KR20120021201A - Functional film manufacturing method - Google Patents

Abstract

PURPOSE: A functional film manufacturing method is provided to manufacture a given shape of a functional film by cutting a support consisting of organic compound and a raw film consisting of inorganic compound. CONSTITUTION: A functional film manufacturing method is as follows. Raw films(12a,12b,12c) with a support consisting of organic compound and an inorganic film(14) consisting of inorganic compound are cut at a temperature over the glass transition temperature of the support to form a given shape of a functional film. The cutting position of the raw film becomes a temperature over the glass transition temperature of the support by the heating of a blade cutting the raw film, the cutting of the raw film by laser, and the heating of the raw film before cutting with a contact or non-contact heating unit.

Description

Method for producing functional film {FUNCTIONAL FILM MANUFACTURING METHOD}

This invention relates to the manufacturing method of the functional film which cut | disconnects the film-form thing which has the support body which consists of organic compounds, and the inorganic membrane which expresses the target function, and manufactures a cut sheet-like functional film of a predetermined shape.

For packaging materials used for packaging parts, parts, foods, medical products, electronic parts, etc. where moisture resistance is required in various devices such as optical devices, display devices such as liquid crystal displays and organic EL displays, semiconductor devices, and thin film solar cells. The gas barrier film which forms (film-forms) the film (gas barrier film) which expresses gas barrier property on this support body using plastic films, such as a polyethylene terephthalate (PET) film, as a support body is used.

Moreover, the antireflection film formed by forming an anti-reflective film on this support using a plastic film as a support body, the light reflection film formed by forming a light reflection film similarly, the UV cut filter formed by forming an ultraviolet shielding film similarly, etc. are also known.

Thus, in the functional film formed by forming a functional film (film | membrane which expresses the objective function) using a plastic film etc. as a support body, the gas barrier film which expresses gas barrier property, and the light reflection film which expresses light reflection property Such a functional film is often an inorganic film (membrane made of an inorganic compound) or an inorganic film is often included.

For example, a film made of various inorganic compounds (inorganic substances) such as silicon nitride, silicon oxide, and aluminum oxide is used as the gas barrier film.

As described in Patent Literature 1, inorganic films such as gas barrier films have low strength and are soft, and thus are easily destroyed by contact or the like.

Moreover, when an inorganic film exceeds 300 nm, it will become hard and it will become easy to produce a crack etc .. Therefore, in a functional film, generally, the inorganic film for obtaining the target function is a thin film.

By the way, what is called a roll to roll is known as a method which can manufacture such a functional film with favorable production efficiency. A roll-to-roll is formed using a supply roll formed by winding a long support (web support (substrate / substrate)) in the form of a roll, forming a film on a support sent out from a supply roll, and forming a film-supported supporter. It is a manufacturing method to wind up in roll shape again.

In the film formation by this roll-to-roll, a long support body is notified from a supply roll to a winding roll in the predetermined | prescribed path | pass which passes through the film-forming chamber which forms a film in a support body, In the film formation chamber, film formation is performed continuously on the support body conveyed, carrying out synchronously winding up the film-forming support body with a delivery film and a winding roll.

Here, in many cases, a functional film is used as a cut sheet of predetermined shape (predetermined size). Therefore, the functional film which formed into a film the inorganic film which expresses the objective functions, such as a gas barrier film by roll-to-roll, needs to be cut | disconnected (cutting process) into the cut sheet of a predetermined shape.

Japanese Patent Laid-Open No. 3-108531

As mentioned above, in the functional film which has an inorganic film which expresses a predetermined | prescribed function, this inorganic film is low intensity | strength, it is soft, and it is thin further.

Therefore, when the film-like object formed by forming an inorganic film on a support body is cut | disconnected in order to manufacture the functional film of a cut sheet shape of a predetermined shape, in particular, the inorganic film near a cutting position is cracked by the force applied at the time of this cutting | disconnection. Cracks are generated. Moreover, generally, when the support body which is an organic compound and the inorganic film which is an inorganic compound have low adhesiveness, and the crack of an edge part is connected, this part will peel.

If the inorganic film which expresses a predetermined | prescribed function has such a crack and peeling, a functional film cannot exhibit the target performance.

For example, in the case of a gas barrier film, if there is a crack or the like in the gas barrier film at the periphery, moisture (water vapor) passes from the cracked part, and thus, the target gas barrier property (water vapor shielding property) is not obtained.

SUMMARY OF THE INVENTION An object of the present invention is to solve the problems of the prior art and to cut a film-like article having a support such as a plastic film and an inorganic film having a desired function to produce a cut sheet-like functional film of a predetermined shape. At the same time, it is to provide a method for producing a functional film which prevents cracking of the inorganic film due to cutting and the like, and makes it possible to stably produce a functional film having a desired performance.

In order to achieve the said objective, the manufacturing method of the functional film of this invention cuts | disconnects the raw material film which has a support body which consists of organic compounds, and the inorganic film which consists of inorganic compounds by cutting | disconnecting cutting position to the temperature more than the glass transition temperature of the said support body. It provides a functional film of a predetermined shape, The manufacturing method of the functional film is provided.

