KR20200064082A - Method and apparatus for manufacturing optical member - Google Patents

Abstract

[Problem] A method and apparatus for manufacturing an optical member with little adhesion to powder such as abrasive waste are provided.
[Solutions] The method of manufacturing the optical member has an optical film 50 and a pressure-sensitive adhesive layer 80 formed on one side of the optical film 50, and a powder f adheres to the end face E It includes the process of preparing the laminated body 100, and the process of removing the powder f from the end face E by colliding the dry ice particles d with the end face E of the laminated body 100. do.

Description

Method and apparatus for manufacturing optical member

The present invention relates to a method and an apparatus for manufacturing an optical member.

Conventionally, an optical member having an optical film such as a polarizer and an adhesive layer is known.

As a method of obtaining an optical member of a desired size, it is known to cut a raw laminate having an optical film and an adhesive layer with a laser or blade (see Patent Documents 1 and 2).

Patent Document 1: Publication of WO2014/189078 Patent Document 2: Japanese Patent Publication No. 2009-86675

However, in recent years, demands for dimensional accuracy for optical members using optical films and pressure-sensitive adhesive layers have become stricter. Therefore, it is difficult to obtain a desired dimensional accuracy only by cutting the disk stack. Therefore, the end face of the laminated body after cutting may be processed such as grinding and polishing.

However, when processing such as polishing is performed on the end surface of the laminate, powders such as abrasive debris may adhere to the end surface of the laminate. When the powder remains in the laminate, the final product containing the laminate, etc., is generated, which is not preferable.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method and apparatus for manufacturing an optical member with less adhesion of powder such as abrasive debris.

The manufacturing method of the optical member which concerns on this invention is a process (preparation process) which prepares the laminated body which has the optical film and the adhesive layer formed in one surface of the said optical film, and the powder is attached to the end surface, And the step of removing the powder from the end surface (collision process) by colliding dry ice particles with the end surface of the laminate.

According to the present invention, powders such as cut chips, cut chips and abrasive chips are suitably removed from the end face of the laminate (optical member) by dry ice particles.

Here, the average particle diameter of the dry ice particles may be 100 to 1000 μm.

Thereby, while the powder such as grinding debris is suitably removed, the distortion of the pressure-sensitive adhesive on the end face is suppressed.

In addition, in the collision step, the dry ice particles may be collided on the end faces of the laminated structure in which the plurality of laminates are stacked.

This enables mass processing of the laminate.

Further, at the same time that the dry ice particles collide with a part of the end face, at least one selected from the group consisting of cutting, cutting and polishing may be performed on other parts of the end face of the laminate.

According to this, it is possible to shorten the process time by simultaneously performing a plurality of processes.

Further, in the preparation step, when the end face is subjected to at least one treatment selected from the group consisting of cutting, cutting and polishing, and when the dry ice particles collide with a part of the end face, the end face is Any treatment selected from the group may not be performed.

According to this, since the atmosphere (space) in which powder is removed by collision of dry ice particles and the processing atmosphere (space) in which powder is generated can be divided, the dry ice is produced by the powder generated by the processing of the end face. It is possible to suppress the collision of the colliding part.

The optical film is a laminated film comprising at least one selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancing film, a window film, and a touch sensor, and at least one selected from the group, or It may be a laminated film comprising at least two selected from the group.

The relative humidity of the atmosphere in the collision process may be 30 to 75%.

An apparatus for manufacturing an optical member according to the present invention includes an end face processing unit for cutting, cutting or polishing an end face of an optical film and a laminate having an adhesive layer formed on one side of the optical film, and the laminate. And a dry ice particle supply unit for colliding dry ice particles with a portion processed in the end surface processing portion.

The apparatus for manufacturing the optical member may further include a conveying unit for moving the laminate between the end face processing unit and the dry ice particle supply unit.

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method and manufacturing apparatus of the optical member with little adhesion of powders, such as abrasive|dust, can be provided.

1A and 1B are cross-sectional views of a laminate 100 according to one embodiment of the present invention.
2A and 2B are cross-sectional views of another example of a laminate.
3 is a schematic configuration diagram of a dry ice particle supply unit.
4 is a conceptual view showing an aspect in which dry ice particles collide with end surfaces of a stacked structure 120 including a plurality of stacks 100.
5 is a perspective view of an apparatus for manufacturing an optical member according to an embodiment of the present invention.
6 is a perspective view showing another example of the end face processing portion in FIG. 5.
7 is a conceptual view showing an aspect in which dry ice particles collide with an end surface inside the stacked structure 120 having a through hole H'.

A manufacturing method and an apparatus for manufacturing an optical member according to an embodiment of the present invention will be described with reference to the drawings.

(Preparation of a laminate with powder attached to the end face)

First, as shown in Fig. 1 (a), the optical film 50, and the pressure-sensitive adhesive layer 80 formed on one side of the optical film 50, the end face (E) of the powder (f) ) Is attached to prepare the laminate 100. Meanwhile, the end face E is not limited to the end face outside the laminate 100. For example, as shown in (b) of FIG. 1, when the stacked body 100 has a hole H passing through in the stacking direction, the inner wall of the hole H, that is, the inner side of the stacked body 100 Powder f such as perforated debris may adhere to the end face E of the case.

(Optical film)

The optical film 50 is a film that transmits at least a part of visible light.

Examples of the optical film 50 are a polarizer, a protective film, a retardation film, a brightness enhancing film, a window film, and a touch sensor, and the optical film 50 may have a laminated structure having a plurality of single species of these films, You may have a laminated structure which has multiple types of these films.

(Polarizer)

A polarizer is a film in which the transmittance of linearly polarized light is different from each other in two orthogonal directions in the plane. As the material of the polarizer, known materials conventionally used for the production of the polarizer can be used. For example, polyvinyl alcohol-based resin, polyvinyl acetate resin, ethylene/vinyl acetate (EVA) resin, polyamide resin, polyester-based And resins. Especially, polyvinyl alcohol-type resin is preferable. After stretching these resin films, dyeing with iodine or a dichroic dye and boric acid treatment can give a film-shaped polarizer (film-shaped polarizer).

The thickness of the film-type polarizer may be, for example, 1 to 75 μm.

Further, as another example of the polarizer, a liquid crystal coated polarizer formed of a liquid crystal compound may be used. This liquid crystal coating type polarizer can be produced, for example, by using a suitable substrate and applying a liquid crystal polarizing composition on the substrate. An alignment film may be formed on the base material before applying the liquid crystal polarizing composition. The liquid crystal polarizing composition may include a liquid crystal compound and a dichroic dye compound. As said liquid crystalline compound, it is only necessary to have the property which shows a liquid crystal state, and it is especially preferable to have a high order liquid crystal state, such as a smectic phase, because the obtained liquid crystal coating polarizer can exhibit high polarization performance. Moreover, it is also preferable that the said liquid crystalline compound has a polymerizable functional group. The dichroic dye compound is a dye that is aligned with the liquid crystal compound and exhibits dichroism, and the dichroic dye itself may have liquid crystallinity or may have a polymerizable functional group. It is preferable that any one compound contained in the liquid crystal polarizing composition has a polymerizable functional group. The liquid crystal polarizing composition may also include an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, and a silane coupling agent.

Here, the typical example of the method of manufacturing a liquid crystal coating type polarizer by forming an alignment film on a base material and apply|coating a liquid crystal polarizing composition on the base material with an alignment film formed is shown.

The liquid crystal coating type polarizer manufactured by this method can make thickness thinner than the said film type polarizer. The thickness of the liquid crystal coating type polarizer is 0.5 to 10 μm, preferably 1 to 5 μm.

