KR102530197B1 - Manufacturing method of optical film with adhesive agent - Google Patents

Abstract

The laminate 154 having the patterned adhesive sheet 21 and the optical film 1 are bonded together on the elongated carrier substrate 4 by roll-to-roll, so that the patterned adhesive sheet and the optical film are formed on the carrier substrate. A long mother board 155 having a is manufactured. By cutting the optical film and the adhesive sheet of the mother board into sheets of a predetermined shape surrounded by cutting lines 32a ₁ and 32a ₂ , a non-adhesive area where the first adhesive sheet is not provided is formed on a part of the main surface of the optical film. An optical film having a pressure-sensitive adhesive is obtained.

Description

Method for manufacturing an optical film with an adhesive {MANUFACTURING METHOD OF OPTICAL FILM WITH ADHESIVE AGENT}

The present invention relates to a method for manufacturing an optical film having a pressure-sensitive adhesive sheet having a patterned pressure-sensitive adhesive sheet on the optical film.

As various image display devices such as mobile phones, smart phones, car navigation devices, monitors, and televisions, liquid crystal display devices and organic EL display devices are widely used. In the liquid crystal display device, a polarizing plate is arranged on the viewing side surface of the liquid crystal cell from the display principle thereof. In a self-luminous type display device such as organic EL, a circular polarizing plate (a laminate of a polarizing plate and a quarter wave plate) is placed on the viewing side surface of a cell in order to suppress external light being reflected by a metal electrode (cathode) and being viewed like a mirror surface. ) may be placed. Generally, an image display cell and a polarizing plate are bonded via a sheet-like adhesive.

BACKGROUND ART An image display device in which a front transparent member such as a touch sensor or a cover glass is provided on a viewer-side surface of an image display panel is popular. In an image display device including a front transparent member, the difference in refractive index at the interface is reduced by bonding the polarizing plate on the surface of the image display panel and the front transparent member through an adhesive, so that the decrease in visibility due to reflection or scattering can be suppressed. there is.

A method of arranging a front transparent member on a viewer-side surface of an image display panel with a pressure sensitive adhesive sheet interposed thereon, on a polarizing plate on the surface of an image display panel, a pressure sensitive adhesive sheet cut to fit the size of a screen is bonded, and the front transparent member is bonded thereon. A method of arranging members is known (for example, Patent Literature 1). In Patent Literature 2, it is proposed to use a polarizing plate having a double-sided adhesive for forming an image display device having a front transparent member. A polarizing plate with double-sided pressure-sensitive adhesive includes a pressure-sensitive adhesive sheet for bonding with an image display cell on one side of the polarizing plate, and a pressure-sensitive adhesive sheet for bonding with a front transparent member on the other side. As described in Patent Literature 2, if a polarizing plate having a pressure-sensitive adhesive is used in which a pressure-sensitive adhesive sheet is previously provided on the surface of the polarizing plate, the operation of positioning and laying the pressure-sensitive adhesive sheet can be omitted when forming an image display device. The process can be simplified.

In Patent Literature 1, an aspect is shown in which the end face of the PSA sheet is located inside the end face of the protective sheet temporarily affixed to the surface of the PSA sheet. Patent Literature 2 shows a mode in which the end faces of the PSA sheet are located inside the end faces of the polarizing plate and the protective sheet bonded to the PSA sheet. By positioning the end face of the PSA sheet on the inside of the end face of the polarizing plate or protective sheet, the protrusion of the PSA from the end face during transportation or processing can be suppressed, and contamination caused by the PSA or adhesive defect can be prevented. there is.

WO2013-161666 Japanese Unexamined Patent Publication No. 2014-115468

A polarizing plate with an adhesive is generally formed by bonding a long sheet-shaped polarizing plate and an adhesive sheet together in a roll-to-roll manner. A polarizing plate having a sheet adhesive for forming an image display device is obtained by cutting from a long mother substrate to a size that matches the screen size of the image display device.

When cutting from a long mother board to a predetermined size, the polarizer and the adhesive sheet are simultaneously cut. Therefore, in a polarizing plate having a sheet of adhesive, an adhesive sheet is provided on the entire surface of the main surface of the polarizing plate. In order to obtain a polarizing plate having a pressure-sensitive adhesive having a region on the main surface of the polarizing plate where the pressure-sensitive adhesive sheet is not provided, as disclosed in Patent Document 1, it is necessary to bond the pressure-sensitive adhesive sheet cut into sheets to the polarizing plate, resulting in significant productivity. It is lowered.

Patent Literature 2 proposes a method of positioning the end face of the PSA sheet inside the end face of the polarizing plate or protective sheet by performing cutting in a state where the PSA protrudes from the end face by pressing from the main surface side. . However, in this method, it is difficult to accurately control the distance from the end face of the polarizing plate to the end face of the adhesive sheet. In addition, in the polarizing plate having a single sheet pressure-sensitive adhesive obtained by this method, the end surface of the pressure-sensitive adhesive sheet is located inside the end surface of the polarizing plate at the center of the thickness direction of the pressure-sensitive adhesive sheet, but in the vicinity of the bonding interface between the pressure-sensitive adhesive sheet and the polarizing plate, the pressure-sensitive adhesive sheet The position of the end face and the position of the end face of the polarizing plate are aligned. That is, with this method, it is not possible to obtain a polarizing plate having a sheet of adhesive having a region on which the adhesive sheet is not laid on the polarizing plate.

The present invention provides a method for efficiently producing an optical film having a single-layer adhesive having a region on a surface of an optical film such as a polarizing plate where no adhesive sheet is applied, by cutting from a long mother substrate. .

A long mother substrate is produced by bonding a layered product provided with a patterned pressure-sensitive adhesive sheet and an optical film on a long carrier substrate in a roll-to-roll manner. The pattern shape of the pressure-sensitive adhesive sheet is not particularly limited. For example, the adhesive sheet is patterned so that the region where no adhesive is provided has a strip shape extending in the longitudinal direction. As the optical film, a polarizing plate, a laminated film in which a polarizing plate and other films are laminated, and the like are used.

The carrier substrate and the pressure-sensitive adhesive sheet may be directly laminated. A protective sheet may be provided between the carrier base material and the adhesive sheet. When a protective sheet is provided between the carrier substrate and the adhesive sheet, the peeling force at the interface between the protective sheet and the adhesive sheet is preferably greater than the peeling force between the protective sheet and the carrier substrate.

The mother substrate has a patterned adhesive sheet on the main surface of the optical film. An optical film having an adhesive is obtained by cutting the optical film and the adhesive sheet of the mother substrate into sheets of a predetermined shape surrounded by cutting lines. When cutting into sheets, cutting lines are formed to include areas where the adhesive sheet is not installed. In formation of a cutting line, you may perform half-cut so that at least a part of the thickness direction of a carrier base material may not be cut.

Since the patterned area of the pressure-sensitive adhesive sheet (void portion from which the pressure-sensitive adhesive is removed) exists in the area surrounded by the cutting line, the optical film having the pressure-sensitive adhesive sheet is not provided with the pressure-sensitive adhesive sheet on a part of the main surface of the optical film. It has a region (non-adhesive region) where the principal surface is exposed. For example, if a cutting line is formed in the laminated optical film in the region of the mother substrate where the adhesive sheet is not provided, an optical film having an adhesive having a non-adhesive region at the periphery of the optical film of each sheet is obtained.

In the non-adhesive area, since no adhesive is provided on the optical film, the optical film is exposed. By the existence of the non-adhesive region on the optical film, in forming the image display device, since physical interference between a constituent member of the image display device such as a flexible wiring board and an adhesive can be avoided, the space of the device can be effectively used. .

The patterning method of the adhesive sheet is not particularly limited. For example, by cutting the adhesive sheet of the laminated adhesive sheet in which the unpatterned adhesive sheet is provided on the carrier sheet, and peeling and removing the adhesive sheet in the area surrounded by the cut line from the carrier sheet, the patterned adhesive is adhered to the carrier sheet. A laminated body comprising sheets is obtained. When cutting the pressure-sensitive adhesive sheet, half-cutting may be performed so that at least a part of the carrier base material in the thickness direction is not cut.