In the method for producing a functional film of the present invention, any one of heating of the blade for cutting the raw material film, cutting of the raw material film by laser light, and heating of the raw material film before cutting by contact or non-contact heating means. It is preferable to make the cutting position of the said raw material film into temperature more than the glass transition temperature of the said support body by this.

Moreover, it is preferable to make the range of 2-10 mm of the direction orthogonal to a cutting direction into the temperature more than the glass transition temperature of the said support body from the said cutting position.

Moreover, it is preferable that the said raw material film is long, and it is preferable to carry out formation of the inorganic film in the said raw film, conveying the long film in which the said inorganic film is formed in a longitudinal direction.

Moreover, it is preferable to perform formation of the said inorganic film in the state which wound the said elongate film on the circumferential surface of a cylindrical drum.

Moreover, at this time, the said long film is formed from the film roll which wound the said long film in roll shape, the said long film is formed, conveying it in the longitudinal direction, and the long film which formed the said inorganic film is rolled again in roll shape. It is desirable to.

Moreover, the said raw material film is long, and it cuts in the width direction orthogonal to a longitudinal direction, and cuts in the longitudinal direction of the said width direction both ends with respect to this elongate raw material film, and makes it the functional film of the said predetermined shape. It is preferable.

Moreover, it is preferable that the temperature of the said cutting position at the time of cutting is the temperature below melting | fusing point of the said support body.

Moreover, it is preferable that the said inorganic film was formed into a film by the vapor-phase film-forming method.

The manufacturing method of the functional film of this invention which has the said structure cut | disconnects the raw material film in which the support body which consists of organic compounds, such as a plastic film, and the inorganic film for expressing the target function which consists of inorganic compounds is formed, When manufacturing a cut sheet-like functional film, the cutting position of the said raw film is heated above glass transition temperature (Tg) of a support body (its organic compound).

In detail later, when cutting the raw material film which has the support body which consists of organic compounds, and an inorganic film into a film of a predetermined shape, the cause which a crack, gold, etc. generate | occur | produce in an inorganic film arises by heating at the time of film-forming of an inorganic film. It is considered to be due to the synergistic effect of the internal stress of the support and the deformation of the raw film at the time of cutting.

On the other hand, the manufacturing method of this invention has the said structure, and can suppress the internal stress of a support body at the time of cutting, and can make an inorganic film dominate the force corresponding to the deformation | transformation of a raw film by cutting, and as a result It is possible to significantly suppress cracks, cracks, and the like of the inorganic film generated during cutting.

Therefore, according to the manufacturing method of this invention, the crack and peeling of an inorganic film are suppressed significantly, and it becomes possible to manufacture the functional film which exhibits the target performance stably.

FIG.1 (A)-(C) is a figure which shows notionally an example of the raw material film which can be used for the manufacturing method of the functional film of this invention.
It is a conceptual diagram for demonstrating an example of the formation method of the inorganic film in the manufacturing method of the functional film of this invention.
FIG.3 (A)-(C) is a conceptual diagram for demonstrating an example of the manufacturing method of the functional film of this invention.
4 is a conceptual diagram for explaining a method for producing a functional film of the present invention.

EMBODIMENT OF THE INVENTION Hereinafter, the manufacturing method of the functional film of this invention is demonstrated in detail based on the preferable Example shown to an accompanying drawing.

The manufacturing method of the functional film of this invention cut | disconnects the raw material film 12 (refer FIG. 3 etc.) which has the support body which consists of organic compounds, such as a plastic film, and the inorganic film which is a film | membrane which consists of inorganic compounds, and predetermined shape (predetermined size) The functional film of the cut sheet form is manufactured.

In the present invention, the raw material film 12 is not particularly limited, and as long as it is a film-like material having a support made of an organic compound and an inorganic film made of an inorganic compound expressing a function intended for the functional film, it is a raw material film having various configurations. (12) can be used.

As an example, as conceptually shown to FIG. 1 (A), the raw material film 12a which forms the inorganic film (inorganic layer) 14 in the surface of the support body Z is illustrated.

There is no restriction | limiting in particular in the support body (Z), Various film-like objects which consist of organic compounds currently used as a support body of a functional film can be used.

Specifically, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyethylene, polypropylene, polystyrene, polyamide, polyvinyl chloride, polycarbonate, polyacrylonitrile, polyimide, polyacrylate, polymethacryl The plastic film which consists of plastics (polymeric material), such as a rate, is illustrated as a preferable example of the support body Z.

In addition, the support body Z has a protective layer, a contact bonding layer, a light reflection layer, an antireflection layer, a light shielding layer, a planarization layer, a buffer layer, and stress on the surface (formation surface of the inorganic film 14), such as a plastic film as mentioned above. The layer (film) for obtaining various functions, such as a relaxation layer, may be formed.

There is no restriction | limiting in particular also in the inorganic film 14, Any film | membrane which consists of an inorganic compound which expresses the function made into the objective by the functional film to manufacture can be used.

For example, when producing a gas barrier film (water vapor barrier film) as a functional film, a silicon nitride film, an aluminum oxide film, a silicon oxide film, etc. are illustrated as the inorganic film 14.

