KR20240042367A - long laminate - Google Patents

Abstract

The long laminate according to the present invention includes a long first base film including a first main surface and a second main surface opposite to the first main surface, and a long first base film laminated on the first main surface side of the first base film. A glass member, a long carrier film laminated on the second main surface side of the first base film, a first adhesive layer interposed between the first base film and the glass member, the first base film, and It includes a first adhesive layer interposed between the carrier films. In the first base film, a plurality of frame-shaped grooves are formed that penetrate the first base film in the thickness direction. A gap is formed within the groove.

Description

long laminate

This disclosure relates to a long laminated body including a plurality of laminated bodies used in, for example, a display panel of a flat panel display (FPD).

Generally, a laminate of a glass member such as a glass film and a resin film is prepared by preparing a roll of a long glass member and a roll of a long resin film and bonding them together by roll to roll to form a laminate. , is formed by cutting. For cutting, for example, a blade or laser light is used. However, when a blade is used, the smoothness of the cutting surface decreases. When using a laser light, the glass member and the resin film have different processing conditions, such as processing temperature suitable for each, and therefore it is difficult to cut both pieces cleanly at the same time. Therefore, a method of first cutting the resin film and then cutting the glass member has been proposed.

For example, Patent Document 1 is a method for producing a flexible film, which includes cutting a laminate including foil glass having a thickness of 100 μm or less and a resin layer disposed on one or both sides of the foil glass, the outer surface of the resin layer A manufacturing method is proposed that includes a step of providing a groove from the side and a step of cutting the laminate along the groove. The groove is formed using a blade or laser light. In Patent Document 1, the depth of the groove is made smaller than the thickness of the resin layer or the total thickness of the resin layer and the adhesive layer to avoid providing grooves in the foil glass.

Patent Document 2 is a method of dividing a composite material in which a brittle material layer and a resin layer are laminated, by irradiating a laser light to the resin layer along the division line of the composite material to remove the resin, thereby forming a processing groove along the division line. A resin removal process to form a process, and after the resin removal process, processing along the division line by irradiating laser light oscillated from an ultra-short pulse laser light source to the brittle material layer along the division line to remove the brittle material. A brittle material removal process forming a mark, and a composite dividing process of dividing the composite material by applying an external force along the division line after the brittle material removal process, wherein the processing mark is along the division line. A method for dividing composite materials is proposed, which is a through hole on a dotted line and the pitch of the through hole is 10㎛ or less. Patent Document 2 also describes a third embodiment in which resin layers 2a and 2b are laminated on both sides of the brittle material layer 1, respectively. In this case, a processing groove is formed in one of the resin layers, and a processing groove is also formed in the other resin layer.

Japanese Patent Publication No. 2014-159352 (Claim 1, [0036], [0041], Figure 2) Japanese Patent Publication No. 2019-122966 (Claim 1, Figure 1, [0055], Figure 3)

If a groove can be formed in the member that holds the glass member (specifically, a resin film or a laminate of an adhesive layer and a resin film, etc.) up to the interface with the glass member, only the glass member is irradiated with laser light in the next step. It can be cut. However, it is not possible to suppress the formation of scratches on the glass member when forming the groove. Such damage causes scattering of the laser beam when cutting the glass member with the laser beam, making it difficult to cut the glass member cleanly.

In the method of Patent Document 1, damage formation in the thin glass when forming the groove is suppressed. However, since the groove is not formed up to the interface between the resin layer or adhesive layer and the thin glass, it becomes necessary to remove the resin layer or adhesive layer. At this time, force is applied to the foil glass, causing damage. Therefore, similarly to the above, it causes laser beam scattering and makes it difficult to cut the thin glass cleanly.

In the method of Patent Document 2, since laser light is irradiated from both the resin layer side and the brittle material layer side, scratches are likely to occur due to the laser light near the interface of these layers, and quality deteriorates. In the case of the third embodiment of patent document 2, since the brittle material layer cannot be cut unless both resin layers are removed, damage is formed in the brittle material layer when removing the resin layer, and the brittle material layer is It is difficult to cut cleanly.

One aspect of the present disclosure is:

a long first base film including a first main surface and a second main surface opposite to the first main surface;

a glass member laminated on the first main surface side of the first base film;

a long carrier film laminated on the second main surface side of the first base film;

a first adhesive layer interposed between the first base film and the glass member;

It includes a first adhesive layer interposed between the first base film and the carrier film,

A plurality of frame-shaped grooves are formed in the first base film, penetrating the first base film in the thickness direction,

It relates to a long laminated body in which a gap is formed in the groove.

It is possible to provide a long laminate that enables clean cutting of a glass member held on a base film.

1A is a plan view showing the configuration of a long laminate according to the first embodiment of the present disclosure.
FIG. 1B is a schematic cross-sectional view of the long laminated body of FIG. 1A taken along line bb and viewed from the direction of the arrow.
Fig. 2A is a schematic cross-sectional view of a long laminate according to the second embodiment.
Fig. 2B is a schematic cross-sectional view of a long laminate according to the third embodiment.
Fig. 2C is a schematic cross-sectional view of a long laminate according to the fourth embodiment.
Fig. 3A is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminated body and its vicinity according to the first embodiment, or the division of the glass member or the long laminated body by irradiation of laser light.
FIG. 3B is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminated body and its vicinity according to the fifth embodiment, or the division of the glass member or the long laminated body by irradiation of laser light.
Fig. 3C is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove and vicinity of the groove of the long laminated body according to the sixth embodiment, or the division of the glass member or the long laminated body by irradiation of laser light.
Fig. 3D is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove and vicinity of the groove of the long laminated body according to the seventh embodiment, or the division of the glass member or the long laminated body by irradiation of laser light.
Fig. 3E is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove and vicinity of the groove of the long laminated body according to the eighth embodiment, or the division of the glass member or the long laminated body by irradiation of laser light.
Fig. 4A is an explanatory diagram of the previous steps of the method for measuring the adhesive force between the first adhesive layer and the glass member.
Fig. 4B is an explanatory diagram of a later step in the method for measuring the adhesive force between the first adhesive layer and the glass member.
Fig. 5 is an explanatory diagram showing an example of a method for manufacturing a long laminated body.
Fig. 6 is a plan view showing an example of arrangement of grooves G on a plurality of frames in the base material laminate.
Figure 7 is an explanatory diagram showing an example of a series of processes in which a laminated body is separated into individual pieces from a long laminated body.
FIG. 8 is a schematic cross-sectional view of the separated laminate with glass members in FIG. 7 (c) cut along the line VIII-VIII and viewed in the direction of the arrow.
FIG. 9 is a process diagram showing an example of a series of steps for manufacturing a laminate with glass members separated into pieces from a long laminate.
Fig. 10 is a process diagram showing another example of a series of steps for manufacturing a laminate with glass members separated into pieces from a long laminate.