In the laminated pressure sensitive adhesive sheet, an easy release sheet may be temporarily affixed on the pressure sensitive adhesive sheet. When the light-peelable sheet is temporarily attached on the pressure-sensitive adhesive sheet, the light-peelable sheet and the pressure-sensitive adhesive sheet are cut on the carrier sheet, the light-release sheet and the pressure-sensitive adhesive sheet in the area surrounded by the cutting line are peeled off, and then the pressure-sensitive adhesive sheet and the optical film By laminating them, a mother board is obtained. The peeling force at the interface between the carrier sheet and the pressure-sensitive adhesive sheet is preferably greater than the peeling force at the interface between the pressure-sensitive adhesive sheet and the easy-peelable sheet.

The method of the present invention can also be applied to the production of an optical film having a double-sided pressure-sensitive adhesive in which pressure-sensitive adhesive sheets are provided on both sides of the optical film and the pressure-sensitive adhesive sheet on at least one side is patterned. In the manufacture of an optical film having a double-sided adhesive, an adhesive sheet is provided on both sides of the optical film, a mother substrate having at least one of the adhesive sheets patterned is prepared, and the optical film is cut from the mother substrate to a region surrounded by a cutting line. You can do it.

In the method of the present invention, an elongated mother board is obtained by patterning an adhesive sheet on a elongated carrier substrate and then bonding it to an optical film by roll-to-roll. By adjusting the position of the cutting line at the time of cutting a single sheet from the mother substrate, an optical film having a pressure-sensitive adhesive having a patterned pressure-sensitive adhesive sheet is obtained. In the method of the present invention, since bonding and cutting are performed on a long carrier substrate by a roll-to-roll process, a step of positioning or bonding the optical film and the pressure-sensitive adhesive sheet is not required after cutting each sheet. ADVANTAGE OF THE INVENTION According to the method of this invention, the optical film which has the pressure-sensitive adhesive of sheet|leaf provided with the patterned adhesive sheet can be mass-produced easily and with high efficiency.

1A is a plan view of an optical film with an adhesive, and B is a cross-sectional view of the optical film with an adhesive.
2 is a process conceptual diagram showing an example of a manufacturing process of an optical film with an adhesive.
3A is a cross-sectional view of a laminate used for manufacturing an optical film having an adhesive.
Fig. 3B is a cross-sectional view showing how the pressure-sensitive adhesive sheet is cut in the cutting unit.
3C is a cross-sectional view of the laminate after removing the cutting pieces.
3D is a cross-sectional view of the laminate after removing the cut piece and the protective sheet.
3E is a cross-sectional view of a laminate (mother substrate) for obtaining an optical film with an adhesive.
Fig. 3F is a cross-sectional view showing how the laminate is cut by a cutting unit.
3G is a cross-sectional view of the laminate after removing the cutting pieces.
Fig. 4 is a plan view showing how the pressure-sensitive adhesive sheet is cut by the cutting unit.
5 is a plan view showing a state of cutting of the optical film in a cutting unit.
6 is a cross-sectional view of an optical film having a double-sided adhesive.
Fig. 7 is a cross-sectional view of a laminate (mother substrate) for obtaining an optical film with double-sided adhesive.
8 is a cross-sectional view of the image display device.
9A is a plan view of an optical film with an adhesive, and B is a cross-sectional view of the optical film with an adhesive.
Fig. 10 is a cross-sectional view showing how the laminate is cut by a cutting unit.
Fig. 11 is a cross-sectional view showing how the laminate is cut by a cutting unit.
12A is a plan view of an optical film with an adhesive, and B is a cross-sectional view of the optical film with an adhesive.
Fig. 13 is a cross-sectional view showing how the laminate is cut by a cutting unit.
Fig. 14 is a cross-sectional view showing how the laminate is cut by a cutting unit.
15 is a cross-sectional view of an optical film having a double-sided adhesive.
Fig. 16 is a cross-sectional view of a laminate (mother substrate) for obtaining an optical film having a double-sided adhesive and having non-adhesive regions on both sides.
17 is a process conceptual diagram showing an example of a manufacturing process of an optical film with an adhesive.
18A is a cross-sectional view of a laminate used for manufacturing an optical film having an adhesive.
Fig. 18B is a cross-sectional view showing how the pressure-sensitive adhesive sheet is cut in the cutting unit.
18C is a cross-sectional view of the laminate after removing the cutting pieces.
18D is a cross-sectional view of the laminate after removing the cut piece and the protective sheet.
18E is a cross-sectional view of a laminate (mother substrate) for obtaining an optical film with an adhesive.
Fig. 18F is a cross-sectional view showing how the laminate is cut by the cutting unit.

[Configuration of optical film with adhesive]

FIG. 1A is a plan view of an optical film with an adhesive according to an embodiment, and FIG. 1B is a cross-sectional view along the line B1-B2. The optical film 51 with an adhesive includes an adhesive sheet 21 on the first main surface of the optical film 1 . The adhesive sheet 21 is patterned, and on the first main surface of the optical film 1, a region where the adhesive sheet 21 is laid (adhesive region) and an area where the adhesive sheet is not provided and the optical film is exposed (non-adhesive area) exists. In the optical film 51 with adhesive shown in FIG. 1, the peripheral area along the side 1a ₁ of the optical film 1 is the non-adhesive area 2x.

(optical film)

As the optical film 1, a polarizing plate is used, for example. In a general polarizing plate, an appropriate transparent protective film is provided on one side or both sides of the polarizer as needed. As the polarizer, for example, a dichroic substance such as iodine or a dichroic dye is adsorbed onto 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 dichroic material orientated by stretching is used. As the transparent protective film provided on the surface of the polarizer, materials having excellent transparency, mechanical strength, and thermal stability, such as cellulose resins, cyclic polyolefin resins, acrylic resins, phenyl maleimide resins, and polycarbonate resins, are preferable. it is used As a transparent protective film of a polarizer, you may use optically anisotropic films, such as a retardation plate.

The optical film 1 may be one in which a plurality of films are laminated through an appropriate adhesive or pressure-sensitive adhesive. Examples of optical films other than polarizing plates include films used for forming image display devices such as retardation films, viewing angle expansion films, viewing angle limiting (peeping prevention) films, and brightness enhancing films. A touch sensor or the like may be installed in the optical film. Further, a hard coat layer, an antireflection layer, an antiglare layer, an antisticking layer, or the like may be formed on the surface of the optical film, or surface treatment may be performed for the purpose of improving adhesiveness or the like.

The area of the optical film 1 is not particularly limited, but is generally about 5 to 25000 cm 2 . When the optical film 1 is rectangular, the length of the diagonal is about 3 to 250 cm. When the optical film 1 is rectangular, it may be a rectangle having a long side and a short side, or it may be a square having four equal sides. The length of the long side of the rectangle is generally no more than 10 times the length of the short side, and may be no more than 5 times, no more than 3 times, or no more than 2 times the length of the short side. When the optical film is an optically anisotropic film such as a polarizing plate or retardation film, the direction of the optical axis such as the absorption axis or the slow axis may be parallel or perpendicular to the direction of extension of the side of the rectangle, or may form a predetermined angle with the direction of extension of the side of the rectangle. do. When the optical film is a laminate of a plurality of films, the arrangement of the optical axis of each film is not particularly limited, and may be parallel or orthogonal, or may form a predetermined angle. For example, in a circular polarizing plate, the polarizer and the 1/4 wave plate are laminated so that the angle between the direction of the absorption axis of the polarizer and the direction of the slow axis of the 1/4 wave plate is 45°.

(adhesive sheet)

It is preferable that the adhesive sheet 21 provided on the 1st main surface of the optical film 1 consists of an optically transparent adhesive. The adhesive sheet 21 is used for bonding the optical film 1 and image display cells, bonding the optical film 1 and a front transparent member (transparent plate such as cover glass, touch sensor, etc.).

Examples of the pressure-sensitive adhesive constituting the pressure-sensitive adhesive sheet include acrylic polymers, silicone polymers, polyesters, polyurethanes, polyamides, polyvinyl ethers, vinyl acetate/vinyl chloride copolymers, modified polyolefins, epoxy-based, fluorine-based, natural rubber, synthetic rubber, and the like. It is possible to appropriately select and use a rubber type or the like as a base polymer. In particular, an acrylic pressure-sensitive adhesive is preferably used because it has excellent optical transparency, exhibits adhesive properties such as moderate wettability, cohesiveness, and adhesiveness, and has excellent weather resistance and heat resistance. The pressure-sensitive adhesive sheet may be a laminate of a plurality of pressure-sensitive adhesive layers.

