubbles. The liquid crystal cell P judged to be a defective product is collect|recovered by the 1st non-defective goods collection|recovery part 92. Liquid crystal cell P determined to be a defective article is collect|recovered by the 1st defective article collection|recovery part 93.

(1st defective film peeling process)

The process of remanufacturing the liquid crystal panel of a defective product into the liquid crystal panel of a good product is demonstrated using FIG. As shown in FIG. 5 , the first optical film 10 is removed from the liquid crystal cell P determined to be defective by the first determination unit 52 . A removal process may be performed manually, and may be performed with a peeling apparatus. Next, a description will be given of remanufacturing (sometimes referred to as “rework”) by attaching the first optical film 2 in the form of a sheet to the first surface P1 of the liquid crystal cell P using a sheet attaching device. .

(First reattachment process)

Next, in a sheet-to-panel system (for example, a sheet-fed attachment device), the sheet-like 1st optical film 2 which peeled the 1st release film 21, the 1st optical film 10 by which the defective product was judged It affixes on the 1st surface P1 of liquid crystal cell P after this peeling. A conventional apparatus can be used as a single-wafer attachment apparatus. Reference is made to the sheet-like first optical film 2 in FIG. 1 .

(Peeling process of 2nd surface protection film)

After a 1st reattachment process, the 2nd surface protection film 25 is peeled from the 1st optical film 2 of sheet-wafer shape. A peeling process may be performed manually and may be performed with a peeling apparatus. Through the above process, it is possible to manufacture (remanufacture) a liquid crystal panel having the same laminated configuration as a liquid crystal panel manufactured by a roll-to-panel method.

(remanufactured using the first and second optical film sets)

Similar to remanufacturing using the first set of optical films, remanufacturing using the second set of optical films can be performed. The roll-shaped 2nd optical film 3 is used for manufacturing an optical display panel by a roll-to-panel system. The sheet-like second optical film 4 is judged to be defective among optical display panels manufactured using the roll-shaped second optical film 3, and the second pressure-sensitive adhesive layer, the second optical function film, and the third surface Used for remanufacturing an optical display panel having a configuration in which a second pressure-sensitive adhesive layer, a second optical function film, and a third surface protection film are laminated in this order on one side of an optical cell of an optical display panel from which a protective film has been peeled off do. Specifically, on one side of the optical cell from which the 2nd adhesive layer 31, the 2nd optical function film 32, and the 3rd surface protection film 33 were peeled, it is sheet-fed by a sheet-to-panel system. Peeling the second release film 41 from the second optical film 4 of After bonding the film 45 in this order, the 4th surface protection film 45 is peeled.

The continuous manufacturing system of an optical display panel is the roll-to-panel system using the roll-formed 2nd optical film 3 in the manufacturing facility of the roll-to-panel system using the 1st optical film 1 on a roll, and further A continuous manufacturing system of an optical display panel is constituted by adding manufacturing equipment of Even if the roll-to-panel system manufacturing facility using the roll-shaped second optical film 3 is configured in the same facility as the roll-to-panel system manufacturing facility using the roll-shaped first optical film 1, do. Another manufacturing facility is demonstrated below.

The liquid crystal cell P judged as good by the 1st inspection part 70 is sent to the rear stage, and an optical cell is affixed to the 2nd surface P2 of the liquid crystal cell P using the 2nd optical film on a roll. A batch replacement unit (not shown) is provided in the second conveyance unit 82 , and the batch replacement unit transfers the high-quality liquid crystal cell P conveyed to the second conveyance unit 82 to the upper and lower surfaces P1 and P2 . It is inverted and the short side and long side of liquid crystal cell P are replaced in a conveyance direction. The arrangement replacement part can employ|adopt a well-known mechanism suitably. In this embodiment, an arrangement|positioning replacement part has the rotating part which adsorb|sucks liquid crystal cell P and horizontally rotates 90 degrees, and the inversion part which adsorb|sucks liquid crystal cell P and reverses the front and back.

After processing of the batch replacement part, the liquid crystal cell P is conveyed to the 2nd attachment part. The second cut portion similar to the first cut portion 61 , the second tension adjustment portion similar to the first tension adjustment portion 62 , the second peel portion similar to the first peel portion 63 , the first winding portion and It has a similar 2nd winding part.