Although the novel features of the present invention are described in the appended claims, the present invention, both in terms of structure and content, as well as other objects and features of the present invention, can be better understood by the following detailed description with reference to the drawings. There will be.

Hereinafter, the long-length laminated body according to the present disclosure and the method of manufacturing a laminated body with separate glass members using the long-length laminated body will be sequentially explained with reference to embodiments. However, the embodiment is an example, and the manufacturing method of the elongated laminated body and the individually divided laminated body with glass members according to the present disclosure is not limited only to the following embodiments.

In this specification, the term 'parallel' is used from time to time, but it does not necessarily have to be strictly parallel, and one side and the other may deviate from the parallel arrangement to the extent of having an angle of, for example, less than 10° (or less than 5°). do. Likewise, the term 'vertical' is often used to refer to an arrangement that is not necessarily strictly vertical, but is vertical to the extent that one side and the other have an angle that is, for example, greater than 80° but less than 100° (or greater than 85° but less than 95°). It may deviate from .

When referring to the drawings, the shape or dimensions of each component in each drawing are not shown at the same scale as the actual figure. In order to clarify the characteristics of each component, the relative relationship between their dimensions is schematically and emphatically shown.

[Long Laminate]

The elongated laminate according to one aspect of the present disclosure includes a laminate including a glass member, and is useful for producing a plurality of separate laminates with glass members by dividing at least a portion of the laminate. . In other words, the elongated laminate is an intermediate product in the case of manufacturing a plurality of separate laminates with glass members. The laminate with separated glass members is useful as an optical laminate used in, for example, an FPD display panel. FPD typically refers to a thin image display device such as an organic EL display device. However, FPD is not limited to these specific examples.

The long laminated body may be completed in a rolled state. The long laminated body may be unwound from a roll-shaped state and supplied to another process (or step) in a roll-to-roll manner. The long laminated body may be unwound from a roll-shaped state and supplied to a step of processing the long laminated body (a step including at least a step of separating the glass member into individual pieces, etc.). The intermediate body before completion as a long laminated body may also be handled in a state wound into a roll. The intermediate body may be unwound from a roll-shaped state and supplied to a process for obtaining a long laminate by a roll-to-roll method.

The roll-to-roll method is a method for handling long-length laminates or intermediate products before completion as long-length laminates. The roll-to-roll method includes unwinding a long laminated body or intermediate body from a roll-shaped state, or winding the long laminated body or intermediate body into a roll shape. In the roll-to-roll method, an unwinding unit for unwinding a long laminated body or an intermediate body and a winding unit for winding a long laminated body or an intermediate body are used.

The long laminate includes a long first base film, a glass member laminated so as to sandwich the first base film, a long carrier film, a first adhesive layer interposed between the first base film and the glass member, and 1 It includes a first adhesive layer interposed between the base film and the carrier film. To explain more specifically, the first base film includes a first main surface and a second main surface on the opposite side to the first main surface. A glass member is laminated on the first main surface side of the first base film, and a carrier film is laminated on the second main surface side.

The first main surface and the second main surface are a pair of front and back surfaces that occupy most of the entire surface of the elongated first base film. In addition to the first and second main surfaces, the first base film includes a side surface (or end face) that connects these main surfaces and defines the outer perimeter of the first base film.

In the elongated laminate of the present disclosure, a plurality of frame-shaped grooves are formed in the first base film, penetrating the first base film in the thickness direction. And, a gap is formed within the groove. Such grooves are formed before laminating the first base film and the glass member. Therefore, unlike the case of forming grooves after lamination in the prior art, it is possible to have grooves formed all the way to the surface of the glass member. In addition, it is possible to suppress scratches on the glass member when forming grooves as in the prior art. The groove is formed prior to lamination with the glass member. Therefore, the first adhesive is applied to the first main surface of the first base film in a state including grooves, and the glass member is laminated on the first base film so as to contact the coating film. Therefore, there are cases where the first adhesive penetrates into the groove and hardens to form a first adhesive layer. However, in the present disclosure, a gap is formed within the groove. Therefore, the first adhesive layer is not formed in the groove, or even if it is formed, the thickness of the first adhesive layer is small. Therefore, by irradiating the laser light from the glass member side to the area corresponding to the groove of the long laminated body, the glass member can be easily cut and the first adhesive layer in the groove can be easily removed. In addition, by irradiating laser light from the first base film side to the area corresponding to the groove of the long laminate, the laser light passes through the groove, so that the first adhesive layer in the groove can be easily removed, and the glass member can be easily cut. As a result of these, the glass member held by the first base film can be cut cleanly.