The pressure-sensitive adhesive constituting the pressure-sensitive adhesive sheet may be a photocurable pressure-sensitive adhesive that can be cured by light irradiation after bonding. For example, when a photocurable pressure-sensitive adhesive is used for bonding with a front transparent member having ridges such as decorative printing, bonding is performed in a soft state of the adhesive before photocuring, so that it has step absorption properties and air bubbles are mixed in the vicinity of the ridges back can be suppressed. Adhesion reliability can be improved by photo-curing the pressure-sensitive adhesive by irradiating UV or the like after bonding. It is preferable that a photocurable adhesive contains, for example, a polymer, a monomer or oligomer having a photopolymerizable functional group, and a photopolymerization initiator. As the monomer or oligomer having a photopolymerizable functional group, you may use a crosslinkable monomer having two or more polymerizable functional groups in one molecule.

The thickness of the pressure-sensitive adhesive sheet is not particularly limited and is generally about 5 to 500 μm. The thickness of the adhesive sheet used for bonding the optical film 1 and the image display cell is preferably about 5 to 50 μm. The thickness of the pressure-sensitive adhesive sheet used for bonding the optical film and the front transparent member may be appropriately set according to the structure of the front transparent member. For example, when the front transparent member has ridges caused by decorative printing or the like, in order to prevent entrainment of air bubbles around the ridges, it is preferable to make the pressure-sensitive adhesive sheet have a thickness of 50 μm or more to have step absorption properties. do.

(Non-adhesive area)

In the optical film 51 with an adhesive shown in FIG. 1 , the periphery along three sides 1a ₂ , 1a ₃ , and 1a ₄ among the four sides of the optical film 1 is formed by the adhesive sheet 21 It is an attached adhesive area. At the periphery along the side 1a ₁ extending in the y direction, the adhesive sheet 21 is not provided on the optical film 1 . In this non-adhesive area 2x, the main surface of the optical film 1 is exposed, and a gap exists on the optical film 1 .

At the periphery along the sides 1a ₂ , 1a ₃ and 1a ₄ , the positions of the end face of the optical film 1 and the end face of the adhesive sheet 21 are aligned. In the non-adhesive area 2x along the side 1a ₁ , the end face 21e of the adhesive sheet 21 is located inside the end face 1e of the optical film 1 . These end faces 1e and 21e extend parallel to the y direction along the side 1a ₁ .

The width W ₁ of the non-adhesive region 2x, that is, the distance from the end face 1e of the optical film 1 to the end face 21e of the adhesive sheet 21 (offset amount) may be appropriately set. For example, when the non-adhesive region 2x is formed for the purpose of preventing the adhesive from protruding from the end face, W ₁ may be set to about 5 to 3000 µm. In the formation of the image display device, when the non-adhesive area 2x is formed for the purpose of preventing physical interference between the constituent members of the image display device and the adhesive sheet, the shape or size of the member installed in the non-adhesive area, etc. Just set W ₁ accordingly. W ₁ is, for example, 10 μm or more, and may be 30 μm or more. W ₁ is generally set to 10% or less of the length of the diagonal of the optical film.

(protective sheet)

As for the optical film 51 with an adhesive, the protective sheet 41 is adhere|attached on the adhesive sheet 21 so that peeling is possible. If the protective sheet is temporarily affixed on the adhesive sheet, the exposed surface of the adhesive sheet 21 can be protected until the optical film 1 is bonded to the adherend.

As a constituent material of the protective sheet 41, a plastic film such as polyethylene, polypropylene, polyethylene terephthalate, or polyester film is preferable. The thickness of the protective sheet 41 is usually about 5 to 200 μm, preferably about 10 to 150 μm. The bonding surface of the protective sheet 41 with the adhesive sheet 21 may be subjected to peeling treatment using a silicone-based mold release agent or the like.

[Method for Manufacturing Optical Film with Pressure-Adhesive]

The optical film having a pressure-sensitive adhesive having a patterned pressure-sensitive adhesive sheet on the optical film is bonded to the optical film and a laminate having a patterned pressure-sensitive adhesive sheet on a long carrier substrate in a roll-to-roll manner to produce a mother substrate, It is produced by cutting a sheet of sheets from a mother board. In this method, the position of the end surface of the adhesive sheet and the position of the end surface of the optical film can be set independently. Since there is no need to bond the sheet optical film and the sheet adhesive sheet, and position alignment is not required when bonding both, an optical film having a sheet adhesive having a non-bonded region can be obtained with high efficiency.

Examples of methods for producing a patterned PSA sheet include a method of performing patterning when forming the PSA sheet on a substrate, and a method of cutting and patterning the PSA sheet formed on the entire surface of the substrate except for the end portions. Patterning by cutting is preferable in that it is possible to form an accurate pattern and it is easy to control the position, shape, size, etc. of the non-adhesive area.

Hereinafter, a method of fabricating a mother substrate by bonding a patterned adhesive sheet and an optical film by cutting on a carrier substrate, and cutting the mother substrate to fabricate an optical film having a single-layer adhesive will be described. Fig. 2 is a process schematic diagram showing an example of a manufacturing process of an optical film having a single sheet adhesive having a non-adhesive region. 3A to G are cross-sectional views showing the structure of the laminate in A to G of FIG. 2 .

A roll of the carrier sheet 4 is set on the unwinding roll 104 . In this embodiment, the carrier sheet 4 is used as a carrier substrate, and the adhesive sheet or the optical film is cut on the carrier sheet.

A roll of the laminated pressure sensitive adhesive sheet 2 is set on the unwinding roll 102 . The laminated pressure sensitive adhesive sheet 2 includes protective sheets 40 and 41 on both sides of the pressure sensitive adhesive sheet 21 . The protective sheet 41 is laid as a protective sheet on the adhesive sheet 21 as it is even in the optical film 51 having an adhesive after being cut into sheets (see Fig. 1B). The protective sheet 40 is temporarily attached to protect the surface of the adhesive sheet 21 until the optical film 1 is bonded on the adhesive sheet 21 .

When peeling off the protective sheet 40 from the surface of the adhesive sheet 21, it is preferable to suppress peeling at the interface between the protective sheet 41 and the adhesive sheet 21. Therefore, the adhesive force between the adhesive sheet 21 and the protective sheet 40 is preferably smaller than the adhesive force between the adhesive sheet 21 and the protective sheet 41 . That is, the protective sheet 40 is a light release sheet having a relatively small peeling force from the adhesive sheet, and the protective sheet 41 bonded to the carrier sheet 4 is a heavy sheet having a relatively large peeling force from the adhesive sheet. It is preferable that it is a re-sheet. The peelability of the protective sheet can be adjusted by, for example, the type of release agent on the surface of the sheet, the coating thickness, and the like.

In the form shown in FIG. 2 , the carrier sheet 4 is adhered to the back surface of the protective sheet 41 (the surface opposite to the laid surface of the adhesive sheet 21) by the first cutting unit 131 for adhesion. Cutting of the sheet 21 and cutting of the optical film 1 and the adhesive sheet 21 by the second cutting unit 132 are performed. Since the carrier sheet 4 is not cut even after the adhesive sheet 21 and the optical film 1 are cut, the laminate can be stably conveyed by roll-to-roll.

As a constituent material of the carrier sheet 4, a plastic film is preferable similarly to the protection sheet 41. The carrier sheet 4 preferably has a small dimensional change due to conveying tension during roll-to-roll conveyance. Further, when cutting (half-cut) is performed so as to reach the surface of the carrier sheet 4 (the interface with the protective sheet 41) by the cutting units 131 and 132, cutting to the back surface of the carrier sheet 4 It is necessary to prevent the arrival of the blade. Therefore, the thickness of the carrier sheet 4 is preferably 10 μm or more, and more preferably 20 μm or more.