Moreover, when manufacturing protective films of various devices and apparatuses, such as display apparatuses, such as an organic electroluminescent display and a liquid crystal display, as a functional film, a silicon oxide film etc. are illustrated as the inorganic film 14.

In addition, when manufacturing a transparent conductive film as a functional film, an ITO (indium tin oxide) film, a tin oxide film, etc. are illustrated as an inorganic film 14.

In addition, when manufacturing optical films, such as a light reflection prevention film, a light reflection film, and various filters, as a functional film, what is necessary is just to have the film | membrane which consists of a material which has the objective optical characteristic, or expresses.

Among them, in general, the inorganic film 14 is preferably a gas barrier film in view of low strength, softness, thinness, and severe performance deterioration due to cracks, gold, and the like. It is suitable for manufacture of a gas barrier film.

Moreover, in the manufacturing method of this invention, a raw material film is not limited to the raw material film 12a which forms the inorganic film 14 in the surface of the support body Z as shown to FIG. 1 (A), As mentioned above, various structures can be used.

As an example, the raw material film which alternately laminate | stacks the inorganic layer 14 and the organic film (organic layer) which consists of organic compounds on the surface of the support body Z is illustrated. In particular, the raw material film which has an organic film (base organic film) on the surface of the support body Z, and laminates | combines one or more combinations of the inorganic film 14 and the organic film on it is preferably illustrated.

Specifically, as shown to FIG. 1 (B), it has the base organic film 16a on the surface of the support body Z, The inorganic film 14 and the surface (support body) of this inorganic film 14 on it. The raw material film 12b which has one combination of the organic film 16b formed in (opposing surface of (Z)) is illustrated.

In the raw material film used for this invention, the combination of this inorganic film 14 and the organic film 16b is not limited to one, and like the raw material film 12c shown to FIG. 1 (C), it is 2 You may have a combination of four inorganic films 14 and organic films 16b. Moreover, the raw film which has a combination of three or more inorganic membranes 14 and the organic membrane 16b may be sufficient.

There is no restriction | limiting in particular in the base organic film 16a and the organic film 16b, The film | membrane which consists of a well-known organic compound can be used.

Specifically, polyester, acrylic resin, methacrylic resin, methacrylic acid-maleic acid copolymer, polystyrene, transparent fluorine resin, polyimide, fluorinated polyimide, polyamide, polyamideimide, polyetherimide, cellulose acylate , Polyurethane, polyether ether ketone, polycarbonate, alicyclic polyolefin, polyallylate, polyether sulfone, polysulfone, fluorene ring modified polycarbonate, alicyclic modified polycarbonate, fluorene ring modified polyester, acryloyl compound Thermoplastic resins, such as these, or a film of polysiloxane and other organosilicon compounds are illustrated preferably.

For example, in the case where the inorganic membrane 14 is a membrane (gas barrier membrane) expressing gas barrier property, from the viewpoint of smoothness and heat resistance effective for gas barrier property, a cationic polymer having a radically polymerizable compound and / or an ether group as a functional group The organic film 16 comprised from the polymer of an on-polymerizable compound is preferable. Especially, the organic film 16 which consists of acrylic resin or methacryl resin which have a polymer of an acrylate and / or methacrylate monomer as a main component is preferably illustrated.

The same organic compound may be sufficient as the base organic film 16a and the organic film 16b, and a different organic compound may be sufficient as it. Moreover, each organic film 16b may also be the same organic compound, for example, different organic compounds, such as only the organic film 16b of the uppermost layer (surface), may differ.

The inorganic film 14, the base organic film 16a, and the organic film 16b (hereinafter, collectively referred to as the organic film 16) are all formed (formed film) by a known method.

Specifically, the inorganic film 14 is generally formed by a vapor deposition method (gas deposition method) such as plasma CVD, sputtering, and vacuum deposition. On the other hand, the organic film 16 is generally formed by a coating method or flash deposition.

Here, in the manufacturing method of this invention, Preferably, the raw material film 12 (support body (Z)) is long, and the inorganic film 14 carries out vapor-phase film-forming, conveying a long film-form base material in the longitudinal direction. It is preferable that it is formed by the method.

Moreover, it is preferable that the inorganic film 14 was formed in the state which wound the to-be-film-form base material (namely, the back surface of the support body Z) on the circumferential surface of a cylindrical drum.

2, the example is shown notionally.

The example shown in FIG. 2 uses the base material roll formed by winding the elongate base material in roll shape, sends out a base material from this roll, carries out film-forming, conveying in the longitudinal direction, and winds up the film-forming base material in roll shape again. The roll-to-roll (hereinafter referred to as "RtoR") described above is used.

In addition, the film formation by RtoR is preferably used not only for forming the inorganic film 14 but also for forming the organic film 16.

In the illustrated example, the film-forming substrate Zi on which the inorganic film 14 is formed is a long film-like article and is loaded as the film-forming substrate roll 26 wound in a roll. The film-forming substrate Zi is, for example, a long support (Z) (FIG. 1 (A)) or a long film-like material formed by forming the base organic film 16a on the surface of the support (Z). (B) or the elongate film-like thing formed by forming the base organic film 16a, the inorganic layer 14, and the organic layer 16b on the support body Z (FIG. 1 (C)).