In addition, in this specification, 'inside the groove' may also include a portion between the edge of the first main surface side of the groove and the glass member. In other words, the space between the edge of the first main surface of the groove and the glass member and the inside of the groove may simply be referred to as the inside of the groove. That is, in the present disclosure, a gap is formed between the end of the first main surface side of the groove and the glass member and at least one of the grooves. The state in which voids are formed in the groove means that these parts are not completely filled with the first adhesive layer. This state can be achieved, for example, by adjusting the position at which the first adhesive is applied (for example, applying it only to parts other than the grooves on the first main surface), or by adjusting the viscosity or application amount of the first adhesive.

The first base film is held by the carrier film via the first adhesive layer. The first adhesive layer is composed of a first adhesive having fluidity, and unlike adhesive layers such as the first adhesive layer, it can be easily removed together with the carrier film. Therefore, when the laser light is irradiated from the first base film side (more specifically, from the second main surface side) to the first adhesive layer in the groove, or to the glass member through the groove, the carrier film and the first adhesive layer It is advantageous to do this after removing the adhesive layer. In this case, the first adhesive layer in the groove can be removed more easily and the glass member held by the first base film can be cut cleanly.

A second base film may be laminated on the glass member on the main surface opposite to the first base film side. A second adhesive layer or a second adhesive layer is interposed between the second base film and the glass member. Such a configuration is also included in the elongated laminate of the present disclosure. In this case, in the area corresponding to the groove of the long laminate, the laser light is applied from the glass member side (more specifically, the second base film side) to the second base film and the second adhesive layer (or the second adhesive layer). ) and cut them. In this part, since the glass member and the second adhesive layer or the second adhesive layer are in contact, problems similar to those in the prior art are likely to occur. However, in the present disclosure, after removing the carrier film and the first adhesive layer, the laser light can be irradiated from the second main surface side of the first base film to the glass member through the groove. Therefore, the formation of damage to the glass member can be suppressed at the interface of the glass member with the first base film, and the glass member can be cut cleanly. Additionally, since a gap is formed in the groove, the first adhesive layer in the groove can be easily removed even when a laser beam is irradiated through the groove from the second main surface side. Therefore, even when the long laminate is a laminate in which a glass member is sandwiched between a first base film and a second base film, high-level control of the laser light irradiation conditions is not required, and the glass member can be cut cleanly.

In the present disclosure, grooves are formed in advance in the first base film, and when providing the second base film, the second base film is cut separately from the glass member. That is, basically, only the glass member needs to be cut with a laser beam. Therefore, compared to the case where the conventional laminate of the base film and the glass film is cut at once with a laser beam, in the present disclosure, it becomes easy to control the irradiation conditions of the laser beam suitable for the glass member, and the glass film can be cut cleanly. there is.

Hereinafter, the components of the elongated laminate will be described in more detail.

(First base film)

In the present disclosure, a frame-shaped groove penetrating the first base film in the thickness direction is formed in the first base film. This groove is formed prior to lamination of the glass member and the first base film. When the laser light is radiated toward the area corresponding to the groove of the long laminate, it is not irradiated to the first base film but is irradiated to the glass member, so the glass member can be cut cleanly.

A plurality of grooves on the frame are formed in the first base film. A plurality of grooves may be formed along the longitudinal direction of the elongated first base film. In the width direction of the first base film, one frame-shaped groove may be formed, or a plurality of grooves may be formed along the width direction. However, it is not limited to these cases, and for example, a plurality of rows of grooves on a plurality of frames formed along the longitudinal direction of the first base film may be formed so as to be shifted from adjacent rows. The arrangement of grooves on the frame in the first base film is not particularly limited.

The groove is formed while the first base film is held by a carrier film via a first adhesive layer. When the first base film is viewed from the first main surface, the shape of the groove is not particularly limited as long as it is frame-like, and can take various shapes. When the first base film is viewed from the first main surface side, the shape of the frame may be, for example, rectangular. Rectangular shape typically means a square or rectangular shape, but it does not necessarily have to be a strict square or rectangular shape. For example, the rectangular corners may be rounded by R-chamfering, or the corners of the rectangle may be C-chamfered. Additionally, the four sides of the rectangle do not have to be straight lines, and may be formed as lines with some curves or irregularities. In addition, the frame may have various shapes depending on the application, such as a parallelogram, rhomboid, circle, or oval.

A first adhesive is applied to the first main surface of the first base film in which the grooves are formed, and a glass member is laminated so as to contact the first adhesive. Therefore, there are cases where the first adhesive penetrates into the groove. Even in this case, it is desirable for the groove to have a certain width so that a gap is formed within the groove. The width of the groove is preferably 5 mm or more, and may be 7 mm or more or 10 mm or more. The upper limit of the groove width is not particularly limited and can be determined by considering the arrangement of the grooves or cost. The width of the groove may be, for example, 20 mm or less. The width of the groove is the average value of the minimum width in each of a plurality of grooves (for example, five) selected arbitrarily.

The first adhesive that penetrates into the groove forms a first adhesive layer by curing. In the present disclosure, since the first adhesive is applied to the first base film after forming the groove, the first adhesive that penetrates into the groove may cover at least part of the cross section of the first base film in the groove. In this case, when the first adhesive is cured, in the groove, at least a part of the cross section of the first base film is covered with the first adhesive layer. When such a state is observed, it can be seen that the groove was formed before lamination of the first base film and the glass member. In addition, when the first adhesive layer formed in the groove is formed so as to cover the cross section of the first base film, and a space on the frame is maintained inside this first adhesive layer, this space is used to form the groove. It is also possible to irradiate the laser light from the second main surface side so that it passes through. In this case, it is advantageous because there is no need to split the first base film by cutting the first adhesive layer with a laser beam.