The 2nd cut|disconnection part cut|disconnects the 2nd release film 31, adsorbing and fixing the 2nd release film 31 side to the strip|belt-shaped 2nd optical film 30 drawn out from the 2nd optical film 3 on a roll. The second optical film 30 is cut to a predetermined size (the length along the long side of the liquid crystal cell P (length substantially shorter than the long side)) without leaving it without it. The strip-shaped second optical film 30 is conveyed to the second peeling part through the second tension adjusting part, wound around the second peeling part and reversed, and the second optical film 30 is formed with the second release film 31 . ) is exfoliated from The 2nd release film 31 is wound up on a roll by a 2nd winding-up part.

The second attachment portion has a configuration similar to that of the first attachment portion 64 . A 2nd adhesive layer with the 2nd optical film 30 from which the 2nd release film 31 peeled to the 2nd surface P2 of liquid crystal cell P, conveying liquid crystal cell P, 2nd adhesion part conveying liquid crystal cell P Attach through (32).

The second inspection unit has a configuration similar to that of the first inspection unit 70 .

The second inspection unit optically inspects the liquid crystal cell P. The second inspection unit is disposed on one side of the liquid crystal cell (P), and a light source that transmits light to the liquid crystal cell (P), and the liquid crystal cell (P) is disposed on the opposite side of the light source, the liquid crystal cell (P) It has an imaging part which picks up a transmitted light image. The 2nd inspection part may have an imaging part (not shown) which picks up the reflected light image for test|inspecting the attachment position of the 2nd optical film 30. The image picked up by the 2nd inspection part is image-analyzed by the 2nd image analysis part.

Based on the result of having analyzed the image by the 2nd image analysis part, a 2nd determination part determines whether liquid crystal cell P is a good product or a defective product. Examples of defective products include misalignment of adhesion and mixing of air bubbles. Liquid crystal cell P determined to be a defective product is collect|recovered by the 2nd defect collection|recovery part. On the other hand, when it is judged as non-defective by a 2nd judgment part, the liquid crystal cell P by which good quality judgment was carried out is conveyed and accommodated in the accommodating part of a good quality.

Remanufacturing using the sheet-like optical film 4 is the same as the above-mentioned remanufacturing using the sheet-like optical film 2 . That is, the 2nd optical film 30 is removed from the liquid crystal cell P by which defect determination was carried out. Then, by a sheet-to-panel system (for example, a sheet-fed device), the sheet-like 2nd optical film 4 which peeled the 2nd release film 31 is the 2nd optical film 30 by which the defective product was judged. ) is attached to the second surface P2 of the liquid crystal cell P after peeling. Then, the 4th surface protection film 45 is peeled from the sheet-like 2nd optical film 4 .

(Embodiment 5: Manufacture of optical display panel using optical film set of optical film roll and sheetfed optical film)

Embodiment 5 is a continuous manufacturing system of an optical display panel using an optical film set. Hereinafter, the continuous manufacturing system of the optical display panel which concerns on this Embodiment 5 is demonstrated concretely, referring FIG.

In the roll-to-panel system similar to the said Embodiment 4 (refer FIG. 4), using the 1st optical film 1 on a roll, the 1st optical film on the 1st surface P1 of the liquid crystal cell P Attach (10). 4 and 6, the same reference numerals have the same functions. The liquid crystal cell P to which the 1st optical film 10 is attached is inverted in the arrangement|positioning replacement part 821, and upper and lower surfaces P1 and P2 are reversed, and the short side and long side of the liquid crystal cell P in the conveyance direction y. replace the stool

Next, the process of affixing the sheet-like 2nd optical film 4 to the 2nd surface P2 of liquid crystal cell P is demonstrated below. From the container 100 in which the sheet-like 2nd optical film 4 was accommodated, the sheet-like 2nd optical film 4 is adsorb|sucked by the adsorption|suction part 164a of the single-wafer attaching apparatus 164, and it is supplied to the bonding position. . The second release film 41 is peeled off from the sheet-like second optical film 4 by a peeling means. The adsorption|suction surface of the adsorption|suction part 164a is circular arc shape in cross section. A peeling means may peel the 2nd release film 41 by bonding an adhesive tape to the 2nd release film 41 surface using an adhesive tape, for example, and moving an adhesive tape by a moving mechanism.