The alignment film can be formed on the substrate by, for example, imparting orientation to rubbing, polarized light irradiation, or the like, to a coating film formed by coating an alignment film forming composition on a substrate. The said alignment film forming composition contains an alignment agent, and may contain a solvent, a crosslinking agent, an initiator, a dispersing agent, a leveling agent, a silane coupling agent, etc. besides an alignment agent. Examples of the alignment agent include polyvinyl alcohols, polyacrylates, polyamic acids, and polyimides. When applying photo-alignment as a method for imparting the orientation, an alignment agent containing a cinnamate group is preferable.

The alignment agent may be a polymer. The alignment agent of the polymer has a weight average molecular weight of about 10,000 to 1000,000. The thickness of the alignment film formed on the substrate is preferably 5 nm to 10000 nm, and particularly preferably 10 to 500 nm, since a sufficient orientation regulating force is expressed, which is preferable.

A coating film of a liquid crystal polarizing composition is formed by coating a liquid crystal polarizing composition on a substrate on which an alignment film is formed, and drying as necessary, to prepare a liquid crystal coating type polarizer from the coating film of the liquid crystal polarizing composition.

The liquid crystal polarizer manufactured in this way may be peeled from the substrate. As a method of peeling a liquid crystal coating type polarizer from a substrate, for example, a liquid crystal coating type polarizer-second substrate is included by peeling the substrate after bonding the second substrate to a surface on which the substrate of the liquid crystal coating type polarizer is not laminated. By using the method for obtaining the laminate to be used, the liquid crystal coated polarizer may be transferred to the second substrate or may be left laminated on the substrate without being transferred to the second substrate. It is also preferable that the base material or the second base material serves as a transparent base material for the protective film, retardation plate, and window film.

(Protective film)

The protective film is a transparent film that prevents damage such as damage to other optical films such as polarizers and/or optical devices (such as liquid crystal cells) to which the laminate 100 is subsequently attached. The protective film may be various transparent resin films.

Here, the protective film for protecting the polarizer is described. Examples of the resin forming the protective film,

A cellulose-based resin having triacetyl cellulose as a representative example;

A polyolefin-based resin having a polypropylene-based resin as a representative example;

Cyclic olefin resins using norbornene resins as representative examples;

An acrylic resin having a polymethyl methacrylate resin as a representative example; And

It is a polyester resin which uses polyethylene terephthalate resin as a representative example. Among these, cellulose-based resins are typical.

The thickness of the protective film may be, for example, 5 to 90 μm.

The protective film, if necessary, plasticizers, ultraviolet absorbers, infrared absorbers, colorants such as pigments or dyes, fluorescent brighteners, dispersants, heat stabilizers, light stabilizers, antistatic agents, antioxidants, lubricants, solvents, etc. You may include it.

A hard coat layer may be formed on at least one surface of the protective film in order to increase the scratch resistance of the protective film surface. The thickness of the hard coat layer is usually in the range of 2 to 100 μm. When the thickness of the hard coat layer is less than 2 µm, it is difficult to ensure sufficient scratch resistance, and when it exceeds 100 µm, the bending resistance decreases, and when the protective film is bonded to a polarizer or the like, the problem of curling due to curing shrinkage occurs. May occur.

The hard coat layer can be formed of a hard coat composition containing a reactive material that forms a crosslinked structure by irradiating active energy rays or thermal energy rays. Among these, a hard coat layer obtained by active energy ray irradiation is preferable. The active energy ray is defined as an energy ray capable of decomposing a compound generating an active species to generate an active species. Examples of the active energy ray include visible light, ultraviolet ray, infrared ray, X ray, α ray, β ray, γ ray and electron beam. Among these, ultraviolet rays are particularly preferable. It is preferable that the said hard-coat composition contains at least 1 sort(s) of a radically polymerizable compound and a cationically polymerizable compound. The oligomer in which these radically polymerizable compounds and cationic polymerizable compounds are partially polymerized may be included in the hard coat composition.

First, a radically polymerizable compound is demonstrated.

The radically polymerizable compound is a compound having a radically polymerizable group. The radically polymerizable group may be any functional group capable of generating a radical polymerization reaction, and examples include a group containing a carbon-carbon unsaturated double bond, and examples thereof include a vinyl group and a (meth)acryloyl group. On the other hand, when the said radically polymerizable compound has 2 or more radically polymerizable groups in 1 molecule, these radically polymerizable groups may be same or different respectively. When the said radically polymerizable compound has two or more radically polymerizable groups in 1 molecule, the hardness of the hard-coat layer obtained tends to improve. As the radically polymerizable compound, from the viewpoint of high reactivity, a compound having a (meth)acryloyl group is preferable, for example, a polyfunctional acrylate having 2 to 6 (meth)acryloyl groups in one molecule. It has several (meth)acryloyl groups in a molecule called a monomer or an epoxy (meth)acrylate, urethane (meth)acrylate, or polyester (meth)acrylate, and has a molecular weight of hundreds to thousands. And oligomers. Among the compounds having a (meth)acryloyl group, at least one selected from epoxy (meth)acrylate, urethane (meth)acrylate and polyester (meth)acrylate is preferable.

Next, a cationic polymerizable compound will be described.

The said cationically polymerizable compound is a compound which has a cationically polymerizable group, such as an epoxy group, an oxetanyl group, and a vinyl ether group. From the viewpoint of improving the hardness of the resulting hard coat layer, the number of cationic polymerizable groups in one molecule of the cationic polymerizable compound is preferably two or more, and more preferably three or more. Moreover, as said cationic polymerizable compound, the compound which has at least 1 type of cationic polymerizable group among an epoxy group and oxetanyl group is preferable. The cyclic ether group of an epoxy group or an oxetanyl group has an advantage that shrinkage due to a polymerization reaction is small. In addition, the compound having an epoxy group in the cyclic ether group is a compound of various structures, is readily available in the market, it is difficult to adversely affect the durability of the obtained hard coat layer. When the hard coat composition is a combination of a radically polymerizable compound and a cationic polymerizable compound, the compound having an epoxy group has an advantage that it is easy to control compatibility with the radically polymerizable compound. In addition, the oxetanyl group in the cyclic ether group is easy to increase the degree of polymerization as compared to an epoxy group, is low toxicity, and accelerates the network formation rate obtained from the cationically polymerizable compound of the obtained hard coat layer, even in the region where it is mixed with the radically polymerizable compound. There are advantages such as forming an independent network without leaving unreacted monomers in the membrane.

As a compound having an epoxy group, for example,

Polyglycidyl ethers of polyhydric alcohols having an alicyclic ring;

Alicyclic epoxy resins obtained by epoxidizing a compound containing a cyclohexene ring and a cyclopentene ring with a suitable oxidizing agent such as hydrogen peroxide and peracid;

Aliphatic polyhydric alcohols, or polyglycidyl ethers of alkylene oxide adducts;

Polyglycidyl esters of aliphatic long-chain polybasic acids;

Aliphatic epoxy resins such as homopolymers and copolymers of glycidyl (meth)acrylate;

Bisphenols such as bisphenol A, bisphenol F and hydrogenated bisphenol A, or derivatives such as alkylene oxide adducts and caprolactone adducts, and glycidyl ethers produced by the reaction of epichlorohydrin;

And glycidyl ether type epoxy resins derived from bisphenols such as novolac epoxy resins and the like.