It is preferable that an adhesive layer (not shown) for fixing the protective sheet 41 is formed on the surface of the carrier sheet 4 . As the carrier sheet 4, a self-adhesive film in which an adhesive layer is integrally formed on the surface of a base film may be used. When peeling off the protective sheet 40 from the surface of the adhesive sheet 21, it is preferable to suppress peeling at the interface between the carrier sheet 4 and the protective sheet 41. When peeling the protective sheet 41 from the carrier sheet 4, it is preferable to suppress peeling at the interface between the protective sheet 41 and the adhesive sheet 21. Therefore, the adhesive force between the carrier sheet 4 and the back surface of the protective sheet 41 (heavy release sheet) is greater than the adhesive force between the adhesive sheet 21 and the protective sheet 40 (light release sheet), and the adhesive sheet ( 21) and the protective sheet 41 are preferably smaller than the adhesive force.

The laminated pressure-sensitive adhesive sheet 2 unwound from the unwinding roll 102 and the carrier sheet 4 unwound from the unwinding roll 104 are bonded together with nip rolls 141 to form a laminate 151 (FIG. 3A). The laminate 151 of the carrier sheet 4 and the laminated pressure-sensitive adhesive sheet 2 moves downstream in the transport direction (y direction) to reach the first cutting unit 131 .

In the 1st cutting unit 131, cutting (half-cut) is performed to the depth which reaches the surface of the carrier sheet 4 from the laminated adhesive sheet 2 side (light release sheet 40 side). By cutting in the first cutting unit, the protective sheet 40, the adhesive sheet 21, and the protective sheet 41 constituting the laminated adhesive sheet 2 have cut lines 31a and 31b throughout the thickness direction. ) is formed (Fig. 3b). In the carrier sheet 4, a notch having a depth that does not reach the back surface may be formed. In the half cut, the cutting is performed so that at least a part of the thickness direction of the carrier sheet 4 is not cut. The depth of the cut formed in the carrier sheet 4 at the time of half-cutting is preferably 1/2 or less of the thickness of the carrier sheet, and more preferably 1/3 or less. The cutting method in the first cutting unit is not particularly limited as long as the protective sheets 40 and 41 and the adhesive sheet 21 constituting the laminated adhesive sheet 2 can be cut, and a rotary cutter, a press-fitting blade (for example, Thomson blade), a suitable cutting method by a laser cutter, etc. can be adopted.

Cutting by the 1st cutting unit 131 may be performed while conveying the laminated body 151, or may be performed in the state which stopped conveyance of the laminated body. For example, when forming a cutting line extending in the width direction, it is preferable to stop conveyance of the layered product and cut it.

4 : is a top view of the laminated body before and after cutting in a 1st cutting unit. In the layered product 151 conveyed along the y direction from the nip roll 141 side, the laminated adhesive sheet 2 is cut by the first cutting unit 131, and the cutting lines 31a and 31b extending in the y direction is formed The adjacent cutting line 31a and cutting line 31b form a pair.

The layered product 152 after forming the cutting lines is conveyed by the nip rolls 142, and the laminated pressure-sensitive adhesive sheet 2 in the region 31 surrounded by the pair of cutting lines 31a and 31b is moved in the longitudinal direction (conveyance). direction), it is peeled from the carrier sheet 4 as a strip-like cut piece 161 extending in the same direction. At the end in the width direction, the region 37 between the cutting line 31b (or 31a) and the end face of the laminated pressure sensitive adhesive sheet 2 may be peeled from the carrier sheet as a cutting piece. The band-shaped cut piece 161 peeled from the layered product 152 is wound up and collected by the take-up roll 192 . In the layered product 153 after removing the cut piece, a groove-shaped void 310 extending in the transport direction is formed (FIG. 3C).

In FIG. 4, a state in which the cutting lines are formed parallel to each other so as to extend in the conveying direction, and the band-shaped region 31 surrounded by the two cutting lines 31a and 31b is peeled off from the laminate as a cutting piece 161 is shown. However, the cutting line need not be parallel to the conveying direction. The cutting line may extend in the oblique direction or may extend in the width direction. In addition, the cutting line does not have to be straight in planar view, and may be curved. The cutting lines may be formed in a lattice shape. In order to continuously peel and remove the region surrounded by the cutting line from the laminate as the cutting piece 161, it is preferable to form the cutting line so that the region surrounded by the cutting line continues in the conveying direction.

The layered product 153 after removing the cut piece is conveyed by the nip roll 144, and the easy-peelable sheet 40 temporarily affixed on the adhesive sheet 21 is peeled off (FIG. 3D). The light release sheet 40 peeled off from the layered product 153 is wound up and collected by the take-up roll 193 . In the embodiment of FIG. 2 , after peeling the cut piece 161 of the pressure-sensitive adhesive sheet with the nip roll 142 , the light release sheet 40 is peeled with the other nip roll 144 . In this way, peeling tension and conveying tension can be stabilized by sequentially peeling the cut piece and the easy-peeling sheet from the laminate. You may peel-remove the cut piece and the light-peeling sheet simultaneously from a laminated body.

The layered product 154 after removing the cut piece and the easy-peeling sheet is conveyed by the nip roll 143, and the optical film 1 unwound from the unwinding roll 101 is laminated on the pressure-sensitive adhesive sheet 21, and laminated. A sieve 155 is formed (FIG. 3E). The optical film 1 is bonded so as to cover the entire surface of the laying surface of the pressure-sensitive adhesive sheet 21 on the carrier sheet 4 . At this time, the optical film 1 is also installed on the gap 310 formed by the removal of the cutting piece.

As described above, the elongated laminate 155 is obtained by cutting the adhesive sheet with the first cutting unit and bonding the optical film 1 on the adhesive sheet 21 after removing the cut piece by roll-to-roll. An optical film having a pressure-sensitive adhesive having a non-adhesive region is formed by using this elongated laminate 155 as a mother substrate and cutting a sheet of sheets from the mother substrate. In the optical film 51 having an adhesive cut into sheets, the portion of the void 310 in the mother substrate becomes the non-adhesive region 2x.

The laminated body 155 moves downstream in the conveying direction and reaches the second cutting unit 132, whereby a cutting line is formed in the laminated body (FIG. 3F). 5 : is a top view of the laminated body before and after cutting in a 2nd cutting unit. In the second cutting unit 132, cutting lines 32a ₁ and 32a ₂ extending in the transport direction and cutting lines 32a ₃ and 32a ₄ extending in the width direction (x direction) are formed. The cutting method in the 2nd cutting unit 132 is not specifically limited, A suitable cutting style can be employ|adopted similarly to the cutting in the 1st cutting unit. Cutting by the 2nd cutting unit 132 may be performed while conveying the laminated body 155, or may be performed while conveyance of the laminated body is stopped. When forming the cutting lines 32a ₃ and 32a ₄ extending in the width direction, it is preferable to stop conveyance of the layered product and perform cutting.

In the 2nd cutting unit 132, the cutting of the laminated body 155 is performed from the optical film 1 side. In the region where the adhesive sheet 21 is provided, cutting is performed so as to reach the surface of the carrier sheet 4, and the optical film 1, the adhesive sheet 21, and the protective sheet 41 are formed throughout the thickness direction. Cutting lines 32a ₂ , 32a ₃ , and 32a ₄ are formed. In the carrier sheet 4, a notch having a depth that does not reach the back surface may be formed.

In the region 310 where the adhesive sheet 21 is not installed, the optical film 1 is cut to form the cutting line 32a ₁ . At this time, the cutting line 32a ₁ should just be formed so that the whole thickness direction of the optical film 1 may be cut, and it does not necessarily need to reach the carrier sheet 4. As shown in Fig. 3F, the cut may be made so as to reach the surface of the carrier sheet 4 so as to form a notch in the carrier sheet 4.

By cutting with the second cutting unit, the optical film 1 is cut into a rectangle surrounded by cutting lines a ₁ and a ₂ extending in the y direction and cutting lines a ₃ and a ₄ extending in the x direction. The cutting line 32a ₁ corresponds to the side 1a1 of the optical film 51 having a sheet of adhesive. The cutting line 32a ₂ corresponds to the side 1a ₂ , and the cutting lines 32a ₃ and 32a ₄ correspond to the sides 1a ₃ and 1a ₄ .

As shown in FIG. 3F , a gap exists between the wall surface of the adhesive sheet 21 formed by the cutting line 31b by the first cutting unit and the cutting line 32a formed in the region 310 . If the cutting line is formed so that the region surrounded by the cutting line overlaps the region 310 where the adhesive sheet 21 is not installed, the optical film having the adhesive cut into sheets is formed so that the adhesive sheet is formed on the main surface of the optical film. It has a non-adhesive area that is not installed.