The sheet-fed device 164 has a fixed surface 164b, and the fixed surface 164b adsorbs and fixes the 1st surface P1 side of the liquid crystal cell P. The second release film 41 is peeled off and the sheet-like second optical film 4 in a state where the second pressure-sensitive adhesive layer 42 is exposed is applied to the second surface P2 of the liquid crystal cell P by the adsorption unit 164a ) and attach it by rolling it.

(4th surface protection film peeling process)

After affixing the sheet-like 2nd optical film 4, the 4th surface protection film 45 is peeled. A peeling process may be performed manually and may be performed with a peeling apparatus.

(Other embodiment of Embodiment 5)

In the fifth embodiment, a sheet-like first optical film (2) is used instead of the roll-like first optical film (1) and attached to the liquid crystal cell in a sheet-to-panel method, and a sheet-like second optical film (2) is used. You may use the 2nd optical film 3 on a roll instead of the film 4, and you may stick to a liquid crystal cell by a roll-to-panel system.

(variant example)

In the fourth and fifth embodiments, the use of an optical film set of a roll-shaped optical film and a single-leaf optical film for a continuous manufacturing method of a liquid crystal display panel has been described, but it is not limited thereto, and the continuous organic EL display panel You may use for a manufacturing method.

In Embodiments 4 and 5, although the said optical film was used as an optical film on a roll, the structure of the optical film on a roll is not limited to this. For example, except a release film, you may use the thing (optical film which put the perforation line) by which the strip|belt-shaped optical film in which a some piercing line was formed in the width direction was wound.

In Embodiments 4 and 5, although the strip|belt-shaped optical film was cut|disconnected (half-cut) at predetermined intervals in the width direction, from a viewpoint of improving a yield, the strip|belt-shaped optical film so as to avoid the fault part of the strip|belt-shaped optical film. may be cut in the width direction (skip cut), or the optical film including the defect portion may be cut to a size smaller than a predetermined interval (size of an optical cell) (more preferably, to a size as small as possible).

In Embodiments 4 and 5, the liquid crystal cell and liquid crystal display panel of a horizontal long rectangle have been described as examples. However, the shape of the liquid crystal cell and the liquid crystal display panel includes another set of opposing sides and another set of opposing sides. It is not specifically limited as long as it has a shape.

1: optical film on roll
11: release film
12: adhesive layer
13: optical function film
14: first surface protection film
2: sheetfed optical film
21: release film
22: adhesive layer
23: optical function film
24: first surface protection film
25: second surface protection film

Claims (17)