The hard coat composition may further include a polymerization initiator. As a polymerization initiator, an appropriate one (radical polymerization initiator, cationic polymerization initiator) can be selected and used depending on the type of the polymerizable compound contained in the hard coat composition. These polymerization initiators are decomposed by at least one of active energy ray irradiation and heating, and generate radicals or cations to advance radical polymerization or cationic polymerization.

The radical polymerization initiator may be capable of releasing a substance that initiates radical polymerization by at least one of active energy ray irradiation and heating. For example, examples of the thermal radical polymerization initiator include organic peroxides such as hydrogen peroxide and perbenzoic acid, and azo compounds such as azobisbutyronitrile.

Examples of the active energy ray radical polymerization initiator include a type 1 radical polymerization initiator in which radicals are generated by decomposition of molecules, and a type 2 radical polymerization initiator that coexists with a tertiary amine to generate radicals through a hydrogen draw reaction. It can also be used alone or in combination.

The cationic polymerization initiator may be capable of releasing a substance that initiates cationic polymerization by at least one of active energy ray irradiation and heating. As the cationic polymerization initiator, aromatic iodonium salt, aromatic sulfonium salt, cyclopentadienyl iron (II) complex, or the like can be used. These can initiate cationic polymerization either by active energy ray irradiation or heating depending on the difference in structure.

The polymerization initiator may contain 0.1 to 10% by weight relative to the total weight of the hard coat composition. When the content of the polymerization initiator is less than 0.1% by weight, curing cannot be sufficiently progressed, and mechanical properties of the finally obtained hard coat layer are lowered, or it is easy to make it difficult to implement adhesion between the hard coat layer and the protective film. When it exceeds 10% by weight, there may be cases in which adhesive strength due to curing shrinkage during formation of the hard coat layer, cracking, and curling occur.

The hard coat composition may further contain at least one selected from the group consisting of solvents and additives.

The solvent is capable of dissolving or dispersing the polymerizable compound and the polymerization initiator, and can be used without limitation as long as it is known as a solvent for the hard coat composition in the art.

The additives are inorganic particles, leveling agents, stabilizers, surfactants, antistatic agents, lubricants, antifouling agents and the like.

Next, the method in the case of bonding a protective film to a polarizer is demonstrated.

It is suitable that the protective film of the polarizer is attached to the polarizer through an adhesive. As this adhesive,

Water-based adhesives using polyvinyl alcohol-based resin aqueous solutions, water-based two-part urethane emulsion adhesives, and the like;

Active energy ray-curable adhesive using a curable composition comprising a polymerizable compound and a photopolymerization initiator, a curable composition containing a photoreactive resin, a curable composition comprising a binder resin and a photoreactive crosslinking agent, and the like

Can be heard.

In addition to the vinyl alcohol homopolymer obtained by saponifying polyvinyl acetate, a homopolymer of vinyl acetate, to the polyvinyl alcohol-based resin contained in the aqueous polyvinyl alcohol-based resin used as the adhesive, vinyl acetate and other monomers copolymerizable therewith And vinyl alcohol-based copolymers obtained by saponifying the copolymer, and modified polyvinyl alcohol-based polymers in which these hydroxyl groups are partially modified. Polyhydric aldehydes, water-soluble epoxy compounds, melamine-based compounds, zirconia compounds, zinc compounds, etc. may also be added to these water-based adhesives as additives.

Moreover, as the active energy ray-curable adhesive used as an adhesive, the same ones as those containing a reactive material that forms a crosslinked structure by irradiating active energy rays, exemplified as one of the hard coat compositions described above, can be mentioned.

As described above, a method of using a resin film as a protective film (or a protective film having a hard coat layer) and bonding it to a polarizer has been described, but instead of the resin film, a thinner protective layer is directly laminated to the polarizer to protect the film. You can also do

As a method of directly laminating a thinner protective layer on a polarizer, for example, a coating film containing an active energy ray-curable resin is formed on the surface of the polarizer, and the coating film is cured by irradiation with active energy rays (UV or the like). A protective film thinner than the protective film can be directly formed on the surface of the polarizer. As this active energy ray-curable resin, what contains the reactive material which forms the crosslinked structure by irradiating an active energy ray illustrated as one of the hard-coat compositions mentioned above is mentioned.

(Window film)

On the other hand, a transparent protective film that prevents damage such as damage to an optical device (such as a liquid crystal cell) to which the laminate 100 is subsequently attached is also referred to as a window film. The window film, for example, when the optical film 50 has a laminated structure having a plurality of films, is disposed on the outermost surface opposite to the surface on which the pressure-sensitive adhesive layer 80 is formed in the plurality of films.

The window film is disposed on the viewer's side of the flexible image display device, and serves to protect other components from environmental changes such as impact from outside or temperature and humidity. Glass has been conventionally used as such a protective layer, but the window film in the flexible image display device is not rigid and hard like glass, and has flexible characteristics. The window film may include a flexible transparent substrate, and may include a hard coat layer on at least one surface.

(Transparent description)

The transparent base material which can be used as a window film is demonstrated.

The transparent substrate has a visible light transmittance of 70% or more, preferably 80% or more. Any of the transparent substrates can be used as long as they are transparent polymer films. Specifically,

Polyolefins such as cycloolefin derivatives having units of monomers including polyethylene, polypropylene, polymethylpentene, norbornene or cycloolefin;

(Modified) celluloses such as diacetyl cellulose, triacetyl cellulose and propionyl cellulose;

Acrylics such as methyl methacrylate (co)polymer;

Polystyrenes such as styrene (co)polymers;

Acrylonitrile-butadiene-styrene copolymers, acrylonitrile-styrene copolymers;

Ethylene-vinyl acetate copolymers;

Polyvinyl chlorides, polyvinylidene chlorides;

Polyesters such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, and polyarylate;

Polyamides such as nylon;

Polyimides, polyamideimides, polyetherimides;

Polyether sulfones, polysulfones;

Polyvinyl alcohols, polyvinyl acetals;

Polyurethanes;

Epoxy resins

Films formed of polymers such as these may be used, or these polymers may be formed individually or in combination of two or more. Moreover, the unstretched, uniaxial or biaxially stretched film can also be used for this film. The polyamide film, the polyamideimide film or the polyimide film, the polyester film, the olefin film, the acrylic film, and the cellulose film are preferable among the transparent base materials of the illustrated polymer. In addition, it is also preferable to disperse inorganic particles such as silica, organic fine particles, and rubber particles in the transparent substrate. Further, colorants such as pigments and dyes, fluorescent brighteners, dispersants, plasticizers, heat stabilizers, light stabilizers, infrared absorbers, ultraviolet absorbers, antistatic agents, antioxidants, lubricants, and solvents may be added. The thickness of the transparent substrate is 5 to 200 μm, preferably 20 to 100 μm.

(Hard coat)

A hard coat layer may be formed on at least one surface of the transparent substrate as a window film. As a hard coat layer, the same thing as the hard coat layer of the protective film mentioned above can be used.

(Phase difference film)

The retardation film is a transparent film whose refractive index is different from each other in the orthogonal two directions in the plane, and gives retardation to the transmitted light.

Examples of the material of the retardation film are polycarbonate resin film, polysulfone resin film, polyethersulfone resin film, polyarylate resin film, norbornene resin film.

By extending|stretching these resin films, a desired retardation can be provided.

Moreover, the retardation film which can be obtained easily from a market can also be used.

The thickness of the retardation film may be, for example, 0.5 to 80 μm.