The film-forming substrate Zi is taken out of the film-forming substrate roll 26, conveyed in the longitudinal direction, guided to the guide roll 28a, and conveyed to the drum 20. The film-forming substrate Zi conveyed to the drum 20 is wound around the drum 20 while being wound around a predetermined area of the circumferential surface of the drum 20, positioned at a predetermined film forming position, and conveyed in the longitudinal direction. The inorganic film 14 is formed by the vapor deposition film formation method, such as sputtering and plasma CVD, by the film-forming means 24 arrange | positioned.

The film-forming substrate Zi on which the inorganic film 14 is formed is guided to the guide roller 28b and is wound again in a roll by the winding shaft 30.

When forming the inorganic film 14 by the vapor phase film-forming method (film formation), the film-forming base material Zi, ie, the support body Z, is heated by the heat which arises at the time of film-forming.

As a result, when it cools to room temperature, the internal stress resulting from the difference of the thermal expansion coefficient with the inorganic film 14 generate | occur | produces in the support body Z. Although described later in detail, the internal stress of this support body Z causes the crack of the inorganic film 14 in the cutting | disconnection of the raw material film 12, etc.

Here, in such an RtoR apparatus, in order to convey the film-forming substrate Zi in the longitudinal direction, a tension for conveyance is applied to the film-forming substrate Zi in the longitudinal direction. Since the support Z is heated by the formation of the inorganic film 14 in a state where tension is applied in one direction, the internal stress of the support Z becomes larger.

Moreover, also when the inorganic film 14 is formed in the state which wound the to-be-film-formed base material Zi, ie, the support body Z, on the drum 20, the support body Z is similarly applied to the bending stress. Is heated by the formation of the inorganic film 14. Therefore, even when the inorganic film 14 is formed on the drum 20, the internal stress of the support Z becomes larger.

In particular, as in the example shown in FIG. 2, in the apparatus for forming a film on the drum by RtoR, the internal stress of the support Z is further increased due to the synergistic effect of the tension and the bending stress.

According to the manufacturing method of this invention, even if it is the raw material film 12 with large internal stress of the support body Z which has the inorganic film 14 formed by such RtoR and drum film-forming, the crack of the inorganic film 14 by cutting | disconnection, etc. Can be suppressed preferably.

That is, by using the raw material film 12 which forms the inorganic film 14 by such a formation method, the effect of the manufacturing method of this invention which prevents the crack of the inorganic film 14 at the time of cutting | disconnection, etc. is seen more. It can express preferably.

The manufacturing method of the functional film of this invention cut | disconnects the raw material film 12 which has such a support body Z and the inorganic film 14, and sets it as the cut sheet functional film of predetermined shape (predetermined size).

An example thereof is shown in FIG. 3.

The example shown in FIG. 3 is a preferable example, and the raw material film 12 is a long sheet-like thing, and is supplied as the film roll 34 which wound this long raw film 12 in roll shape.

In the example shown in FIG. 3, the elongate raw material film 12 is first taken out from the film roll 34, it cuts in the width direction (direction orthogonal to a longitudinal direction), and is set as the short raw material film 12S. Next, both ends of the short direction raw material film 12S in the width direction are cut | disconnected in the longitudinal direction, and it is set as the functional film F of a predetermined shape. In addition, in the cutting | disconnection of the short raw material film 12S, the width direction and a longitudinal direction are the width direction and the longitudinal direction in the raw material film 12 which is long before being cut | disconnected shortly (Hereinafter, a "width direction" and `` Length direction ''.

An example of the cutting of the width direction is shown to FIG. 3 (A) conceptually.

In this example, first, the elongate raw film 12 is taken out of the film roll 34 by the conveying roller pair 36, and further conveyed in the longitudinal direction (in the arrow a direction) by the conveying roller pair 36. While cutting, the rotary cutter 38 cuts in the width direction. By cutting | disconnection in this rotary cutter 38, it is set as the short raw material film 12S of the cut sheet | seat along the length of the functional film F to manufacture.

The rotary cutter 38 is a well-known rotary cutter which has the edge 38b extended in the width direction on the circumferential surface of the circumferential rotating body 38a which has the rotation axis (center line) corresponding to the width direction. In addition, the code | symbol 40 in FIG. 3 (A) is a support stand (lower blade / blade support).

The rotary cutter 38 synchronizes with the conveyance of the elongate raw material film 12 similarly to the known rotary cutter (by making the rotational speed of the tip of the blade 38b match with the conveyance speed of the raw material film 12). By rotating in the conveyance direction (arrow b direction) of the raw material film 12, the raw material film 12 conveyed in a longitudinal direction is cut | disconnected in the width direction, and it is set as the short raw material film 12. FIG.

Here, in the example shown to FIG. 3 (A), the elongate raw material film 12 is taken out, forming the surface of the inorganic film 14 etc. upward in the figure, and conveyed by the conveying roller pair 36 Is cut. In addition, the short raw material film 12S manufactured by cutting is conveyed by the conveying roller pair 36 downstream of the rotary cutter 38 to a predetermined position.