In this embodiment, by cutting with the second cutting unit, a cutting line is formed in the region 310 where the adhesive sheet 21 is not installed, and the optical film is non-adhesive to the periphery along the side 1a ₁ . An optical film having a pressure-sensitive adhesive having regions is obtained. By adjusting the positional relationship between the cutting line 31b by the first cutting unit and the cutting line 32a ₁ by the second cutting unit, the width W ₁ of the non-adhesive region 2x can be arbitrarily set.

As shown in Fig. 5, by cutting in the second cutting unit 132, the optical film 1 is cut into a rectangle surrounded by cutting lines. Roll-to-roll conveyance as a single unit is difficult for a film or an adhesive sheet surrounded by cut lines. In the laminate 156 of this embodiment, the optical film 1, the adhesive sheet 21, and the protective sheet 41 are cut, but the carrier sheet 4 is not cut. The protection sheet 41, the adhesive sheet 21, and the optical film 1 adhered on the carrier sheet are also integrated, and the laminate 156 can be conveyed downstream from roll to roll.

The layered product 156 after being cut by the second cutting unit 132 is conveyed to the nip roll 146, and the optical film 1 and the adhesive sheet in the region 32 surrounded by the cutting lines 32a ₁ and 32a ₂ 21 and the protective sheet 41 are peeled from the carrier sheet 4 as cut pieces 162 . At the end in the width direction, the regions 38 and 39 between the cutting lines 32a ₁ or 32a ₂ and the end faces of the optical film 1 and the adhesive sheet 21 may be peeled from the carrier sheet as cutting pieces. .

By removing the cut pieces 162, an optical film 51 having a rectangular adhesive surrounded by cut lines remains on the carrier sheet 4 (FIG. 3G). The laminate 157 on which the optical film 51 having a plurality of adhesives is applied on the carrier sheet 4 is wound up in a roll shape by a winding roll 150 . By peeling the pressure-sensitive adhesive sheet 21 and the optical film 1 along with the protective sheet 41 from the carrier sheet 4 of the layered body 157, the optical film 51 having a single-layer pressure-sensitive adhesive shown in FIG. 1 is obtained. is obtained

Without peeling the cut piece 162 from the carrier sheet 4, you may wind up the laminated body 156 in which the cut line was formed as it is in roll shape. The cut piece 162 may remain on the carrier sheet 4 of the laminate 156, and the optical film 51 having an adhesive surrounded by the cut line may be peeled from the carrier sheet 4.

In the process shown in FIG. 2 , the bonding of the laminated adhesive sheet 2 onto the carrier sheet 4, the cutting of the adhesive sheet by the first cutting unit 131, the cutting piece 161 and the easy-peeling sheet 40 ), bonding of the adhesive sheet 21 and the optical film 1 after patterning, and cutting of the optical film and the adhesive sheet by the second cutting unit 132 are performed as a series of continuous steps. These steps need not necessarily be performed continuously.

For example, the laminate 151 in which the laminated pressure-sensitive adhesive sheet 2 is bonded on the carrier sheet 4 is once wound into a roll shape, the laminate 151 is unwound from the roll, and the first cutting unit 131 You may perform cutting of the adhesive sheet to . After the laminate 152 after cutting the adhesive sheet with the first cutting unit 131 or the laminate 153 after peeling and removing the cut piece 161 is once rolled up in a roll form, the laminate is unwound from the roll. And you may perform bonding of the optical film 1 onto the adhesive sheet 21 after peeling and patterning of the easy release sheet 40. Since the pressure-sensitive adhesive sheet 21 is exposed during the period from the peeling of the easy-release sheet 40 to the bonding of the optical film 1, the peeling of the easy-release sheet 40 and the bonding of the optical film 1 It is preferably carried out in a series of roll-to-roll processes. The layered product 155 (mother substrate) having the optical film 1 bonded onto the pressure-sensitive adhesive sheet 21 may be wound once.

As described above, in this embodiment, the adhesive sheet 21 is cut on the carrier sheet 4, the cut piece is peeled off, and then the optical film 1 is bonded onto the adhesive sheet 21, thereby forming a long mother board. {Laminate 155} is obtained. The mother substrate is a region where the optical film 1 is bonded through the adhesive sheet 21 on the carrier sheet 4, and the carrier sheet 4 without the adhesive sheet on the carrier sheet 4. It has a region where a gap exists between the optical films (1). After the optical film 1 is cut into a predetermined shape on this mother substrate, the cut piece is peeled off from the carrier sheet 4 together with the adhesive sheet 21, so that the area where the adhesive sheet is not provided (non-adhesive area) An optical film 51 having a pressure-sensitive adhesive having is obtained.

[Optical film with double-sided adhesive]

The optical film having an adhesive shown in the sectional view of FIG. 6 includes a first adhesive sheet 21 on one main surface of the optical film 1 and a second adhesive sheet 22 on the other main surface. In the optical film 52 with double-sided adhesive, the first adhesive sheet 21 is patterned similarly to the optical film 51 with adhesive in FIG. 1 .

At the periphery along one side extending in the y direction, the first adhesive sheet 21 is not provided on the optical film 1, and the adhesive sheet 21 is more The end face 21e is located inside. The position of the end face 41e of the first protective sheet 41 provided on the adhesive sheet 21 coincides with the position of the end face 1e of the optical film 1 .

The second adhesive sheet 22 is not patterned, and the position of the end face 1e of the optical film 1 coincides with the position of the end face 22e of the second adhesive sheet 22 in all sides. there is. The position of the end surface 42e of the protective sheet 42 attached to the second adhesive sheet 22 also coincides with the position of the end surface 1e of the optical film 1 . The optical film 52 with double-sided adhesive has a non-adhesive region 2x on the first main surface of the optical film 1 and no non-adhesive region on the second main surface of the optical film 1. .

The optical film 52 with double-sided adhesive shown in FIG. 6 can be manufactured by the same method as the optical film 51 with single-sided adhesive shown in FIG. In the production of the optical film 52 with double-sided adhesive, the laminated adhesive sheet 2 is cut, the cut piece and the easy-peelable sheet are removed to form the laminate 154 shown in FIG. 3D, and then the laminate What is necessary is just to bond the optical film which has a single-sided adhesive to the adhesive sheet 21 of (154).

7 is a cross-sectional view showing a state in which a long, adhesive-bearing optical film 50 is bonded onto the adhesive sheet 21 of the laminate 154 . The optical film 50 having an adhesive includes an adhesive sheet 22 on the optical film 1 . A protective sheet 42 is provided on the adhesive sheet 22 . The laminated body 755 (mother substrate) is formed by bonding the optical film 1 of the optical film 50 with the pressure-sensitive adhesive to the pressure-sensitive adhesive sheet 21 after patterning by roll-to-roll. On the laminate 154, instead of bonding the optical film 50 having an adhesive, the optical film 1 is bonded, and the adhesive sheet 22 with the protective sheet 42 attached to one side is applied on the optical film. A laminated body 755 may be formed by bonding.

The laminated body 755 shown in FIG. 7 is cut from the protective sheet 42 side by the second cutting unit 132 . In the second cutting unit 132 , in addition to the optical film 1 , the adhesive sheet 22 and the protective sheet 42 provided on the optical film 1 are also cut. Other than that is the same as the cutting by the 2nd cutting unit 132 in formation of the optical film with the above-mentioned single-sided adhesive. In the area where the adhesive sheet 21 is installed, a half-cut is performed to a depth reaching the surface of the carrier sheet 4, and the protective sheet 42, the adhesive sheet 22, the optical film 1, the adhesive sheet ( 21) and the protective sheet 41, cutting lines 732a ₂ are formed throughout the thickness direction. In the region 310 where the adhesive sheet 21 is not installed, the protective sheet 42 , the adhesive sheet 22 and the optical film 1 are cut to form a cutting line 732a ₁ . Also in the formation of the cutting lines 732a ₁ , half-cutting may be performed so as to reach the surface of the carrier sheet 4 .

By peeling the adhesive sheet 21, the optical film 1, the adhesive sheet 22, and the protective sheet 42 together with the protective sheet 41 from the carrier sheet 4 of the laminated body after cutting, as shown in FIG. , an optical film 52 having a single sheet double-sided adhesive is obtained.