(Brightness enhancement film)

The brightness enhancing film is a film that transmits polarized light parallel to the first direction in the plane and reflects polarized light parallel to the second direction orthogonal to the first direction in the plane. When the optical film used for this invention has a polarizer, it is suitable to make the 1st direction match the transmission axis of a polarizer.

The luminance-enhancing film may be a multi-layer laminate in which layers having birefringence and layers having substantially no birefringence are alternately stacked. Examples of the material of the layer having birefringence are naphthalenedicarboxylic acid polyester (e.g. polyethylene naphthalate), polycarbonate and acrylic resin (e.g. polymethylmethacrylate), and an example of a layer substantially free of birefringence Is a copolyester of naphthalenedicarboxylic acid and terephthalic acid.

The thickness of the brightness enhancing film may be, for example, 10 to 50 μm.

Each film constituting the optical film exemplified above may have a plurality of functions. For example, the protective film may be a film having both optical functions such as a retardation film and a brightness enhancing film.

(Adhesion in optical film)

When the optical film 50 has a laminated structure including a plurality of films, the films may be adhered with an adhesive. The adhesive is not particularly limited, but any of the above-described water-based adhesive or active energy ray-curable adhesive may be used.

Moreover, an adhesive can also be used as an adhesive. This adhesive will be described later.

The thickness of the adhesive can be 1 to 200 μm.

(The thickness of the optical film in the case of a laminate)

When the optical film 50 has a laminated structure including a plurality of films, the overall thickness of the optical film 50 can be 10 to 1200 μm.

(Adhesive layer)

As described above, the laminate used in the present invention has an optical film and an adhesive layer formed on one surface thereof. This pressure-sensitive adhesive layer is formed of an adhesive. Here, the adhesive will be described.

The pressure-sensitive adhesive is a pressure-sensitive adhesive, refers to a material having a soft solid (viscoelastic) state in a temperature range around room temperature (for example, 25°C), and having a property of simply adhering to an adherend by pressure. The pressure-sensitive adhesive referred to herein is, as defined in "CA Dahlquist, "Adhesion: Fundamental and Practice", McLaren & Sons, (1966), P.143", in general, the complex tensile modulus E ^* (1 ㎐) <10 ^It may be a material having a property satisfying ⁷ dyne/cm 2 (typically, a material having the property at 25°C). The pressure-sensitive adhesive in the technology disclosed herein can also be grasped as a solid content (non-volatile content) of the pressure-sensitive adhesive composition or a constituent component of the pressure-sensitive adhesive layer.

An example of the pressure-sensitive adhesive is a composition in which an acrylic resin, a styrene resin, a silicone resin or the like is used as a base polymer, and a crosslinking agent such as an isocyanate compound, an epoxy compound or an aziridine compound is added thereto. In this specification, the "base polymer" of the pressure-sensitive adhesive refers to the main component of the rubbery polymer contained in the pressure-sensitive adhesive. The rubber-like polymer refers to a polymer exhibiting rubber elasticity in a temperature region near room temperature. In addition, in this specification, the "main component" refers to a component contained in excess of 50% by weight unless otherwise specified.

The thickness of the pressure-sensitive adhesive can be 1 to 40 μm.

(The thickness of the optical film in the case of a laminate)

When the optical film 50 has a laminated structure including a plurality of films, the overall thickness of the optical film 50 can be 10 to 1200 μm.

The pressure-sensitive adhesive layer 80 is formed on at least one surface of the optical film (single-layer structure or laminated structure) 50.

As an adhesive, what was mentioned above can be used.

(Separator film)

The laminate 100 may have a separator film 90 on a surface opposite to the surface contacting the optical film 50 in the pressure-sensitive adhesive layer 80.

The separator film 90 is a film having weak adhesion to the pressure-sensitive adhesive layer 80 as compared to the optical film 50. When transporting or storing the laminate 100 before the optical film 50 is attached to another member such as an optical device (liquid crystal cell) through the adhesive layer 80, the separator film 90 is formed of an adhesive layer ( 80) to protect the surface. When the pressure-sensitive adhesive layer 80 is attached to another member, the separator film 90 is easily peeled off from the pressure-sensitive adhesive layer 80.

The separator film need not be transparent, but is preferably transparent. An example of the material of the separator film is polyethylene terephthalate. The thickness of the separator film can be 1 to 40 μm.

(Protect film)

In addition, the laminate 100 may have a protective film 70 disposed on an outer surface opposite to a surface on which the pressure-sensitive adhesive layer 80 is formed in the optical film 50.

The protective film 70 is being processed during the stacking of the laminate 100, or when the laminate 100 is attached to an optical device (such as a liquid crystal cell), or during transportation of the optical device to which the laminate 100 is attached. It has a function of suppressing damage to the optical device and/or the optical film 50 in the back.

Examples of the material for such a protective film are polyethylene terephthalate, polyethylene, polypropylene, and the like. The protective film 70 need not be transparent, but is preferably transparent. The thickness of the protective film can be 1 to 40 μm.

The protective film 70 may be a film that protects the optical film 50 until use of a product using the optical film 50. In this case, even after the optical film 50 is attached to the optical device (such as a liquid crystal cell) through the pressure-sensitive adhesive layer 80, the protective film 70 does not peel off from the optical film 50.

The protective film 70 may be attached to the optical film 50 through a pressure-sensitive adhesive layer or by self-adhesion by electrostatic adsorption.

The specific example of the laminated structure of the laminated body 100 is shown in FIG. 2 (a) and (b).

In the layered product 100 of Fig. 2(a), the protective film 70, the protective film 2, the polarizer 3, the protective film 2, and the pressure-sensitive adhesive layer 80, the separator film 90 are , Are stacked in this order. The protective film 2, the polarizer 3, and the protective film 2 constitute the optical film 50.

In the layered product 100 of Fig. 2B, the protective film 70, the protective film 2, and the polarizer 3, the pressure-sensitive adhesive layer 80, and the separator film 90 are laminated in this order. It is. The protective film 2 and the polarizer 3 constitute the optical film 50. In addition, although not illustrated, in any example, between the films in each optical film 50 may be adhered with an adhesive or an adhesive.

(Laminated body for flexible image display device)

The optical film 50 used in the present invention may be a laminate for a flexible image display device used in a flexible image display device capable of bending or the like.

The flexible image display device is a typical example of an image display device having a laminate for a flexible image display device and an organic EL display panel. In this typical example, a laminate for a flexible image display device is usually arranged on the viewer side with respect to the organic EL display panel, and the flexible image display device is configured to be bendable. The laminated body for a flexible image display device may contain a window film, a circular polarizing plate, and a touch sensor, and the stacking order of these may be arbitrary, but the stacking order of a window film, a circular polarizing plate, and a touch sensor from the viewer side or a window film or touch sensor And a stacking order of circularly polarizing plates. When the circular polarizing plate is present on the viewing side of the touch sensor, it is preferable because the pattern of the touch sensor is difficult to visualize and the visibility of the display image is improved. Each member can be laminated using an adhesive, an adhesive, or the like. In addition, a light blocking pattern formed on at least one surface of any one of the window film, the circular polarizing plate, and the touch sensor may be provided.

(Circular polarizer)

The circularly polarizing plate is a functional film having a function of transmitting only the right or left circularly polarized component by laminating a λ/4 phase difference plate, which is a phase difference film, on a linear polarizing plate. When external light that has entered the display device passes through the circular polarizing plate disposed on the viewer side, it is converted into right circularly polarized light and emitted to the organic EL panel side. When the right circularly polarized light is reflected (reflected light) by the metal electrode of the organic EL panel, the reflected light becomes left circularly polarized light. Since the left circularly polarized light cannot pass through the circularly polarizing plate, as a result, the reflected light is never emitted outside the display device. With this function, only the light emitting component of the organic EL is visible in the display panel of the display device, and by transmitting only the light emitting component, the influence of reflected light can be prevented to make the image easier to see.