In the conveyance roller pair 36, the roller 36b which abuts on the lower support body Z is a normal cylindrical roller, but the roller which abuts on the formation surface of the upper inorganic film 14 in the figure has the edge part ( Or the diameter of the edge part vicinity is what is called a step | step roller 36a whose diameter is larger than the diameter of the area | region (central area | region) other than that.

As described above, since the inorganic film 14 is thin and its strength is low, the inorganic film 14 is also relatively easily damaged by contact with other members.

However, as in the example shown in FIG. 3, the roller which abuts on the formation surface side of the inorganic film 14 is set as the step roller 36a, and the structure which abuts only in the non-product area isolate | separated later makes the inorganic film 14 of a product area | region. It is possible to prevent breakage, damage, and the like, and to stably manufacture an appropriate product.

In the example shown in FIG. 3, when the elongate raw film 12 is cut | disconnected in the width direction in this way, and it is set as the short raw material film 12S, as shown to FIG. 3 (B), the short raw material film 12S ), Both ends in the width direction are cut in the longitudinal direction (arrow a direction) to obtain a functional film F having a predetermined shape.

Cutting of this width direction both ends is performed by the cutting device 42 as shown to FIG. 3 (C) as an example.

This cutting device 42 is configured with two slitters 46 and a split roller 48.

The dividing roller 48 conveys the short raw material film 12S in the longitudinal direction (the direction perpendicular to the paper surface in the arrow a direction = FIG. 3 (C)), the center portion of the inner side of the cutting position at both ends in the width direction, and the width thereof. It is a dividing roller divided | segmented into three outer side parts outside the cutting position of a direction end.

The slitter 46 is a known slitter having a disk-shaped (circular) rotating upper blade 46a and a rotating lower blade 46b. Both rotary blades have a rotating shaft that coincides with the direction orthogonal to the conveyance direction of the short raw material film 12S by the split roller 48 (that is, the width direction of the short raw material film 12S). In the example of illustration, the two slitters 46 are arrange | positioned at the cutting position of the width direction of both ends in the same position of a longitudinal direction (conveying direction). Moreover, the rotation lower blade 46b is the same diameter as the division roller 48, and is fixed to the rotating shaft 48a of the division roller 48 between a center part and an outer side part.

Therefore, in the example of illustration, while the short raw material film 12S is conveyed in the longitudinal direction by the split roller 48, the predetermined position of the width direction both ends is cut | disconnected by the two slitters 46 in the longitudinal direction. And the cut film-form functional film F of a predetermined shape as shown to FIG. 3 (B).

Here, in the manufacturing method of the functional film of this invention, cutting (cutting / cutting) of such raw material film 12 is carried out, and the cutting position of raw material film 12 (12S) is a glass transition of support body Z. It is carried out at a temperature equal to or higher than the temperature Tg. In addition, the temperature of Tg or more of the support body Z is the temperature of Tg or more of the organic compound which forms the support body Z.

In the example shown to FIG. 3A, as an example, by heating the support stand 40 by a heating means not shown, the cutting position of the raw material film 12 is made into the temperature more than Tg of the support body Z, and is rotary By the cutter 38, the raw material film 12 is cut | disconnected in the width direction, and it is set as the short raw material film 12S. In addition, in the example shown to FIG. 3 (C), as an example, the cutting position of the short raw material film 12S is more than Tg of the support body Z by heating the lower blade 46b by the heating means which is not shown in figure. With the temperature, the width direction edge part of the raw material film S short-cut by the slitter 46 is cut | disconnected in the longitudinal direction, and it is set as the functional film F. FIG.

By having such a structure, the manufacturing method of this invention suppresses generation | occurrence | production of the inorganic film 14 resulting from a crack, gold | metal | money, this crack etc. in the inorganic film 14 by cutting | disconnection, and significantly reduces predetermined performance. It is possible to manufacture the functional film which exhibits the stability stably.

As mentioned above, the inorganic film 14 formed in the raw material film 12 used as a functional film is low in strength, is soft, and is generally thin. Therefore, when cutting to make into a predetermined shape, a crack and gold generate | occur | produce in the vicinity of a cut part (cut line). Moreover, since the adhesiveness of an inorganic compound and an organic compound is not so high, when this crack etc. are connected, peeling of the inorganic film 14 etc. generate | occur | produce.

In a functional film, when a crack, peeling, etc. generate | occur | produce in the inorganic film 14 which expresses the target function, a functional film cannot exhibit the target performance. For example, in the case of a gas barrier film, if there is a crack or the like in the gas barrier film at the periphery, water vapor passes from the crack part, and thus, the target gas barrier property is not obtained.

On the other hand, in the manufacturing method of this invention, the cutting position (cutting | disconnection) which arises by cutting | disconnection by making the cutting position of the raw material film 12 (12S) at the temperature more than Tg of the support body Z at the time of cutting | disconnection. Line) The crack of the inorganic film 14 of the vicinity is suppressed significantly.

Here, as shown in Japanese Unexamined Patent Application Publication No. 2001-337411, Japanese Unexamined Patent Application Publication No. Hei 4-372396 and the like, when cutting a long object or the like, heating a cutting blade or a to-be-cut object is performed.