[Use of optical film with adhesive]

The optical films 51 and 52 having a pressure-sensitive adhesive in which a patterned pressure-sensitive adhesive sheet 21 is provided on the optical film 1 are suitably used for forming an image display device. Since the end face 21e of the adhesive sheet 21 is located inside the end face 1e of the optical film 1, contamination caused by the adhesive protruding from the end face, adhesive failure, etc. can be prevented. there is. In addition, since the area 2x where the adhesive sheet 21 is not provided exists on the main surface of the optical film 1, physical interference between the constituent members of the image display device and the adhesive sheet is prevented, and the space within the device is effectively saved. available.

8 is a cross-sectional view of an image display device 801 produced using an optical film 52 having a double-sided adhesive. In the image display device 801, an optical film 1 is disposed on an image display cell 60, and a cover glass 71 having a touch sensor is provided on the viewing side of the optical film 1. The optical film 1 and the image display cell 60 are bonded via the second adhesive sheet 22, and the optical film 1 and the cover glass 71 are bonded via the first adhesive sheet 21. has been The image display cell 60 is, for example, a liquid crystal cell, organic EL (OLED), or micro LED. Instead of the cover glass 71, a transparent resin plate made of a transparent resin material such as acrylic may be used.

Near the end of the cover glass 71, a flexible printed wiring board (FPC) 91 as an electrical connection member is connected to a touch sensor (not shown) provided on a surface facing the optical film 1. The FPC 91 is bent so as to go around the back side of the image display cell 60.

In the image display device 801, on the end surface 1e of the optical film 1 by disposing the FPC 91 in the space of the non-adhesive area 2x along the side 1a ₁ of the optical film 1. Alternatively, the contact point 7a between the touch sensor and the FPC 91 can be formed inside the end face 1e. In this way, by forming the non-adhesive region 2x on the optical film 1 and arranging the FPC or the like in the gap portion thereof, the frame width of the image display device can be narrowed by effectively using the space at the periphery of the screen and its vicinity. It can be realized.

In the non-adhesive area 2x, constituent members of various image display devices as well as the FPC can be disposed. Examples of the member disposed in the non-adhesive region include cover glass, touch sensor, housing, conductive material, and resin material. In FIG. 8 , the form in which the adhesive sheet 21 for bonding the optical film 1 and the cover glass 71 is patterned is shown, but the adhesive sheet on the image display cell 60 side may be patterned.

[Structural example of optical film with adhesive]

In FIGS. 1 and 6 , an example having a non-adhesive region 2x at the periphery along one side 1a ₁ of a rectangular optical film is shown, but the position, shape, size, etc. of the non-adhesive region 2x Not particularly limited. An optical film having an adhesive in which the position, shape, size, etc. of the non-adhesive area is adjusted according to the shape or size of a member to avoid physical interference with the adhesive is used.

For example, non-adhesive regions may be formed along two or more sides of the rectangle, or non-adhesive regions may be formed along the long sides of the rectangle. In the non-adhesive area, the end face of the pressure-sensitive adhesive sheet need not extend parallel to the side of the optical film. For example, the non-adhesive region may have a portion where the width decreases from the end of the rectangular side (vertex of the rectangle) toward the center of the side. The non-adhesion area does not have to be formed along the entire length of the side. For example, the non-adhesion area may be formed only in a part of the rectangular side or the vertex of the rectangle. A non-adhesive area may be formed in the center of the surface of the optical film.

A pressure-sensitive adhesive sheet having an arbitrary pattern shape can be produced by adjusting the formation position of the cutting line on the pressure-sensitive adhesive sheet by the first cutting unit before bonding the pressure-sensitive adhesive sheet and the optical film. In addition, when the mother substrate after bonding the adhesive sheet and the optical film is cut with the second cutting unit, the position, shape, size, etc. of the non-adhesive region can be arbitrarily adjusted by adjusting the formation position of the cutting line.

The optical film 56 with adhesive shown in the top view of FIG. 9A has a non-adhesive region 2x ₁ at the periphery along one side 1a ₁ , and the periphery along the other side 1a ₂ . has a non-adhesive area (2x ₂ ) in B of FIG. 9 is a cross-sectional view of the optical film 56 with an adhesive along the line B1-B2. The width W ₁ of one non-adhesive region ( _2x1 ) and the width W ₂ of the other non-adhesive region ( _2x2 ) may be the same or different. By adjusting the formation position of the cutting line in the 2nd cutting unit, the optical film which has the adhesive which has a non-adhesive area|region along two sides is obtained.

For example, as shown in FIG. 10 , by forming one cutting line 32a ₁ extending in the y-direction in the region 310 where the adhesive sheet 21 is not installed, An optical film having an adhesive having an adhesive region is obtained. As shown in FIG. 11 , two cutting lines 32a ₁ and 32a ₂ may be formed in the region 310 . In either form, the widths W ₁ and W ₂ of the non-adhesive region can be adjusted to desired values by adjusting the formation position of the cutting line in the region 310 .

In the optical film 57 with adhesive shown in the plan view of A of FIG. 12 , no non-adhesive area exists in the peripheral area along the sides 1a ₁ and 1a ₂ , and in the non-peripheral area, the edge 1a ₁ , 1a ₂ ) and a non-adhesive area (2x ₃ ) extending in parallel. By adjusting the formation position of the cutting line in the second cutting unit, an optical film having a pressure-sensitive adhesive having a non-adhesive region in the center of the surface can be formed.

For example, as shown in FIG. 13 , one cutting line 32a ₁ extending in the y direction is formed in the area where the adhesive sheet 21 is installed, and surrounded by the two cutting lines 32a ₁ . It is only necessary to cut the optical film and pressure-sensitive adhesive sheet of the area into sheets. As shown in FIG. 14 , two cutting lines 32a ₁ and 32a ₂ may be formed in the area where the adhesive sheet 21 is installed. In any form, the region 310 becomes a non-adhesive region ( _2x3 ) in the optical film 57 having an adhesive after cutting.

As shown in the above example, the optical film which has the adhesive which has a non-adhesive area|region at arbitrary positions is obtained by adjusting the formation position of the cutting line to a long mother board (laminated body 156). Furthermore, by adjusting the formation direction of the cutting line in the first cutting unit and the spacing between the paired cutting lines 31a and 31b, etc., an optical film having an adhesive having various shapes of non-adhesive regions is obtained.

Also in the formation of the optical film with double-sided adhesive, by adjusting the formation position of the cutting line in the 1st cutting unit and the 2nd cutting unit, etc., the non-adhesive area of various shapes is formed on the 1st main surface of the optical film 1. can form The optical film with double-sided adhesive may have non-adhesive regions on both the first main surface and the second main surface of the optical film. For example, the optical film 59 with double-sided adhesive shown in the sectional view of FIG. 15 has a non-adhesive area ( _2x11 ) on the first main surface in the peripheral area along one side of the optical film 1. and has a non-adhesive area ( _2x12 ) on the second main surface.

The optical film having a double-sided pressure-sensitive adhesive having non-adhesive regions on both sides of the optical film is a first pressure-sensitive adhesive sheet 21 patterned on the first main surface of the optical film 1, as in the laminate 955 shown in FIG. is bonded, and the second adhesive sheet 22 patterned on the second main surface of the optical film 1 can be manufactured from the bonded mother substrate. A layered body 955 having pressure-sensitive adhesive sheets patterned on both sides is obtained by bonding the layered body 154 shown in FIG. 3D to the first main surface of the optical film 1, and bonding the second main surface of the optical film 1 to the second main surface of the optical film 1. to the laminated body 254 including the patterned adhesive sheet 22. In the layered body 254 in which the protective sheet 42 is installed on the patterned adhesive sheet 22, the adhesive sheet 22 and the protective sheet 42 are placed on the carrier sheet 44 in the same manner as in the manufacture of the laminated body 154. It can be made by cutting and patterning.

After half-cutting the layered body 955 from the carrier sheet 44 side to a depth reaching the carrier sheet 4, the double-sided carrier sheets 4 and 44 are peeled off, thereby forming both sides of the single sheet shown in FIG. 15. An optical film 59 having an adhesive is obtained. The laminate 955 may be cut so as to reach the carrier sheet 44 from the carrier sheet 4 side. The carrier sheet may be provided only on either side. For example, the carrier sheet 44 may be peeled off from the layered body 955 before cutting, and half-cut may be performed so as to reach the carrier sheet 4 from the protective sheet 42 side.