It is preferable that the first adhesive layer covering at least part of the glass member along the width direction of the groove is not formed between the end of the groove on the first main surface side and the glass member. It is preferable that the first adhesive layer is not formed in the groove to block at least part of the groove in the width direction of the groove. This is because such a first adhesive layer reconnects the first base film divided by the grooves. Moreover, even when the laser light is irradiated from the second main surface side of the first base film through the groove, it is difficult to irradiate it directly to the glass member. Therefore, it is preferable that the thickness of this first adhesive layer is smaller. The minimum thickness of such a first adhesive layer is preferably 0 μm or more and 3 μm or less, and may be 0 μm or more and 2 μm or less. In addition, when the first adhesive layer is continuously formed between the edge of the first main surface side of the groove and the glass member and both within the groove, it is preferable that the minimum thickness of this first adhesive layer is within the above range. When the first adhesive layer formed between the end on the first main surface side of the groove and the glass member and at least one of the grooves is divided into plural pieces, the total thickness is preferably within the above range. A first adhesive layer formed between the end of the first main surface side of the groove and the glass member to cover at least part of the glass member along the width direction of the groove, and within the groove, at least part of the groove in the width direction of the groove. The minimum thickness of the first adhesive layer formed to block is the minimum length in the direction parallel to the depth direction of the groove. Therefore, while maintaining the space on the frame within the groove, it is unrelated to the thickness of the first adhesive layer covering the cross section of the first base film, and the thickness of this first adhesive layer (parallel to the depth direction of the groove) The minimum length in one direction) does not need to be within the above range.

The first base film is, for example, a resin film made of resin. The first base film may be a single-layer film or a multilayer film. A multilayer film is a laminate of two or more layers of resin films. The resin films of each layer constituting the multilayer film may be bonded directly, and the resin films of each layer may be bonded together with an adhesive layer or adhesive layer.

The resin constituting the resin film may be a thermoplastic resin or a thermosetting resin. Examples of thermoplastic resins include polyethersulfone-based resin, polycarbonate-based resin, acrylic resin, polyester-based resin, polyolefin-based resin, cycloolefin-based resin, polyimide-based resin, polyamide-based resin, polyimide-based resin, These are polyarylate-based resin, polysulfone-based resin, and polyetherimide-based resin. An example of a polyester resin is an aromatic polyester resin (polyalkylene arylate resin, etc.). Examples of polyalkylene arylate resins are polyethylene terephthalate resin, polybutylene terephthalate resin, and polyethylene naphthalate resin. An example of a cycloolefin-based resin is norbornene-based resin. Examples of thermosetting resins are epoxy-based resins, urethane-based resins, and silicone-based resins. However, these resins are mere examples, and the resins constituting the resin film are not limited to these. The resin film may contain one type of resin, or may contain a combination of two or more types of resin. Each layer constituting the multilayer film may contain one type of resin, or may contain a combination of two or more types of resin.

The storage elastic modulus of the first base film at 25°C is not particularly limited, and may be, for example, 1.5 GPa or more and 10 GPa or less, 1.8 GPa or more and 9 GPa or less, or 1.8 GPa or more and 8 GPa or less. When the storage elastic modulus of the first base film is in this range, the effect of supporting and protecting the glass member is high, and productivity when manufacturing a laminate with separate glass members is further improved. The storage modulus can be determined by performing dynamic viscoelasticity measurement. Since it tends to exhibit such a storage modulus, polyethylene terephthalate (PET) resin is preferable as the resin constituting the first base film. When using a multilayer film as the first base film, it is preferable that the storage elastic modulus of the layer on the glass member side is in the above range.

The first base film is not limited to the above, and may be, for example, a multilayer film containing an optical film. Such a multilayer film may be a multilayer film containing an optical film and a base film (such as the above resin film), may be a multilayer film containing two or more layers of an optical film, or may be a multilayer film containing one or two or more layers of an optical film and a separator. It may be a multilayer film. Each film constituting the multilayer film may be bonded directly, or may be bonded through an adhesive layer or adhesive layer.

The optical film is not particularly limited, but includes, for example, a polarizing plate, a retardation plate, and an isotropic film. Materials constituting the optical film include, for example, polyvinyl alcohol-based resin, polyolefin-based resin, cyclic olefin-based resin, polycarbonate-based resin, cellulose-based resin, polyester-based resin, polyvinyl alcohol-based resin, polyamide-based resin, and polyester resin. Examples include mead-based resin, polyether-based resin, polystyrene-based resin, (meth)acrylic resin, (meth)acrylic urethane-based resin, polysulfone-based resin, acetate-based resin, epoxy-based resin, and silicone-based resin. The optical film may be a metal oxide film (metal film, ITO film, etc.) or a laminated film of a metal film and a resin film.

As a separator, for example, a release sheet provided with a base material sheet and a release agent disposed on at least one main surface of the base sheet is used. For the base sheet, for example, a material similar to the resin film exemplified as the first base film can be arbitrarily selected and used. Examples of the release agent include known release agents (eg, silicone-based release agents and fluorine-based release agents).

The thickness of the first base film is, for example, 5 μm or more and 300 μm or less. When the first base film is a single-layer film, the thickness may be, for example, 5 μm or more and 60 μm or less, 5 μm or more and 50 μm or less, or 10 μm or more and 40 μm or less. When the first base film is a multilayer film, the thickness may be, for example, 10 μm or more and 300 μm or less, and may be 30 μm or more and 200 μm or less. The thickness of each layer constituting the multilayer film is adjusted so that the thickness of the multilayer film is within this range.

In addition, in this specification, the thickness of the component of each laminate is the average value of the thickness measured at a plurality of arbitrary locations (for example, 5 locations), unless otherwise specified.

(no glass)

As a glass member, for example, a glass film is used. Glass film is generally sometimes referred to as thin glass. The glass member preferably has a uniform thickness.