These heating / cutting is for sheet-like objects which consist only of organic compounds, and the heating according to Tg of the image forming layer described in Unexamined-Japanese-Patent No. 2001-337411, and is described in Unexamined-Japanese-Patent No. 4-372396. As is clear from the heating according to the softening point of the polyolefin resin film, the sheet-like object cut at the temperature according to these physical properties is heated for the film (layer) which is easily damaged by cutting or the film to be protected.

On the other hand, the manufacturing method of this invention targets the raw material film 12 which has the support body Z and the inorganic film 14 which consist of organic compounds, and the inorganic film 14 which wants to prevent generation | occurrence | production of a crack etc. is made. Instead of this, cracking of the inorganic film 14 is prevented by heating the cutting position of the raw film to a temperature corresponding to Tg of the support of the raw film (functional film).

The heating of this cutting position is based on the following technical idea which is completely different from the heating of the to-be-cut object and the blade in the conventional cutting process.

As mentioned above, the inorganic film 14 which expresses predetermined | prescribed functions, such as a gas barrier film and an antireflection film, is formed (formed into a film) in many cases by vapor-phase film-forming methods, such as plasma CVD, sputtering, and vacuum deposition. .

As described above, when the inorganic film 14 is formed by such a vapor phase film forming method, the film-forming substrate Zi on which the inorganic film 14 is formed is heated during film formation. That is, in this invention which manufactures the functional film which has the support body Z which consists of organic compounds, such as a plastic film, at the time of formation of this inorganic film 14, the support body Z is also heated. In the case of drum film formation as shown in FIG. 2, although the drum 20 is cooled normally, the film-forming base material Zi is cooled, but heating of the support body Z cannot be avoided.

By this heating, the support body Z expands. In addition, the inorganic film 14 to be formed is also expanded by heat. Here, in the support body (Z) which is an organic compound, and the inorganic film 14 which is an inorganic compound, thermal expansion coefficient differs significantly.

Therefore, when it cools to room temperature after film-forming, the internal stress different from each other arises in the support body Z and the inorganic film 14 by the difference of the thermal expansion coefficient of the support body Z and the inorganic film 14. That is, in the raw material film 12, the internal stress of this support body Z is in the state which applied unnecessary force to the inorganic film 14.

In addition, this internal stress is formed when carrying out film formation, conveying the film-forming base material Zi like RtoR etc. shown in FIG. 2, or the drum-forming film which winds up the film-forming base material Zi on the drum 20, and forms a film. In the case of, the increase is as described above.

Here, at the time of cutting | disconnection of the raw material film 12 (and short raw material film 12S, hereinafter abbreviate | omitted), the vicinity of the cutting position of the raw material film 12 is deformed by the press etc. by a blade, and after cutting Wants to go back from the transformation.

When the raw film having the support Z and the inorganic film 14 is cut off, it is desired to return from internal stresses different from the inorganic film 14 included with the support Z, and the forces and strains at which the raw film 12 is deformed. Power is synthesized. As a result, a large force is applied to the inorganic film 14 at the cut position, and cracks, gold, and the like occur near the cut position of the inorganic film 14.

On the other hand, in the manufacturing method of this invention, the state in which the internal stress of this support body Z was removed (suppressed) by heating the cutting position more than Tg of the support body Z at the time of the cutting of the raw material film 12 is carried out. Carry out the cutting at. That is, by setting the temperature of the support Z to be Tg or more, the deformation and the restoration from the deformation during the cutting are in a state governed by the inorganic film 14, and the force applied to the inorganic film 14 is greatly reduced. .

As a result, an excessive force is not applied to the inorganic film 14 at the time of the cutting of the raw material film 12, and it can greatly reduce the generation | occurrence | production of a crack and gold in the vicinity of a cutting position. Moreover, since it is a heating cutting, generation | occurrence | production of the burr, dust, etc. from the support body Z, the organic film 16, etc. can also be suppressed.

Therefore, according to the manufacturing method of this invention, the inorganic film 14 which expresses a predetermined | prescribed function is prevented from being damaged by cutting | disconnection, it has a predetermined shape (predetermined size), and also aims at the target performance. The functional film (F) which has can be manufactured stably.

In the manufacturing method of this invention, the temperature of the cutting position of the raw material film 12 at the time of cutting should just be Tg or more of the support body Z.

However, when it becomes too high, when it has a support body Z, the organic film 16, etc., there exists a possibility that a bad influence may also arise in these films, and also deformation | transformation of the support body Z may occur. Therefore, it is preferable that the temperature of the cutting position of the raw material film 12 at the time of cutting shall be below melting | fusing point of the support body Z.

Moreover, in view of the above point, the temperature of the cutting position of the raw material film 12 is preferably Tg + 20 ° C. or lower of the support Z, and particularly preferably Tg + 10 ° C. or lower of the support Z.

Here, the inorganic film (like the raw film 12b shown in FIG. 1 (B) and the raw film 12c shown in FIG. 1 (C)) has a structure in which the raw film 12 has a film made of an organic compound. 14) In the case of the raw material film having the structure sandwiched between the organic films 16, the internal stress of the organic film 16 is also applied at the time of cutting, and the crack of the inorganic film 14 at the time of cutting, and the like. Easy to generate.