In order to achieve the circular polarization function, the absorption axis of the linear polarizing plate and the slow axis of the λ/4 retardation plate need to be theoretically 45°, but is practically 45±10°. The linear polarizing plate and the λ/4 retardation plate do not necessarily need to be stacked adjacent to each other, and the relationship between the absorption axis and the slow axis should just satisfy the aforementioned range. Although it is desirable to achieve complete circular polarization at all wavelengths, in practice, the circular polarizing plate in the present invention also includes an elliptical polarizing plate. It is also preferable to improve the visibility in the state of wearing polarized sunglasses by laminating a lambda /4 phase difference plate on the viewing side of the linear polarizing plate and making the emitted light circularly polarized.

A linear polarizing plate is a functional layer having a function of passing light oscillating in the direction of the transmission axis, but blocking polarization of a vibration component perpendicular to it. The linear polarizing plate is usually configured with a polarizer and a protective film attached to at least one surface thereof. The polarizer may be any of the above-described film type polarizer or liquid crystal coating type polarizer. The protective film can also use what has already been described. The thickness of the linear polarizing plate constituting the circular polarizing plate is preferably 200 µm or less, and more preferably 0.5 µm to 100 µm. When this thickness exceeds 200 micrometers, the flexibility (flexibility) applicable to the laminated body for flexible image display apparatus may fall. By appropriately adjusting the thickness of the above-mentioned polarizer and protective film, it is possible to adjust the thickness of a suitable straight polarizing plate.

The λ/4 retardation plate, which is a retardation film, is also referred to as a 1/4 wavelength plate, and provides a retardation of π/2 (=λ/4) to the polarization surface of incident light. A retardation film having such a performance may be selected from the retardation films described above to prepare a λ/4 retardation plate, but as another example, a liquid crystal coated retardation plate formed by applying a liquid crystal composition may be used as a λ/4 retardation plate. It might be. The liquid crystal coating type retardation plate formed by coating the liquid crystal composition can obtain a very thin lambda /4 retardation plate as described later. Therefore, this liquid crystal coating type retardation plate is particularly preferable as a λ/4 retardation plate constituting a circular polarizing plate of a laminate for a flexible image display device.

Here, the liquid crystal composition forming the lambda / 4 phase difference plate will be described.

The liquid crystal composition includes a liquid crystal compound having properties of exhibiting liquid crystal states such as nematic, cholesteric, and smectic. The liquid crystal compound has a polymerizable functional group. The liquid crystal composition may contain a plurality of liquid crystal compounds, and when a plurality of liquid crystal compounds are included, at least one of the liquid crystal compounds has a polymerizable functional group. The liquid crystal composition may also include an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, a silane coupling agent, and the like. The liquid crystal coating type retardation plate can be produced by forming a liquid crystal retardation layer on the alignment film by applying and curing a liquid crystal composition on an alignment film of a substrate on which an alignment film is previously formed, as described in the manufacturing method of the liquid crystal polarizer. . The liquid crystal-coated retardation plate can be formed to have a thinner thickness than the stretched retardation plate. The thickness of the liquid crystal polarizing layer is 0.5 to 10 μm, preferably 1 to 5 μm. The liquid crystal coating type retardation plate may be peeled off from a substrate, transferred, and laminated, or the substrate may be laminated as it is. It is also preferable that the substrate serves as a transparent substrate for the protective film or retardation plate.

In general materials constituting the retardation film, the shorter wavelengths tend to show greater birefringence and the longer wavelengths show smaller birefringence. In this case, since a phase difference of λ/4 cannot be achieved in the entire visible light region, an in-plane retardation of 100 to 180 nm, preferably 130 to 150 nm, such as λ/4 in the vicinity of 560 nm with high visibility, cannot be achieved. It is often designed to be. It is preferable to use a reverse dispersion λ/4 retardation plate using a material having a birefringence wavelength dispersion characteristic as opposed to normal because it can improve visibility. As such a material, it is also preferable to use those described in Japanese Patent Laid-Open No. 2010-30979 for liquid crystal coating type retardation plates, such as Japanese Patent Laid-Open No. 2007-232873 in the case of a stretched retardation plate.

In addition, as another method of forming a preferred retardation film constituting a circular polarizing plate, a technique of obtaining a wideband λ/4 retardation plate by combining with a λ/2 retardation plate is also known (Japanese Patent Laid-Open Publication No. 10-90521). . The λ/2 phase difference plate is also manufactured by the same material method as the λ/4 phase difference plate. Although the combination of a stretched retardation plate and a liquid crystal coating type retardation plate is arbitrary, it is preferable to use a liquid crystal coating retardation plate for both, because the thickness of the film can be reduced.

In order to increase the visibility of the circularly polarizing plate in an oblique direction, a method of laminating a positive C plate is also known (Japanese Patent Publication No. 2014-224837). The positive C plate may be a liquid crystal coating type retardation plate or a stretched retardation plate. The phase difference in the thickness direction of this positive C plate is -200 to -20 nm, preferably -140 to -40 nm.

(Touch sensor)

The touch sensor is used as an input means. As a touch sensor, various modes, such as a resistive film method, a surface acoustic wave method, an infrared method, an electromagnetic induction method, and a capacitive method, have been proposed, and any method may be used. Among these, the electrostatic capacity method is preferred.

The capacitive touch sensor is divided into an active area and an inactive area located on an outer portion of the active area, as viewed from the display panel surface. The active area is an area corresponding to an area (display area) where a screen is displayed on the display panel, an area where a user's touch is detected, and an inactive area is an area corresponding to an area (non-display area) where no screen is displayed on the display device. .

The touch sensor includes a substrate having flexible characteristics; A sensing pattern formed in the active region of the substrate; It is formed in an inactive region of the substrate, and may include each sensing line for connecting to an external driving circuit through the sensing pattern and the pad portion. As the substrate having flexible properties, a substrate formed of the same material as the transparent substrate of the window film can be used. It is preferable from the viewpoint of suppressing cracking of the touch sensor that the toughness of the substrate of the touch sensor is 2,000 MPa or more. More preferably, the toughness may be 2,000 ㎫% to 30,000 ㎫%.