In this embodiment, the patterning of the first adhesive sheet 21 on the carrier sheet 4 and the patterning of the second adhesive sheet 22 on the carrier sheet 44 are performed independently. Therefore, the shape, size and position of the cut and removed area 310 of the first adhesive sheet 21 and the shape, size and position of the cut and removed area 320 of the second adhesive sheet 22 can be individually set. .

The non-adhesive area ( _2x11 ) on the first main surface of the optical film with double-sided adhesive and the non-adhesive area ( _2x12 ) on the second main surface may be different in shape, size and position. For example, as shown in FIG. 15 , the width of the non-adhesive region _2x11 on the first principal surface may be larger than the width of the non-adhesive region _2x12 on the second principal surface. An optical film having a double-sided adhesive having non-adhesive regions at different positions on the first main surface and on the second main surface may be produced.

The shape of the optical film with adhesive, which is cut by the second cutting unit, is not limited to a rectangular shape, and may be an appropriate shape depending on the shape or size of the screen of the image display device. For example, the planar view shape of the optical film may be a polygon such as a triangle, a rhombus, a parallelogram, a ladder, a pentagon, or a hexagon, a circle, an ellipse, or a star.

[Combined use of carrier base material and protective sheet]

In the above embodiment, on the carrier sheet 4 as the carrier base material, the protective sheet (heavy release sheet) 41, the adhesive sheet 21, and the protective sheet 40 (light release sheet) are laminated and cut, Patterning of the adhesive sheet 21 is being performed. In this way, in the form using the carrier sheet, after the mother substrate is cut with the second cutting unit, peeling is performed at the interface between the carrier sheet 4 and the protection sheet 41 to protect on the adhesive sheet 21. An optical film having a sheet 41 and having a single sheet adhesive is obtained.

Instead of the carrier sheet 4, the protective sheet 41 attached to the pressure-sensitive adhesive sheet 21 may be used as a carrier base material, and an optical film having an adhesive may be produced. In cutting with the first cutting unit and the second cutting unit, if the cutting (half-cut) is performed to a depth reaching the surface of the protective sheet, the protective sheet is not cut, so the protective sheet can be used as a carrier base material.

Fig. 17 is a process schematic diagram showing an example of a manufacturing process of an optical film having a single-layered adhesive having a non-adhesive region, using the protective sheet 41 attached to the adhesive sheet 21 as a carrier base material. 18A to F are sectional views showing the structure of the laminated body in A to F of FIG. 17 . Here, the manufacturing example of the optical film with adhesive shown in FIG. 1 is demonstrated, but this embodiment is the optical film with the double-sided adhesive described above, and the optical film with the adhesive which has non-adhesive areas in various areas. It can also be applied to the production of

In Fig. 17, a roll of the laminated pressure sensitive adhesive sheet 2 is set on the unwinding roll 602. The laminated pressure sensitive adhesive sheet 2 includes protective sheets 40 and 41 on both sides of the pressure sensitive adhesive sheet 21 . The protective sheet 41 is a heavy release sheet having higher adhesiveness to the adhesive sheet 21 than the protective sheet 40, and also functions as a carrier substrate when cutting and conveying the adhesive sheet and the optical film.

The laminated pressure sensitive adhesive sheet 2 (see FIG. 18A ) unwound from the unwinding roll 602 passes through the nip rolls 641 and moves downstream in the conveyance direction to reach the first cutting unit 631 . In the 1st cutting unit 631, cutting (half-cut) is performed from the light release sheet 40 side to the depth which reaches the surface of the heavy release sheet 41 as a carrier base material. By cutting so as to reach the surface of the heavy-release sheet 41, the light-release sheet 40 and the pressure-sensitive adhesive sheet 21 constituting the laminated pressure-sensitive adhesive sheet 2 have cutting lines 531a and 531b throughout the thickness direction. ) is formed (Fig. 18b). In the heavy release sheet 41 as a carrier base material, the incision of the depth which does not reach the back surface may be formed. Except that the cutting lines 531a and 531b are formed so as not to reach the back surface of the heavy release sheet, the cutting by the first cutting unit 631 is the same as the case of using the carrier sheet 4 as the carrier base material (Fig. see 4).

After forming the cutting lines, the layered product 652 is conveyed by the nip roll 642, and the adhesive sheet 21 and the easy-release sheet 40 in the area 531 surrounded by the pair of cutting lines 531a and 531b Is peeled as a cut piece 661 from the heavy release sheet 41 as a carrier substrate. The cut piece 661 peeled from the layered product 652 is wound up and collected by a take-up roll 692 (FIG. 18C). Thereafter, the light release sheet 40 temporarily affixed on the pressure-sensitive adhesive sheet 21 is peeled off ( FIG. 18D ), and is wound up and collected by the take-up roll 693 . You may peel-remove the cut piece and the light-peeling sheet simultaneously from a laminated body.

The layered product 654 after removing the cut piece and the easy-peeling sheet is conveyed by a nip roll 643, and the optical film 1 unwound from the unwinding roll 601 is layered on the pressure-sensitive adhesive sheet 21, thereby forming a layered product. 655 is formed (FIG. 18E). In this way, by using the heavy release sheet 41 as a carrier substrate, cutting the adhesive sheet by half-cutting with the first cutting unit, and bonding the optical film 1 on the adhesive sheet after removing the cut pieces by roll-to-roll , an elongated laminate 655 is obtained.

The laminated body 655 moves downstream in the transport direction, and is cut by the second cutting unit 632 (FIG. 18F). In the region where the adhesive sheet 21 is provided, half-cutting is performed so as to reach the surface of the heavy release sheet 41 as the carrier substrate, and the optical film 1 and the adhesive sheet 21 are cut throughout the thickness direction. Lines 532a ₂ , 532a ₃ , and 532a ₄ are formed. The heavy release sheet 41 may be formed with a notch having a depth that does not reach the back surface. In the region 310 where the adhesive sheet 21 is not installed, the optical film 1 is cut to form a cutting line 532a1. At this time, the cutting line 532a ₁ should just be formed so that the whole thickness direction of the optical film 1 may be cut. The cutting may be performed so as to reach the surface of the heavy release sheet 41 so that incisions may be formed in the heavy release sheet 41 .

When forming the cutting lines (532a ₁ , 532a ₂ , 532a ₃ , 532a ₄ ), except that the half-cut is performed so as not to reach the back surface of the heavy release sheet 41, cutting by the second cutting unit 632 This is the same as the case where the carrier sheet 4 is used as the carrier base material (see Fig. 5). Even after cutting the optical film 1 and the adhesive sheet 21 by cutting with the second cutting unit, in the layered product 656, on the heavy release sheet 41 as a carrier substrate via the adhesive sheet 21 The optical film 1 is fixed to, the heavy release sheet 41 is not cut. Therefore, the adhesive sheet 21 laminated in contact with the heavy release sheet 41 as a carrier substrate and the optical film 1 bonded to the adhesive sheet 21 are integrally formed to form a laminate 656. Roll-to-roll conveyance is possible downstream.

After being cut by the second cutting unit 632, the layered product 656 is conveyed to the nip roll 646, and is wound up into a roll shape by the take-up roll 694 and collected. The laminate obtained in this way includes a laminate of the optical film 1 cut into a rectangle and the adhesive sheet 21 on the elongated protective sheet 41 . By peeling this laminate at the interface between the protective sheet 41 and the adhesive sheet 21, the peeled laminate of the optical film 1 and the adhesive sheet 21 can be used as an optical film having a sheet of adhesive. .

A protective sheet of another sheet may be bonded onto the pressure-sensitive adhesive sheet of the optical film having the pressure-sensitive adhesive after peeling from the protection sheet 41 . If the optical film with the adhesive is peeled off from the protective sheet 41 immediately before bonding of the image display cell or the front transparent member, it is not necessary to provide another protective sheet on the adhesive sheet 21 .

Also in the method of using the protective sheet 41 laid on the adhesive sheet 21 as a carrier base material, by adjusting the formation position of the cutting lines in the first cutting unit and the second cutting unit, etc., non-adhesive regions of various shapes An optical film having a pressure-sensitive adhesive having can be produced. In addition, an optical film having a double-sided adhesive may be produced by using the protective sheet 41 as a carrier base material. As shown in FIG. 15, in the case of manufacturing an optical film having a double-sided adhesive having non-adhesive regions on both sides of the optical film 1, the first adhesive sheet 21 and the protective sheet ( 41) is patterned, and when patterning the second adhesive sheet 22, the patterning may be performed using the protective sheet 42 as a carrier base material.