Glass films such as foil glass have high flexibility and are sometimes supplied in roll form. Therefore, a long glass member (glass film, etc.) may be used in the long laminated body. In this case, it is convenient because the glass member can be laminated on the first base film using a roll-to-roll method. However, it is not limited to this case, and for example, the glass members of the base plate may be laminated in a row on the first base film. When using multiple glass members of the base plate, all of them may be the same glass members, or different glass members may be arranged at different positions depending on the purpose. When using a glass member for a base plate, a glass member with an area of one main surface larger than the size of the groove on the frame is used.

The composition of the glass constituting the glass member is not particularly limited. Examples of glass are soda lime glass, boric acid glass, aluminosilicate glass, and quartz glass. The glass may be alkali-free glass or low-alkali glass. The total content of alkali metal components (for example, Na ₂ O, K ₂ O, Li ₂ O) of the glass is, for example, 15 mass% or less, and may be 10 mass% or less.

The thickness of the glass member is, for example, 100 μm or less, and may be 10 μm or more and 60 μm or less.

The density of the glass member may be, for example, 2.3 g/cm ³ or more and 3.0 g/cm ³ or less, and may be 2.3 g/cm ³ or more and 2.7 g/cm ³ or less.

The glass member is manufactured by any suitable method. Typically, glass films are made by melting a mixture containing ceramics (silica, alumina, etc.) as the main raw material, an antifoaming agent (corrosion, antimony oxide, etc.), and a reducing agent (carbon, etc.) at a temperature of 1400°C or higher and 1600°C or lower. It is produced by forming it into a film and then cooling it. Examples of glass film forming methods include the slot down draw method, fusion method, and float method. The glass film obtained by these methods may be chemically polished with a solvent such as hydrofluoric acid as needed in order to further thin the film or improve the smoothness of the surface and edges.

The surface of the glass member may be subjected to surface treatment in order to improve adhesion with the adhesive layer or pressure-sensitive adhesive layer in contact with the glass member. The surface treatment is not particularly limited and includes corona treatment, plasma treatment, and coupling treatment.

Additionally, if necessary, a surface coating layer having various functions may be provided on at least part of the surface layer on the side opposite to the first base film of the glass member.

Examples of the surface coat layer include an anti-fingerprint coat layer, a hard coat layer, an anti-reflection layer, an anti-glare layer, an anti-fouling layer, an anti-sticking layer, a color adjustment layer, an anti-static layer, an easy adhesion layer, an anti-component precipitation layer, a shock absorption layer, and an anti-scattering layer. You can. The surface coat layer may be made of various materials. For example, the anti-fingerprint coat layer includes, for example, fluorine resin, silicone resin, etc. Other surface coat layers are formed of, for example, an acrylic coating agent, a melamine coating agent, a urethane coating agent, an epoxy coating agent, a silicone coating agent, an inorganic coating agent, etc. Coating agents may include additives such as silane coupling agents, colorants, dyes, pigments, fillers, surfactants, plasticizers, antistatic agents, surface lubricants, leveling agents, antioxidants, light stabilizers, ultraviolet absorbers, polymerization inhibitors, and antifouling agents. You can.

The surface coat layer may be formed in the form of a long laminate, or, if necessary, after the glass members are separated into individual pieces. Additionally, a surface coat layer may be formed on the glass member prior to forming the elongated laminate.

(Carrier film)

The long carrier film is not particularly limited and can be made of, for example, a resin film. The resin constituting the resin film can be arbitrarily selected, for example, from the resins exemplified for the resin film of the first base film. Considering transportability and strength, etc., films made of PET resin are preferable.

The thickness of the carrier film may be, for example, 10 μm or more and 200 μm or less, 30 μm or more and 150 μm or less, and 40 μm or more and 100 μm or less.

(Second base film)

The long laminate may further include a long second base film. The second base film is laminated on the main surface of the glass member on the opposite side to the first base film.

The second base film is not particularly limited and may be selected depending on the purpose of the individualized laminate with glass members, and may be a protective film for protecting the glass member. The second base film can be selected from the resin films, optical films, etc. exemplified for the first base film. The second base film may be a single-layer film or a multilayer film. When the second base film is a multilayer film, each layer may be bonded directly or may be bonded through an adhesive layer or adhesive layer. For contents other than the groove, reference may be made to the description of the first base film. The elastic modulus of the second base film may be set in the range described for the elastic modulus of the first base film.

If necessary, a surface coating layer having various functions may be provided on at least a part of the surface layer on the side opposite to the glass member of the second base film. As the surface coat layer, reference may be made to the description of the surface coat layer formed on the surface of the glass member. In addition to the above, for example, a surface coat layer may be formed on the second base film prior to forming the elongated laminate.

(Adhesive layer)

In the present disclosure, the adhesive layer is formed by curing a coating film of the adhesive. Therefore, the adhesive layer has substantially no fluidity. On the other hand, the adhesive layer is composed of an adhesive, but is non-curing and has fluidity. As such, in the present disclosure, the adhesive layer and the pressure-sensitive adhesive layer are distinguished.

The storage modulus of the adhesive layer at 25°C is greater than 10 MPa, may be 100 MPa or more, and is usually about 1 GPa. The adhesive layer is distinguished from the adhesive layer also by its storage modulus.

(First adhesive layer)

The first adhesive layer is interposed between the first base film and the glass member. The first adhesive layer is formed by applying the first adhesive to the first main surface of the first base film in which the grooves were formed, overlapping the glass member so as to contact the first adhesive, and then curing the first adhesive. The first adhesive is usually applied to the portion excluding the groove of the first main surface of the first base film.

From the viewpoint of reducing the flow and penetration of the first adhesive into the groove, it is preferable that the first adhesive is applied so that the thickness of the first adhesive layer is 0.5 μm or more and 5 μm or less. The thickness of the first adhesive layer is more preferably 0.5 μm or more and 3 μm or less. However, the thickness of this first adhesive layer is the thickness of the first adhesive layer in the portion excluding the groove from the first main surface of the first base film.