The sensing pattern may include a first pattern formed in a first direction and a second pattern formed in a second direction. The first pattern and the second pattern are arranged in different directions. The first pattern and the second pattern are formed on the same layer, and in order to sense a touched point, each pattern must be electrically connected. In the first pattern, each unit pattern is connected to each other through a seam, but since the second pattern has a structure in which each unit pattern is separated from each other in the form of an island, a separate pattern is required to electrically connect the second pattern. Bridge electrodes are required. The sensing pattern is formed of a known transparent electrode material. Examples of the transparent electrode material include indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium zinc tin oxide (IZTO), cadmium tin oxide (CTO), and PEDOT (poly(3,4). -ethylenedioxythiophene)), carbon nanotubes (CNT), graphene, metal wires (metals used for metal wires are not particularly limited, for example, silver, gold, aluminum, copper, iron, nickel, titanium, telenium, chromium Etc. These can be used individually or in mixture of 2 or more types.) These etc. are mentioned, These can be used individually or in mixture of 2 or more types. It is preferably ITO. The bridge electrode may be formed on the insulating layer over the sensing pattern, and the bridge electrode may be formed on the substrate, and an insulating layer and the sensing pattern may be formed thereon. The bridge electrode may be formed of the same material as the sensing pattern, or may be formed of metal such as molybdenum, silver, aluminum, copper, palladium, gold, platinum, zinc, tin, titanium, or an alloy of two or more of them. Since the first pattern and the second pattern must be electrically insulated, an insulating layer is formed between the sensing pattern and the bridge electrode. The insulating layer may be formed only between the seam of the first pattern and the bridge electrode, or may be formed in the structure of the layer covering the sensing pattern. In the latter case, the bridge electrode can connect the second pattern through the contact hole formed in the insulating layer. The touch sensor appropriately compensates for a difference in transmittance between a patterned region where a pattern is formed and a non-patterned region where no pattern is formed, specifically, a difference in light transmittance caused by a difference in refractive index in these regions. As a means for it may further include an optical control layer between the substrate and the electrode. The optical control layer may include an inorganic insulating material or an organic insulating material. The optical control layer may be formed by coating a photocurable composition comprising a photocurable organic binder and a solvent on a substrate. The photocurable composition may further include inorganic particles. The refractive index of the optical control layer may be increased by the inorganic particles.

The photocurable organic binder may include, for example, a copolymer of each monomer such as an acrylate-based monomer, a styrene-based monomer, and a carboxylic acid-based monomer. The photocurable organic binder may be a copolymer containing each repeating unit different from each other, such as an epoxy group-containing repeating unit, an acrylate repeating unit, and a carboxylic acid repeating unit.

The inorganic particles may include, for example, zirconia particles, titania particles, alumina particles, and the like.

The photocurable composition may further include additives such as a photopolymerization initiator, a polymerizable monomer, and a curing aid.

Each layer (window film, circular polarizing plate, touch sensor) forming the laminate for the flexible image display device can be formed by an adhesive. As the adhesive, water-based adhesives, active energy ray-curable adhesives, and pressure-sensitive adhesives already described are frequently used.

(Shading pattern)

The light-shielding pattern can be applied as at least a part of the bezel or housing of the flexible image display device. The visibility of the image is improved by making the wiring disposed at the edge portion of the flexible image display device hidden by the light-shielding pattern, making it difficult to visually recognize. The light shielding pattern may be in the form of a single layer or multiple layers. The color of the light-shielding pattern is not particularly limited, and various colors such as black, white, and metal may be used. The light-shielding pattern may be formed of a pigment for realizing color, and a polymer such as acrylic resin, ester resin, epoxy resin, polyurethane, and silicone resin. It may be used alone or as a mixture of two or more. The light-shielding pattern can be formed by various methods such as printing, lithography, and inkjet. The thickness of the light shielding pattern may be 1 µm to 100 µm, and preferably 2 µm to 50 µm. Further, a shape such as an inclination may be provided in the thickness direction of the light-shielding pattern.

In the above, the optical film and adhesive included in the laminated body used for the manufacturing method of this invention were demonstrated. Next, the manufacturing method of the present invention will be described.

(Powder)

Again, the manufacturing method of the present invention will be described with reference to Figs. 1A and 1B.

The powder f attached to the end face E of the optical film 50 is attached to the end face by processing the end face of the laminate 100. Normally, the end face of the laminate 100 is processed from the disk of the laminate 100 to obtain the laminate 100 of a desired size. Examples of processing are cutting, cutting, and polishing. Here, cutting is a concept including perforation. Therefore, as described above, the end face of the laminate 100 is not only the end face E of the outside of the laminate 100 as shown in Fig. 1(a), but also of the laminate 100. It also includes the inner end face E forming the inner wall of the hole (opening) H.

Cutting is a process of forming a cut portion from the surface of the stacked body to the back side of the stacked body by insertion of a blade, removal by a laser, or the like, whereby an alternative form of the stacked body can be determined.

Cutting is a process of cutting a part of the end and forming a new end surface by bringing a relatively moving bite (blade) into contact with the end of the laminate. In addition, this cutting includes perforation, as described above. The punching process is, for example, a process of forming a hole H at a desired position by using a drill or the like on the laminate 100, as shown in FIG. 1B. In such a perforation process, powder f (perforation debris) may be attached to the inner end face E forming the inner wall of the hole H.

Polishing is a process in which a relatively moving abrasive grain (a fixed abrasive grain or a glass abrasive grain may be contacted) is brought into contact with the end face of the laminate, and a part of the end face is cut. Polishing also includes a process called grinding.

For example, after cutting the disk of the laminate 100 into a plane shape slightly larger than a desired size by a blade or a laser, the planar shape of the laminate is previously determined by grinding and/or polishing the end face of the cut laminate. It can be set to a predetermined dimension, and also can improve the squareness and flatness of the end face.

There is no particular limitation on the planar shape (shape viewed from the thickness direction) of the laminate. For example, it can be square, rectangular, or circular.

By these processing on the end face of the laminate, powder of the materials constituting the laminate 100 is generated, and a part of it is attached to the end face E of the laminate 100. Therefore, it is one embodiment of the preparation process in the manufacturing method of this invention that these processes are performed to the said laminated body. The end surface E may be a surface that connects between two main surfaces of the laminate 100.

The average particle diameter of the powder may be, for example, 10 to 3000 μm. This particle diameter is D50 of the particle size distribution based on weight by laser diffraction.

(Collision process (process of removing powder by collision of dry ice particles))

Subsequently, dry ice particles collide with the end face E of the laminate 100 to remove the powder f on the end face from the end face.

Specifically, it is suitable to transport dry ice particles with gas to collide with the end face E of the laminate 100.

The average particle diameter of the colliding dry ice particles is not particularly limited, but is preferably 100 μm or more from the viewpoint of efficiently removing the powder. Moreover, it is preferable that it is 1000 micrometers or less from a viewpoint of suppressing the adhesive layer from being distorted by collision of dry ice.

The average particle diameter of the dry ice particles can be measured by a laser Doppler flow meter.

The speed of the dry ice particles to be collided can be 5 m/sec to 100 m/sec.

The conveyance gas of dry ice is not specifically limited, For example, it can be nitrogen, air, or carbon dioxide gas.

Specifically, the dry ice particle supply unit (device) 300 as shown in FIG. 3 can be used.

The apparatus includes a liquid carbon dioxide source 310, a nozzle 320, a carrier gas source 330, a liquid carbon dioxide source 310 and a line L1 connecting the nozzle 320, and a carrier gas source 330 and A line L2 connecting the nozzles 320 is provided.

A valve 340 and an orifice 350 are provided in the line L1, and a valve 360 is provided in the line L2.

By opening the valve 340, the liquid of the liquid carbon dioxide source 310 is adiabatically expanded in the orifice 350 to generate dry ice particles (dry ice snow) and sent to the nozzle 320. The valve 360 is opened, the gas is supplied to the nozzle 320 from the conveying gas source 330, and the dry ice particles d are ejected from the nozzle 320 as gas, so that the end face of the laminate 100 (E).

The particle size of the dry ice particles (d) is the distance from the orifice 350 to adiabatic expansion and ejection to the nozzle 320 (dielectric insulation expansion distance), or the distance between the nozzle 320 and the supply target of the dry ice particles. It can be adjusted by (Ejection distance). In addition, an appropriate preliminary experiment using a dry ice particle supply unit (apparatus) can be performed to confirm the degree of removal of the powder f to adjust the adiabatic expansion distance or spray distance.

It is preferable that the distance (injection distance) between the nozzle 320 and the end face E of the laminate 100 is less than 20 mm. In addition, the adiabatic expansion distance can be, for example, 10 to 500 mm.