Therefore, when the raw material film 12 has a film | membrane which consists of organic compounds, such as the organic film 16, the film | membrane which consists of a support body Z and the organic compound which exists at the temperature of the cutting position of the raw material film 12 is present. It is preferable to set it as the temperature more than Tg of the thing with the highest Tg among these. Thereby, the crack etc. of the cutting position vicinity at the time of a cutting | disconnection can be suppressed more preferably.

There is no restriction | limiting in particular in the heating method of the cutting position of the raw material film 12. As an example, as shown in FIG. 3, the raw material film 12 is directly heated by the method of heating the blade which cut | disconnects, the method of heating the member which contacts the raw material film 12 at the time of cutting, a heater, etc. The method is illustrated. In addition, the method of cutting while heating the cutting position of the raw material film 12 using a laser beam (laser beam) can also be used preferably.

Moreover, what is necessary is just to perform the heating of the raw material film 12, the day of cutting, and the heating of the member which contacts the raw film 12 by a well-known method by contact or non-contact.

In addition, the cutting means of the raw material film 12 is also not limited to the rotary cutter like the example of illustration, and the slitter using two disk-shaped rotary blades.

For example, a well-known sheet | seat, such as a guillotine cutter, the slitter which has a lower blade fixed with the upper blade of the disk-shaped rotary blade, and the punch (punching) using the blade of the shape surrounding the functional film F to manufacture. All cutting means of the object can be used.

In the manufacturing method of this invention, what is necessary is just to make a cutting position into the temperature more than Tg of the support body Z at the time of the cutting of the raw material film 12 basically.

However, when the range which makes temperature more than Tg of the support body Z is too wide, the support body Z may receive thermal damage, and there exists a possibility that problems, such as a deformation | transformation of a functional film F and a fall of mechanical strength, may arise. In addition, in this invention, suppressing the crack of the inorganic film 14, etc. is in the vicinity of the cutting position of the raw material film 12, and heating of the position away from the cutting position is wasteful.

On the contrary, if the range in which the temperature is equal to or larger than the Tg of the support Z is too narrow, it is impossible to sufficiently supply a region deformed by cutting, so that the crack of the inorganic film 14 due to the cutting of the raw material film 12 is sufficient. It may not be possible to suppress it.

Therefore, in this invention, as shown conceptually in FIG. 4, in the direction orthogonal to the cutting position (cutting direction / cutting line) L shown by a dashed-dotted line in a figure, the temperature of the raw material film 12 is a support body ( It is preferable to make the regions w1 and w2 to be Tg or more of Z) to 2 to 10 mm.

Thereby, it can also preferably prevent that damage | damage, such as support body Z by heat, widens extensively while suppressing generation | occurrence | production of the crack of the inorganic film 14 in a cutting position, etc. fully.

In the example shown in FIG. 3, the elongate raw film 12 was cut | disconnected in the width direction, After that, the both ends of the width direction were cut | disconnected, and it was set as the functional film F of a predetermined shape. However, the present invention is not limited to this, but first, both ends in the width direction of the elongated raw film 12 may be cut out with slitter or the like, and then cut in the width direction to form a functional film F having a predetermined shape. .

However, by finally leaving the end portion in the width direction to be cut out to the end, conveyance or handling in contact with this portion becomes possible, and damage to the inorganic film 14 due to contact with the product region can be prevented. have. Therefore, as shown in FIG. 3, it is preferable to cut | disconnect to the width direction first, and to cut | disconnect the width direction edge part at the end.

In addition, although the above example manufactures the functional film of a predetermined shape by cutting a elongate raw material film in the width direction and the both-end longitudinal direction, this invention is not limited to this. For example, you may cut a long raw film only in the width direction, and may manufacture the functional film of a predetermined shape.

Moreover, you may manufacture the functional film of a predetermined shape by cutting this raw material film 1 or more times using a cut sheet-like raw material film.

As mentioned above, although the manufacturing method of the functional film of this invention was demonstrated in detail, this invention is not limited to the above-mentioned example, You may implement various improvement and modification in the range which does not deviate from the summary of this invention. Of course.

For example, the cut sheet-like functional film manufactured by this invention is not limited to rectangles, such as a square and a rectangle, Various shapes, such as a shape which has a round or curved edge, can be used.

[Example]

Hereinafter, the present invention will be described in more detail with reference to specific examples of the present invention.

Example 1

The raw material film 12 formed by forming the base organic film 16a / inorganic film 14 / organic film 16b on the support body Z of width 1000mm as shown to FIG. 1 (B), The film roll 34 formed by winding in roll shape was prepared.

The support body Z used the PET film (Tg: 80-90 degreeC) of thickness 100micrometer.

The organic film 16 prepared the coating material which melt | dissolved the acrylate-type monomer and the photoinitiator in the organic solvent, and after apply | coating this coating material with a die coater and drying, it made into the film which hardened the coating film with the ultraviolet-ray. The film thickness of both the base organic film 16a and the organic film 16b was 1000 nm. In addition, formation of the organic film 16 was performed by the apparatus of RtoR.

In addition, the inorganic film 14 was made into the aluminum oxide layer of thickness 50nm. Formation of the inorganic film 14 was performed by reactive sputtering using the film-forming apparatus which carries out the drum-forming by RtoR as shown in FIG.