For voids to form in the groove, the viscosity of the first adhesive is also important. The viscosity of the first adhesive at 25°C is preferably 150 mPa·s or less or 100 mPa·s or less. When the viscosity of the first adhesive is in this range, a first adhesive layer is formed between the edge of the first main surface side of the groove and the glass member to cover at least a portion of the glass member along the width direction of the groove, and the groove. Within the groove, the thickness of the first adhesive layer formed to block at least a portion of the groove in the width direction of the groove can be reduced (preferably, such a first adhesive layer is not formed). The viscosity of the first adhesive at 25°C may be 0.1 mPa·s or more.

The viscosity of the first adhesive is measured under the conditions of 25°C and a shear rate of 200 (1/s) using a commercially available viscoelasticity measuring device. As a viscoelasticity measuring device, specifically, a rheometer MCR302 manufactured by Anton Paar is used.

The adhesive force between the first adhesive layer and the first base film and the adhesive force between the first adhesive layer and the glass member may be, for example, 0.1 N/mm or more and 1 N/mm or more at 25°C, respectively. By setting such an adhesive force, peeling between the first base film and the glass member can be suppressed to a higher degree. Such adhesive strength can be adjusted, for example, by selecting the type or composition of the first adhesive.

The first adhesive is not particularly limited, and any suitable adhesive can be used. Examples of the first adhesive include an adhesive containing a resin having a cyclic ether group (epoxy group, glycidyl group, oxetanyl group, etc.), an adhesive containing an acrylic resin, an adhesive containing a silicone resin, etc. The first adhesive is preferably of an ultraviolet curing type. When the first adhesive is an ultraviolet curing type, the productivity of the laminate can be further increased in the laminate manufacturing method.

(Other adhesive layers)

When the elongated laminate includes a second base film, a second adhesive layer may be interposed between the second base film and the glass member. Additionally, when the first base film or the second base film is a multilayer film, the layers constituting the multilayer film may be bonded together with an adhesive layer. These adhesive layers can also be formed, as in the case of the first adhesive layer, by arranging and curing adhesive coating films between the bonding layers.

Examples of the adhesive including the second adhesive that forms the second adhesive layer and forming adhesive layers other than the first adhesive layer include the adhesives exemplified for the first adhesive. The second adhesive is preferably of an ultraviolet curing type for the same reason as the first adhesive. Other adhesives may be thermosetting type or photocuring type (ultraviolet curing type, etc.).

The viscosity at 25°C of the adhesive forming the adhesive layer other than the first adhesive layer may be, for example, 0.1 mPa·s or more and 1000 mPa·s or less, and may be 0.1 mPa·s or more and 300 mPa·s or less. The viscosity of the adhesive is measured in the same manner as for the first adhesive.

The thickness of adhesive layers other than the first adhesive layer may be, for example, 0.5 μm or more and 10 μm or less, and may be 1 μm or more and 5 μm or less.

(Adhesive layer)

The adhesive layer has fluidity as described above. The storage modulus of the adhesive layer at 25°C is, for example, 10 MPa or less, and is usually 1 MPa or less. The storage modulus of the adhesive layer at 25°C may be 0.2 MPa or less or 0.1 MPa or less. When the storage modulus of the adhesive layer is in this range, the adhesive layer can be relatively easily peeled from the layer in contact with the adhesive layer. The storage modulus of the adhesive layer at 25°C may be 0.001 MPa or more.

(First adhesive layer)

The first adhesive layer is interposed between the first base film and the carrier film. Therefore, when cutting a glass member by irradiating a laser beam to a long laminate, when the first adhesive layer and the carrier film are peeled from the first base film, the groove passes from the second main surface side of the first base film, Laser light irradiation can be performed. For example, when a long laminated body includes a second base film, it is difficult to irradiate the laser light directly to the glass member from the second base film side. However, in the present disclosure, a groove is formed in the first base film, and a void exists even if the first adhesive layer is formed in the groove or near the groove. Therefore, by peeling the first adhesive layer and the carrier film from the first base film, it is easy to irradiate the laser light to the glass member through the groove of the first base film, forming a shape surrounded by a frame along the shape of the groove, Glass members can be cut cleanly.

The first adhesive layer is formed, for example, by applying a first adhesive to at least one of opposing surfaces of the carrier film and the first base film, and overlapping the carrier film and the first base film. At this stage, since no groove is formed in the first base film, a long base material laminate is formed in a roll-to-roll manner, including a carrier film, a first base film, and a first adhesive layer interposed between them. can be easily formed. A first adhesive layer may be formed on the surface of the carrier film, and the first base film may be bonded to the carrier film through this first adhesive layer.

The first adhesive constituting the first adhesive layer is not particularly limited and includes, for example, acrylic adhesives, rubber adhesives, silicone adhesives, urethane adhesives, vinyl alkyl ether adhesives, polyvinylpyrrolidone adhesives, polyacrylamide adhesives, A cellulose-based adhesive is included.

Each adhesive includes, for example, base polymer, crosslinking agent, additives (e.g., tackifier, coupling agent, polymerization inhibitor, crosslinking retarder, catalyst, plasticizer, softener, filler, colorant, metal powder, ultraviolet absorber, light stabilizer, antioxidant) , deterioration inhibitors, surfactants, antistatic agents, surface lubricants, leveling agents, corrosion inhibitors, and particles of inorganic or organic materials (metal compound particles (metal oxide particles, etc.), resin particles, etc.) may be included. However, the components of the adhesive are not limited to these.

The thickness of the first adhesive layer may be, for example, 3 μm or more and 50 μm or less, and may be 5 μm or more and 30 μm or less.