It is an optical film set having an optical film on a roll and an optical film on a sheet,
The optical film on the roll has a configuration in which a release film, an adhesive layer, an optical function film, and a first surface protection film are laminated in this order,
The sheet-fed optical film has a configuration in which the release film, the pressure-sensitive adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are laminated in this order,
The first surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The second surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The first surface protection film and the second surface protection film have the same configuration,
The relationship between the peeling force between the respective layers of the single-leaf optical film is as follows: the delamination force A between the release film and the pressure-sensitive adhesive layer, the delamination force B between the pressure-sensitive adhesive layer and the optical function film, and the interlayer between the optical function film and the first surface protection film When the peeling force C and the interlayer peeling force D of the first surface protection film and the second surface protection film are A<D<C<B,
Optical film set. The optical film set according to claim 1, wherein the optical function film is a polarizing film. The optical film set according to claim 2, wherein the polarizing film has a thickness of 60 μm or less. The optical film set according to claim 3, wherein the polarizing film has a polarizer having a thickness of 10 µm or less. The said 1st surface protection film has a 1st base film and a 1st adhesive layer, and is laminated|stacked on the said optical function film via the said 1st adhesive layer. Features an optical film set. The optical film set according to claim 1, wherein the first surface protection film and the second surface protection film are the same material, the same thickness, or the same material and the same thickness. According to claim 1, wherein the thickness of the first surface protection film is 10 μm to 150 μm,
The thickness of the second surface protection film is 10 μm to 150 μm,
Optical film set. The method according to any one of claims 1 to 3, wherein the second surface protection film has a second base film and a second pressure-sensitive adhesive layer, and is laminated on the first surface protection film through the second pressure-sensitive adhesive layer. Optical film set, characterized in that. The optical film of claim 1 , wherein the optical film on the roll has a width corresponding to a set of sides that the optical cells face;
The sheet-fed optical film has a length corresponding to one set of opposite sides of the optical cell, and another set of opposite sides of the optical cell is opposite to that of the other set of sides. An optical film set, characterized in that it has a corresponding length. According to claim 1, wherein the optical film on the roll and the optical film on the sheet, the pressure-sensitive adhesive layer, the optical function film, and the first surface protection film are laminated on one side of an optical cell in this order. An optical film set used for manufacturing an optical display panel. 10. The method of claim 9, wherein the optical film on the roll is used to manufacture the optical display panel in a roll-to-panel method,
An optical film set, characterized in that the sheet-fed optical film is used to manufacture an optical display panel in a sheet-to-panel method. The method according to claim 11, wherein the sheet-like optical film is determined as a defective product among the optical display panels manufactured by the roll-to-panel method using the roll-shaped optical film, and the pressure-sensitive adhesive layer, the optical function film and Remanufacture of the optical display panel having a configuration in which a pressure-sensitive adhesive layer, an optical function film and a first surface protection film are laminated in this order on one side of the optical cell of the optical display panel from which the first surface protection film is peeled Used to, optical film set. A method for producing the optical film set according to any one of claims 1 to 2,
The manufacturing method of the optical film on the said roll,
A step of preparing an optical film original fabric having a configuration in which the release film, the pressure-sensitive adhesive layer, the optical function film, and the first surface protection film are laminated in this order;
The optical film raw material is slitted and wound to produce an optical film on the roll,
The manufacturing method of the said sheet-fed optical film,
A step of bonding a second surface protection film original to the first surface protection film side of the optical film original fabric, and manufacturing an optical film original fabric on which a second surface protection film is laminated;
The method of manufacturing an optical film set, comprising a step of manufacturing a sheet-like optical film by cutting the optical film raw material on which the second surface protection film is laminated. a double-sided optical film set having a first optical film set and a second optical film set,
The first optical film set has a first optical film on a roll and a first optical film on a sheet,
The first optical film on the roll has a configuration in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are laminated in this order,
The sheet-like first optical film has a configuration in which the first release film, the first pressure-sensitive adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film are laminated in this order, ,
The first surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The second surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The first surface protection film and the second surface protection film have the same configuration,
The relationship between the peeling force between the respective layers of the single-leaf optical film is as follows: the delamination force A between the release film and the pressure-sensitive adhesive layer, the delamination force B between the pressure-sensitive adhesive layer and the optical function film, and the interlayer between the optical function film and the first surface protection film When the peeling force C and the interlayer peeling force D of the first surface protection film and the second surface protection film are A<D<C<B,
The second optical film set has a second optical film on a roll and a second optical film on a sheet,
The second optical film on the roll has a configuration in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are laminated in this order,
The sheet-like second optical film has a configuration in which the second release film, the second pressure-sensitive adhesive layer, the second optical function film, the third surface protection film, and the fourth surface protection film are laminated in this order. ,
The third surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The fourth surface protection film has a pressure-sensitive adhesive layer or is a self-adhesive film,
The third surface protection film and the fourth surface protection film have the same configuration,
The relationship between the peeling force between the respective layers of the single-leaf optical film is as follows: the delamination force A between the release film and the pressure-sensitive adhesive layer, the delamination force B between the pressure-sensitive adhesive layer and the optical function film, and the interlayer between the optical function film and the third surface protection film When the peeling force C and the interlayer peeling force D of the third surface protection film and the fourth surface protection film are A<D<C<B,
Two-sided optical film set. 15 . The optical cell according to claim 14 , wherein the first optical film on the roll and the first optical film on the sheet and the second optical film on the roll and the second optical film on the sheet are on one side of the optical cell. The pressure-sensitive adhesive layer, the first optical function film and the first surface protection film are laminated in this order, and the second pressure-sensitive adhesive layer, the second optical function film and the third surface protection film are laminated on the other side of the optical cell. A set of double-sided optical films used to manufacture an optical display panel of a configuration in which films are laminated in this order. The method according to claim 14, wherein the first surface protection film and the second surface protection film are the same material, the same thickness, or the same material and the same thickness;
The optical film set on both sides, wherein the third surface protection film and the fourth surface protection film are the same material, the same thickness, or the same material and the same thickness. 15. The method of claim 14, wherein the thickness of the first surface protection film is 10 μm to 150 μm,
The thickness of the second surface protection film is 10 μm to 150 μm,
Two-sided optical film set.

Images