In each of the above embodiments, half-cutting is performed so that the carrier base material is not cut during cutting with the second cutting unit, but in the second cutting unit, the carrier base material is added in addition to the optical film 1 and the adhesive sheet 21. may be cut to perform a full cut. The laminated body after full cutting may be loaded on an appropriate conveying means such as a belt conveyor, transported downstream, and the optical film with adhesive cut into sheets may be recovered.

The 2nd cutting unit WHEREIN: You may use a full cut and a half cut together. For example, the formation of the cutting lines 532a ₁ and 532a ₂ extending in the transport direction may be performed by a full cut, and the formation of the cutting lines 532a ₃ and 532a ₄ extending in the width direction may be performed by a half cut. Since the protective sheet 41 as a carrier base material maintains continuity in the conveying direction by half-cutting in the width direction, conveyance of the laminated body by roll-to-roll is possible. In the transport direction, by forming a cutting line in full cut, an elongated laminate according to the size of the width direction of the optical film with an adhesive, which is the final product, is obtained. In this elongated laminate, an optical film having a plurality of sheets of pressure-sensitive adhesive is adhered on a protective sheet 41 as a carrier substrate along the transport direction. This laminate can also be used for bonding with a work such as an image display cell by roll-to-panel (for example, Japanese Patent No. 4503689).

The cutting (cutting into sheets of the optical film) in the second cutting unit may be divided into a plurality of steps and may be performed. For example, after forming a cutting line extending in a direction parallel to the transport direction, a cutting line extending in the width direction may be formed, and the optical film having an adhesive may be cut into sheets. A cutting line extending in the conveyance direction may be formed by full cut, divided into a plurality of strip-shaped sheets, and a cutting line extending in the width direction may be formed on the mother substrate after the division. After once winding up the mother board after forming the cutting line extending parallel to the conveyance direction, you may form the cutting line extending in the width direction in another process.

51, 52, 56, 57, 59: optical film with adhesive
1: optical film
21, 22: adhesive sheet
2x: non-glued area
40: protective sheet (light release sheet)
41: protective sheet (heavy release sheet)
42: protective sheet
4, 44: carrier sheet
60: image display cell
71 Cover glass with touch sensor
91: flexible printed wiring board
801 image display device
31a, 31b, 531a, 531b: cutting line
32a ₁ , 32a ₂ , 32a ₃ , 32a ₄ , 532a ₁ , 532a ₂ , 532a ₃ , 532a ₄ , 732a ₁ , 732a ₂ : cutting line
161, 661: cutting piece
131, 132, 631, 632: cutting unit
155, 755, 955: laminate (mother board)

Claims (13)

A first adhesive sheet is provided on a first main surface of an optical film having a first main surface and a second main surface, and a non-adhesive area in which the first pressure sensitive adhesive sheet is not provided is provided on a part of the first main surface of the optical film. A method for producing an optical film having an adhesive,
A laminate in which a protective sheet is bonded to a long carrier substrate, a first adhesive sheet is provided on the protective sheet, and the first adhesive sheet is patterned in areas where the adhesive is provided and areas where the adhesive is not provided. prepare,
The laminate and the optical film are bonded together in a roll-to-roll manner so that the first adhesive sheet of the laminate and the first main surface of the optical film face each other, and the protective sheet and the patterned first adhesive sheet and the optical film are formed on the carrier substrate. Produce a long mother board having a,
A method for manufacturing an optical film with an adhesive, wherein the optical film, the first adhesive sheet, and the protective sheet are cut from the mother substrate into sheets having a predetermined shape including a region where the first adhesive sheet is not provided. . The method of claim 1, wherein a protective sheet and an unpatterned first adhesive sheet are provided on a carrier sheet to prepare a laminated adhesive sheet,
The first adhesive sheet and the first adhesive sheet patterned on the carrier substrate are formed by cutting the first adhesive sheet and the protective sheet on the carrier sheet, and peeling and removing the protective sheet and the first adhesive sheet in the area surrounded by the cut lines from the carrier sheet. The manufacturing method of the optical film with an adhesive which manufactures the said laminated body provided with. The method of claim 2, wherein an easy-release sheet is temporarily attached on the first adhesive sheet before patterning,
On the carrier sheet, the light release sheet, the first pressure-sensitive adhesive sheet and the protective sheet are cut,
Manufacturing the laminate having a protective sheet and a first adhesive sheet patterned on a carrier substrate by removing the easy-release sheet and the first adhesive sheet and the protective sheet in the area surrounded by the cutting line from the carrier sheet, A method for producing an optical film having an adhesive. The method of manufacturing an optical film with an adhesive according to claim 3, wherein a peeling force at an interface between the protective sheet and the first adhesive sheet is greater than a peeling force at an interface between the first adhesive sheet and the easy-peelable sheet. . The pressure-sensitive adhesive according to any one of claims 1 to 4, wherein the peeling force at the interface between the protective sheet and the first adhesive sheet is greater than the peeling force at the interface between the protective sheet and the carrier substrate. A method for manufacturing an optical film. A first adhesive sheet is provided on a first main surface of an optical film having a first main surface and a second main surface, and a non-adhesive area in which the first pressure sensitive adhesive sheet is not provided is provided on a part of the first main surface of the optical film. A method for producing an optical film having an adhesive,
A laminated pressure-sensitive adhesive sheet having an unpatterned first pressure-sensitive adhesive sheet installed on a carrier sheet and an easy-release sheet temporarily attached to the first pressure-sensitive adhesive sheet is prepared, and on the carrier sheet, the light-release sheet and the first adhesive sheet are prepared. 1 The adhesive sheet is cut, and the first adhesive sheet in the area surrounded by the easy-peelable sheet and the cut line is peeled off from the carrier sheet to separate the area where the adhesive is provided and the area where the adhesive is not provided on the elongated carrier substrate. manufacturing a laminate having a patterned first adhesive sheet;
In the laminate, the first adhesive sheet is laminated in contact with the carrier substrate, and the peeling force at the interface between the carrier sheet and the first adhesive sheet is such that the first adhesive sheet and the easy-peelable sheet is greater than the peeling force of the interface of
Bonding the laminate and the optical film in a roll-to-roll manner so that the first adhesive sheet of the laminate and the first main surface of the optical film face each other, and providing a patterned first adhesive sheet and optical film on the carrier substrate. Produce a long mother board,
The method of manufacturing an optical film with an adhesive, wherein the optical film and the first adhesive sheet are cut from the mother substrate into sheets having a predetermined shape including a region where the first adhesive sheet is not installed. The adhesive-containing first adhesive sheet according to any one of claims 1 to 4 and 6, wherein the area where the adhesive is not provided is patterned in a strip shape extending in the longitudinal direction. A method for manufacturing an optical film. The method according to any one of claims 1 to 4 and 6, wherein a cutting line is formed in the laminated optical film in a region of the mother substrate where the first adhesive sheet is not installed, thereby forming a periphery of the sheet-fed optical film. A method for producing an optical film having a pressure-sensitive adhesive, wherein a non-adhesive region is formed thereon. The method according to any one of claims 1 to 4 and 6, wherein when the optical film and the first adhesive sheet of the mother substrate are cut into sheets having a predetermined shape surrounded by cutting lines, A method for manufacturing an optical film with an adhesive, wherein half-cutting is performed so that at least a part in the thickness direction is not cut. The method according to any one of claims 1 to 4 and 6, wherein a second adhesive sheet is installed on a second main surface of the optical film before cutting the optical film and the first adhesive sheet into sheets,
A method for manufacturing an optical film having an adhesive, wherein the optical film, the first adhesive sheet, and the second adhesive sheet are cut into sheets having a predetermined shape surrounded by cutting lines. The method for manufacturing an optical film having an adhesive according to any one of claims 1 to 4 and 6, characterized in that the optical film is cut into a rectangle from the mother substrate. The method for manufacturing an optical film having an adhesive according to any one of claims 1 to 4 and 6, wherein the optical film includes a polarizing plate. delete

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