(Other adhesive layers)

When the elongated laminate includes a second base film, a second adhesive layer may be interposed between the second base film and the glass member. Additionally, when the first base film or the second base film is a multilayer film, the layers constituting the multilayer film may be bonded together with an adhesive layer. These adhesive layers can also be formed by disposing an adhesive between the layers to be bonded, as in the case of the first adhesive layer.

Examples of the adhesive including the second adhesive constituting the second adhesive layer and constituting the adhesive layer other than the first adhesive layer include the adhesives exemplified for the first adhesive. The thickness of the adhesive layer other than the first adhesive layer can be selected, for example, from the range described for the thickness of the first adhesive layer.

<Method for measuring physical properties 1>

(1) Storage modulus

(1-1) Base film

Each storage elastic modulus of the first base film and the second base film can be measured as a tensile storage modulus based on JIS K 7244-1:1998. Specifically, first, each base film is cut out to a predetermined size to produce a test piece. Using this test piece, viscoelasticity was measured under the following conditions using a dynamic viscoelasticity measuring device (e.g., multi-functional dynamic viscoelasticity measuring device "DMS6100" manufactured by Hitachi High-Tech Science Co., Ltd.), and the tensile storage modulus at 25°C was calculated as Save. Measurements may be performed 5 or more times and the average value may be obtained.

Measuring conditions

Temperature range: -100℃~+200℃

Temperature increase rate: 2℃/min

Mode: Seal

Sample width: 10mm

Distance between chucks: 20mm

Frequency: 10Hz

Strain amplitude: 10㎛

Atmosphere: Ambient (250ml/min)

Data acquisition interval: 0.5 min (every 1°C)

(1-2) Adhesive layer

The storage modulus of the adhesive layer can be measured as the tensile storage modulus, similar to the case of the base film. Specifically, first, the adhesive is molded into a film and cured to produce a film of the cured product with a thickness of approximately 20 μm. This film is cut out to a predetermined size to produce a test piece. Using this test piece, viscoelasticity is measured as in the case of the base film, and the tensile storage modulus at 25°C is determined. Measurements may be performed 5 or more times and the average value may be obtained.

(1-3) Adhesive layer

The storage modulus of the adhesive layer can be measured in torsion mode based on JIS K 7244-1:1998. Specifically, the adhesive coating film is inserted into a parallel plate, and the viscoelasticity is measured using a dynamic viscoelasticity measuring device (e.g., 'Advanced Rheometric Expansion System (ARES)' manufactured by Rheometric Scientific) under the following conditions, Determine the storage modulus at 25°C. Measurements may be performed 5 or more times and the average value may be obtained.

Measuring conditions

Deformation Mode: Torsion

Measurement frequency: 1Hz

Measurement temperature: -40℃~+150℃

Temperature increase rate: 5℃/min

(2) Adhesion

The adhesive force between the first adhesive layer and the glass member is measured under the following conditions and methods using a surface/interface property analysis device "SAICAS DN-20 type" manufactured by Dypla Wintes Co., Ltd. As shown in FIG. 4A, the surface/interface physical property analysis device 41 includes a blade 42 having the following characteristics, a moving device not shown, and a pressure measuring unit. The blade 42 is movable. The blade 42 has a blade tip 43 formed at the tip.

Characteristics of blade (42)

Material of blade 42: single crystal diamond

Width of blade tip (43): 1mm

Rake angle of blade tip (43): 10°

First, as shown in FIG. 4A, the laminated body is set in the analysis device 41. The first base film 100 is moved to one side of the horizontal direction D1 (corresponding to the surface direction of the laminate) so as to be inclined with respect to the vertical direction D2 (corresponding to the thickness direction of the laminate). By press-fitting, the blade tip 43 is cut into the first base film 100. The horizontal speed is 10㎛/sec, and the vertical speed is 0.5㎛/sec. For the measurement, a laminate in which the first base film 100 is not formed with a frame-shaped groove is used. The laminate includes a first base film 100, a glass member 200, and a first adhesive layer 300 interposed between them.

After cutting the blade tip 43 into the first base film 100, the blade tip 43 is also cut into the first adhesive layer 300, as shown in FIG. 4B. When the blade tip 43 reaches the interface between the first adhesive layer 300 and the glass member 200, the blade tip 43 is moved horizontally to one side. As a result, the first adhesive layer 300 is peeled from the glass member 200. The peeling strength at this time is measured as the adhesive force between the first adhesive layer 300 and the glass member 200.

Additionally, the adhesive force between the first adhesive layer 300 and the first base film 100 can be measured similarly by replacing the top and bottom of the laminate in FIGS. 4A and 4B. However, when measuring the adhesive force between the first adhesive layer 300 and the first base film 100, the blade tip 43 is press-fitted into the first substrate film 100, and the blade tip 43 is pressed into the first substrate film 100. It is cut into the film 100. When the blade tip 43 reaches the interface between the first base film 100 and the first adhesive layer 300, the blade tip 43 is moved horizontally to one side, and the first adhesive layer 300 is formed on the first substrate 300. The peeling strength when peeling from the film 100 is measured as adhesive force.

FIG. 1A is a plan view showing the configuration of a long laminated body 10C according to one embodiment, and FIG. 1B is a cross section of the long laminated body 10C of FIG. 1A taken along the line b-b, viewed in the direction of the arrow. This is a schematic cross-sectional view. On the long carrier film 400, a long first base film 100 in which a plurality of rectangular frame-shaped grooves G are formed is laminated with a first adhesive layer 500 interposed therebetween. Furthermore, on the first base film 100, a film-shaped elongated glass member 200 is laminated with the first adhesive layer 300 interposed therebetween. The groove G is formed by the carrier film 400 and the first base film 100 and the first adhesive layer 500 interposed between them before applying the first adhesive forming the first adhesive layer 300. ) is formed by shaving or cutting the first base film 100 into a frame shape at a plurality of locations in the state of a laminate (also referred to as a base laminate). The arrangement and number of grooves G on the frame are not limited to the illustrated examples and are set appropriately. 1A and 1B, the width of the groove G on the frame is indicated as Wg.