It is preferable that the positions of the stacked body 100 and the nozzle 320 are moved relative to each other by the conveying unit 400 to scan the portion where the dry ice particles d collide on the end face E. For example, in FIG. 3, the dry ice particles d on the end face E are in a plane orthogonal to the ejection direction (horizontal direction) of the dry ice particles d using the transport unit 400. The stack 100 may be injected so that the collision portion of the body moves.

The scanning speed of the collision portion of the dry ice particles d on the end face E can be 1 to 100 m/sec.

(Action)

According to the present embodiment, since dry ice particles d are sprayed on the end surface E of the laminate 100, powders such as cutting debris, cutting debris, punching debris, abrasive debris from the end face are suitable. Is removed. Thereby, contamination by powder in a post-process is reduced and is preferable. In addition, compared to methods such as tape attachment and peeling, the time taken to remove the powder is also shortened.

Further, when the particle size of the dry ice particles to be collided is 100 to 1000 µm, it is preferable to suppress the distortion of the pressure-sensitive adhesive layer on the end face while increasing the removal rate of the powder, and more preferably 200 to 700 µm. .

(Removal of powder to a laminate structure in which multiple laminates are stacked)

In the above, although the dry ice particles collide with one stacked body 100, as shown in FIG. 4, the end surface of the stacked structure 120 in which a plurality of stacked bodies 100 are stacked in the thickness direction ( It is also suitable to collide dry ice with E). According to this, mass processing of the laminated body 100 becomes possible.

(Processing of end face and removal of powder)

After the machining (cutting, cutting and polishing) of a part of the end face of the laminate 100 is finished, while processing another part of the end face of the laminate 100, at the same time, in parallel, at the end face The powder may be removed by spraying dry ice particles to the portion where the processing is completed. This makes it possible to shorten the process time.

Conversely, after all the cutting, cutting, polishing, and the like on the end surface of the laminate are finished, the dry ice particles are collided on the end surface of the laminate 100 to clean the powder on the end surface, and dry ice is applied to the end surface. When the particles collide, it is also possible to not process other parts of the end face of the laminate. In this case, since the atmosphere (space) for removing the powder and the atmosphere (space) for processing the end face can be divided by the collision of dry ice particles, it is possible to prevent the end face from being formed by the powder generated by processing. It also becomes possible.

(Atmosphere during collision process (powder removal process))

The atmosphere around the laminate and the laminate structure during the process of removing the powder on the end faces of the laminate and the laminate structure by dry ice particles may be an air atmosphere, but may be an atmosphere such as nitrogen or carbon dioxide, if necessary. In addition, the temperature of the atmosphere is usually 20 to 30°C, and preferably 20 to 27°C. The relative humidity of the atmosphere is usually less than 80%, preferably 30 to 75%, and more preferably 40 to 70%. When the relative humidity of the atmosphere is 80% or more, dew condensation occurs due to cooling of the laminate or the laminate, and the absorbent film (such as a polarizer) in the laminate absorbs and swells, and thus the appearance of the laminate or laminate. However, there may be a problem in optical properties.

(Optical member manufacturing apparatus)

Subsequently, with reference to Fig. 5, a description will be given of an apparatus for manufacturing an optical member 1000 suitable for carrying out the above-described method.

The manufacturing apparatus 1000 includes an end face processing unit 200 for cutting, cutting, or polishing the end faces of the stacked body 100 or the stacked structure 120, and the stacked body 100. A dry ice particle supply unit 300 that collides dry ice particles with a portion processed in the end surface processing unit 200 and a transport unit 400 for transporting the laminate 100 are provided.

In Fig. 5, a cutting device is drawn as the end face processing portion 200. The cutting device includes a rotating shaft 210 extending in a horizontal direction, a disk 220 attached to the rotating shaft, and a bite 230 attached to the disk 220. By rotating the bite 230, it is possible to cut the end face of the laminate or the like.

In the dry ice particle supply unit 300, only the nozzle 320 is described for simplicity.

The conveying unit 400 includes a pair of upper jigs 420 and lower jigs 422 and upper jigs 420 that sandwich and support the stack 100 or the stack structure 120 in the thickness direction. Cylinder 430 for pressing in the thickness direction (downward), a rotating mechanism 410 connected to the lower jig 422 and rotating the upper jig 420 and the lower jig 422 around a vertical axis (Z axis), and It has a moving mechanism 440 for moving the upper jig 420 and the lower jig 422 in the horizontal direction (X direction).

Next, a method of manufacturing the optical member using this device will be described. First, the stacked body 100 or the stacked structure 120 is sandwiched between the upper jig 420 and the lower jig 422. Next, the upper jig 420 is pressed toward the lower jig 422 by the cylinder 430 to fix the stacked body 100 or the stacked structure 120. In the present embodiment, the laminate 100 or the laminate structure 120 is rectangular as viewed from above and has four end faces. Therefore, the rotational position of the stacked body 100 or the stacked structure 120 is adjusted by the rotation mechanism 410 so that the two end surfaces E are parallel to the X axis.

Subsequently, the end face processing unit 200 is started. Specifically, the disk 220 is rotated. Next, the stacking body 100 and the stacked structure 120 are moved in the X direction by the moving mechanism 440 to make the bite 230 of the end face processing part 200 contact the end face E. Thereby, the pair of end surfaces E facing each other of the stacked body 100 and the stacked structure 120 are cut by the bite 230. At this time, cutting chips are attached to the end face E.

Subsequently, the stacked body 100 and the stacked structure 120 are moved in the -X direction by the conveying unit 400, and dry ice particles are supplied from the nozzle 320 of the dry ice particle supply unit 300. Thereby, the dry ice particles collide with the cut end surfaces E of the stacked body 100 and the stacked structure 120, and the powder of the end face E is removed.

Subsequently, the stacked body 100 and the stacked structure 120 are further moved in the-direction by the conveying unit 400, and by the rotation mechanism 410, the other two end faces are parallel to the X direction, The stacked body 100 and the stacked structure 120 are rotated. Thereafter, as in the previous example, the remaining two end faces may be processed in order to remove the powder by subsequent dry ice particles.

The end face processing unit 200 can be formed into various shapes depending on the mode of processing. For example, as shown in FIG. 6, the cylindrical body 240 rotates around the vertical axis and the long blade 250 installed to extend in the axial direction on the outer circumferential surface of the cylindrical body 240 is cut with a planar rotating blade. You may do

Further, instead of the bite 230, polishing can also be performed by using a polishing plate in which a large number of abrasive grains are formed on the surface of the disk.

Moreover, when cutting and polishing are not required, it can also be set as a cutting device.

Finally, an example of a method of removing the powder f (perforated debris) attached to the end face E of the hole H formed in the laminate 100 will be described with reference to FIG. 7.

First, each of the stacked bodies 100 is punched, and a plurality of stacked bodies 100 having powders (perforated chips) f attached to the inner end surface E of the hole H are prepared. . As shown in Fig. 1(b), each layered product 100 has a hole H formed at a predetermined position by drilling. Next, the stacked structures 100 are obtained by stacking these stacks 100 so that the positions of the holes H of each stack 100 are lined up on one axis (axis extending in the thickness direction). Then, each hole H of each stacked body 100 is connected, and through holes H'penetrating in the thickness direction of the stacked structure 120 are formed in the stacked structure 120.