This film roll 34 is first cut | disconnected in the width direction by the cutting device using the rotary cutter 28 as shown to FIG. 3 (A), and is a short raw material film whose length is 500 mm (width 1000 mm). It was set as (12S).

The cutting was performed by heating the support base 40 with the sheath heater provided in the inside of the support body 40, making the temperature of the cutting position of the raw material film 12 into 100 degreeC. In addition, the temperature of the cutting position of the raw material film 12 was measured by the sheath thermoelectric pair.

Subsequently, both ends of the short direction raw material film 12S of the width direction were cut | disconnected in the longitudinal direction using the cutting device 42 as shown in FIG.3 (C), and a rectangular functional film of 500x600 mm (gas barrier) Film).

The cutting was performed by heating the lower blade 46d with an infrared lamp to set the temperature at the cutting position of the short raw material film 12S to 100 ° C. In addition, the temperature of the cutting position of the short raw material film 12S was measured with the radiation thermometer.

[Example 2]

It carried out except having changed the support body Z into the PEN film (Tg: 120 degreeC) of thickness 100micrometer, and changing the temperature of the cutting position of the raw material film 12 and the short raw material film 12S to 130 degreeC. A functional film was produced in the same manner as in Example 1.

[Comparative Example 1, Comparative Example 2]

Example 1 (support body (Z) =) except having changed the temperature of the cutting position of the raw material film 12 and the short raw material film 12S into 30 degreeC (comparative example 1), and 60 degreeC (comparative example 2). PET) to prepare a functional film.

[Comparative Example 3, Comparative Example 4]

Example 2 (support body (Z) =) except having changed the temperature of the cutting position of the raw material film 12 and the short raw material film 12S into 100 degreeC (comparative example 3) and 60 degreeC (comparative example 4). PEN) was prepared in the same manner as the functional film.

[evaluation]

The cracks of the inorganic film 14 were observed and evaluated with the naked eye and the optical microscope (500 times) in the vicinity of the cut position of the produced functional film.

○ Cracks could not be confirmed by microscope ○:

It is not possible to confirm the crack with the naked eye, but it can be confirmed with the microscope.

What was able to confirm a crack also visually evaluated by x :.

The results are shown in Table 1 below.

As shown in the said Table 1, according to this invention which made the cutting position into the temperature more than Tg of a support body at the time of cutting, a high quality functional film without a crack etc. can be manufactured in the vicinity of a cutting position.

On the other hand, as for the comparative example whose temperature of a cutting position is Tg or less of a support body, the crack was confirmed by the cutting | disconnection vicinity all. In particular, the comparative example 1 and the comparative example 4 whose temperature of a cutting position is significantly lower than Tg of a support body could confirm the crack of the inorganic film 14 visually.

From the above result, the effect of this invention is clear.

It is used for manufacture of a functional film which has a desired shape, such as a gas barrier film of the shape according to a use.

12a, 12b, 12c: raw film
14: inorganic film
16a: lower organic film
16b: organic film
20: drum
24: film forming means
26: film-forming base material roll
28a, 28b: guide roller
30: winding shaft
34: film roll
36: conveying roller pair
38: rotary cutter
40: support
42: cutting device
46: slitter
48: split roller

Claims (9)

The raw material film which has a support body which consists of organic compounds, and the inorganic film which consists of inorganic compounds is cut | disconnected at the cutting position to the temperature more than the glass transition temperature of the said support body, and it is set as the functional film of a predetermined shape, The manufacturing method of the functional film characterized by the above-mentioned. . The method of claim 1,
The cutting position of the raw material film is determined by any one of heating of a blade for cutting the raw material film, cutting of the raw material film by laser light, and heating of the raw material film before cutting by contact or non-contact heating means. The manufacturing method of a functional film made into temperature more than the glass transition temperature of this. The method according to claim 1 or 2,
The manufacturing method of the functional film which makes the range of 2-10 mm of the direction orthogonal to a cutting direction from the said cutting position into the temperature more than the glass transition temperature of the said support body. The method according to claim 1 or 2,
The said raw material film is long, and the formation method of the functional film which carries out formation of the inorganic film in the said raw film, conveying the long film in which the said inorganic film is formed in a longitudinal direction. The method of claim 4, wherein
The formation method of the said functional film is a manufacturing method of the functional film which winds up the said elongate film on the circumferential surface of a cylindrical drum, and is dry. The method of claim 4, wherein
Production of the functional film which forms the said inorganic film, takes out the said elongate film from the film roll which wound the said elongate film in roll shape, conveys it in the longitudinal direction, and winds the elongate film which formed the said inorganic film in roll shape again. Way. The method according to claim 1 or 2,
The said raw material film is long, The functional film made into the said functional film of the said predetermined shape by cutting | disconnecting the width direction orthogonal to a longitudinal direction, and the longitudinal direction cutting of the said width direction both ends with respect to this elongate raw material film. Method of preparation. The method according to claim 1 or 2,
The manufacturing method of the functional film whose temperature of the said cutting position at the time of cutting is the temperature below melting | fusing point of the said support body. The method according to claim 1 or 2,
A method for producing a functional film, wherein the inorganic film is formed by a vapor deposition method.

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