In the pair of upper jigs 420 and lower jigs 422 for pressing the stacked structure 120 in the thickness direction, a dry ice particle supply port 420a is provided in one jig and dry ice is applied in the other jig. The particle recovery port 422b is formed in advance. The upper jig 420 and the lower jig 422 are disposed so that the through hole H'communicates with the dry ice particle supply port 420a and the dry ice particle recovery port 422b, and this laminated structure 120 ) Is pressed in the thickness direction. This completes the preparation process before the dry ice collision process.

Next, dry ice particles are supplied from the nozzle 320 into the through hole H'through the dry ice particle supply port 420a (collision process). The dry ice particles sprayed from the nozzle 320 diffuse in the width direction as they progress, collide with the end face E of the through hole H'of the stacked structure 120, and dry ice together with the powder f It is discharged from the particle recovery port 422b. If such a device is used, the powder f can be efficiently removed from the layered product 100 in which the powder f is attached to the end face E, which is the inner wall of the hole H, by drilling. .

Example

(Laminated disk)

Protective film (PET (polyethylene terephthalate) agent: 53 µm) / protective film (TAC (triacetyl cellulose) agent: 32 µm) / polarizer (PVA (iodine adsorption polyvinyl alcohol): 12 µm) / protective film (COP ( A cyclic olefin resin) agent: 23 µm)/adhesive layer (acrylic pressure-sensitive adhesive: 20 µm)/disc layer having a layer structure such as a separator film (PET: 38 µm) was obtained.

The protective film and the polarizer were adhered with a water-based adhesive. The thickness of the laminate was 178 μm.

(Processing of the end face of the laminate)

The disk laminate was punched in a rectangular shape having a size of 140 x 65 mm with a Thompson blade to obtain a laminate.

Next, 50 layers were stacked to obtain a laminate structure. Each end surface of the laminated structure was cut by a cutting device. Then, each end surface of the laminated structure was polished by a polishing apparatus.

(Removal of powder on the end face of the laminate)

About each Example and the comparative example, the powder of the end face of the laminated body was removed on condition of the following.

(Example 1)

Dry ice particle supply device: Carbonated gas type dry ice blast

CO ₂ pressure: 5 ㎫ (Meanwhile, CO ₂ pressure is the supply pressure to the orifice.)

Air pressure: 0.5 ㎫

Distance between nozzle tip and end face: about 50 mm

Nozzle scanning speed: 50 mm/5 seconds

Nozzle center position and nozzle scanning direction: The nozzle was directed to the center of the thickness direction on the end surface of the laminated structure, and the nozzle was scanned in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle diameter of dry ice particles: 1-100 μm

Atmosphere temperature: 24°C to 26°C, relative humidity in the atmosphere: 45% to 65%

(Example 2)

Dry ice particle supply device: Carbonated gas type dry ice blast

CO ₂ pressure: 7 ㎫

Air pressure: 0.5 ㎫

Distance between nozzle tip and end face: about 50 mm

Nozzle scanning speed: 50 mm/5 seconds

Nozzle center position and nozzle scanning direction: The nozzle was directed to the center of the thickness direction on the end surface of the laminated structure, and the nozzle was scanned in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle diameter of dry ice particles: 200 to 700 μm or less

Atmosphere temperature: 24°C to 26°C, relative humidity in the atmosphere: 45% to 65%

(Example 3)

Dry ice particle supply device: Pellet type dry ice blast

Pellet diameter: φ3 mm

Air pressure: 0.5 ㎫

Distance between nozzle tip and end face: about 50 mm

Nozzle scanning speed: 50 mm/5 seconds

Nozzle center position and nozzle scanning direction: The nozzle was directed to the center of the thickness direction on the end surface of the laminated structure, and the nozzle was scanned in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle diameter of dry ice particles: 1000 μm or more

Atmosphere temperature: 24°C to 26°C, relative humidity in the atmosphere: 45% to 65%

(Example 4)

The powder on the end face of the laminate was removed under the same conditions as in Example 2 except that the ambient temperature was 26°C and the relative humidity of the atmosphere was 80 to 90%.

On the other hand, upon removal, the laminate was cooled by contact with the dry ice particles, and condensation occurred in the laminate. When the condensation was confirmed, there was no occurrence of abrasive debris or distortion, but swelling occurred at the end of the laminate.

(Comparative Example 1)

The end surface of the laminated structure was rubbed with a wiper for clean rooms impregnated with ethanol (manufactured by Kurare Kuraflex).

(Comparative Example 2)

The cutter knife manufactured by OLFA was moved along the end face of the laminated structure.

(Comparative Example 3)

After the adhesive tape (cello tape (registered trademark) manufactured by Nichiban Corporation) was attached to the end face of the laminated structure, the adhesive tape was peeled from the end face.

(Comparative Example 4)

In the same manner as in Example 1, except that liquid carbon dioxide was not supplied, an air stream was sprayed onto the end face of the laminated structure.

(evaluation)

The end face was observed under a microscope to investigate the state of powder residue on the end face and the presence or absence of distortion of the pressure-sensitive adhesive layer on the end face.

Table 1 shows the results.

On the other hand, ○ in the “powder retention on the end face” indicates that powder was not observed in the field of view of 30 mm in length (hereinafter simply referred to as length) in the direction perpendicular to the thickness, and △ means 30 mm. 1 to 2 powders were observed in the field of view of the length, and x indicates that 3 or more powders were observed in the field of view of 30 mm in length.

In addition, "circle of the pressure-sensitive adhesive layer of the end face" indicates that distortion is not observed in the field of view of a length of 30 mm (hereinafter simply referred to as length) in a direction perpendicular to the thickness, and the? , 1 to 2 distortions were observed in a 30 mm long field of view, and "x" indicates that 3 or more locations were observed in a 30 mm long field of view.

50: optical film 80: adhesive layer
100: laminated body 120: laminated structure
200: end face processing unit 300: dry ice particle supply unit
400: conveying unit 1000: optical member manufacturing apparatus
f: powder E: end face

Claims (9)

A process of preparing an optical film and a laminate having a pressure-sensitive adhesive layer formed on one side of the optical film and having powder attached to its end face;
A method of manufacturing an optical member comprising the step of colliding dry ice particles against the end surface of the laminate to remove the powder from the end surface. The method of claim 1, wherein the average particle diameter of the dry ice particles is 100 to 1000 μm. The method according to claim 1 or 2, wherein, in the colliding step, the dry ice particles are collided on end surfaces of a multilayer structure in which the stacked bodies are stacked. The method according to claim 1 or 2, wherein the dry ice particles are collided on a part of the end face, and at least selected from the group consisting of cutting, cutting and polishing the other part of the end face of the laminate. How to do one. The method according to claim 1 or 2, wherein at least one selected from the group consisting of cutting, cutting and polishing is performed on the end face in the preparing step, and when the dry ice particles collide with a part of the end face. , No method selected from the group for the end face. The optical film is at least one selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancing film, a window film and a touch sensor, or selected from the group. A method of being a laminated film comprising two or more of at least one type, or a laminated film comprising at least two types selected from the group. The method according to any one of claims 1 to 6, wherein the relative humidity of the atmosphere in the step of colliding the dry ice particles with the end face is 30 to 75%. An end face processing portion for cutting, cutting or polishing an end face of an optical film and a laminate having an adhesive layer formed on one side of the optical film,
An apparatus for manufacturing an optical member comprising a dry ice particle supply unit that causes dry ice particles to collide with a portion processed in the end surface processing portion of the laminate. The apparatus for manufacturing an optical member according to claim 8, further comprising a transport unit for moving the laminate between the end surface processing unit and the dry ice particle supply unit.

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