2A, 2B, and 2C are schematic cross-sectional views each showing an embodiment of a long laminate including a second base film. These figures are cross-sectional views showing a cut surface parallel to the thickness direction of the long laminated body as seen from the direction parallel to the longitudinal direction of the long laminated body, as shown in FIG. 1B.

In the elongated laminate of FIG. 2A , a second base film 600 is formed on the glass member 200 with a second adhesive layer 700 interposed therebetween. In the elongated laminate of FIG. 2B , a second base film 600 is formed on the glass member 200 with a second adhesive layer 800 interposed therebetween. Other than these configurations, it is the same as the elongated laminate 10C in FIGS. 1A and 1B, and the description of FIGS. 1A and 1B can be referred to.

In the elongated laminate shown in FIG. 2C , a second base film 600 is formed on a glass member 200 via a second adhesive layer 800, as shown in FIG. 2B. The stacked structure of the carrier film 400 and the first adhesive layer 500 is the same as Figures 1A and 1B. However, the elongated laminate in FIG. 2C includes a first base film 1100 with a multilayer structure instead of the first base film 100 with a single-layer structure. The first base film 1100 includes a separator 120 on the first adhesive layer 500 side and a polarizing plate 110 laminated on the separator 120 with the adhesive layer 130 interposed therebetween. A glass member 200 is laminated on the polarizing plate 110 with a first adhesive layer 300 interposed therebetween. Although the first base film 1100 has a multilayer structure, since it is composed of all resin materials, the grooves G can be easily formed with a laser beam or the like in the base material laminate state. After forming the groove (G) in the first base film 1100, the first adhesive is applied to parts other than the groove (G) of the first main surface (main surface on the polarizing plate 110 side) of the first base film 1100. By applying and overlapping the glass member 200 or a laminate of the glass member 200 and the second base film 600 and the second adhesive layer 800 interposed between them, and curing the first adhesive. The first adhesive layer 300 is formed. In the illustrated example, the first adhesive applied to the first main surface rides on the end surface (or wall surface) of the first base film 1100 in the groove G, penetrates into the inside of the groove G, and covers the end surface. It shows the case where the first adhesive layer 300 is formed.

In the manufacturing process of a long laminated body, a first adhesive layer may be formed in the groove as described above. Additionally, a first adhesive layer may be formed between the edge of the groove on the first main surface side of the first base film and the glass member. In the elongated laminate of the present disclosure, a gap is formed between the edge of the groove on the first main surface side of the first base film and the glass member and at least one side of the groove. Therefore, by irradiating laser light to the area corresponding to the groove of the long laminated body, the glass member can be cut cleanly.

3A to 3E are schematic cross-sectional views for explaining the state of the first adhesive layer in the groove of the long laminated body and its vicinity, or the division of the glass member or the long laminated body by irradiation of laser light. In these figures, the grooves are enlarged and shown so that the state of the grooves and the first adhesive layer near them can be easily understood.

In FIG. 3A, as in FIGS. 1B, 2A, and 2B, the first adhesive layer 300 is formed on a portion other than the groove G of the first main surface of the first base film 100 and the glass member 200. It is formed only between . In other words, all parts between the end of the first main surface side of the groove G and the glass member 200 and within the groove G are voids. The elongated laminate in FIG. 3A does not include the second base film 600, and the outermost layer is the glass member 200. The carrier film 400 and the first adhesive layer 500 are peeled from the long laminate, and placed in the area corresponding to the groove G of the peeled long laminate (specifically, in this case, the glass member 200). By irradiating the laser light L from the glass member 200 side, the glass member 200 can be easily cut. Therefore, the glass member 200 can be divided according to the shape of the groove G. In this way, a laminate with separate glass members divided into shapes surrounded by a frame can be obtained.

3B to 3D, like the case of FIG. 3A, the elongated laminate does not include the second base film 600, and the outermost layer is the glass member 200. However, in FIGS. 3B to 3D, the state of the first adhesive layer 300 in or near the groove G is different from that in FIG. 3A. More specifically, in FIG. 3B , as in the case of FIG. 2C , the end surface (or wall surface) of the first base film is covered with the first adhesive layer 300 in the groove G. In FIG. 3B, as in the case of FIG. 2C, a gap is formed inside the groove G. In FIG. 3B, the glass member 200 can be clearly divided by irradiating the laser light L as in the case of FIG. 3A.

In FIGS. 3C and 3D , as in the case of FIG. 3B , the end surface (or wall surface) of the first base film is covered with the first adhesive layer 300 in the groove G. In addition, a first adhesive layer 300 is formed on the top or bottom of the groove G. More specifically, in FIG. 3C , the first adhesive layer 300 is formed between the end of the first main surface side of the groove G and the glass member 200 and at the upper end of the groove G. In FIG. 3D, the first adhesive layer 300 is formed at the bottom of the groove G (the end on the first adhesive layer 500 side). In these examples as well, a gap is secured within the groove G, and the thickness T ₁ of the first adhesive layer 300 formed at the top or bottom of the groove is small. Therefore, even when the laser light L is irradiated from the glass member 200 side, the glass member 200 can be cut cleanly, and an unnecessary first adhesive layer is formed on the top or bottom of the groove G. (300) can be easily removed with laser light (L). Therefore, the glass member 200 can be clearly divided, and a laminate with separate glass members can be easily manufactured.

FIG. 3E is an example of dividing a long laminate including a second base film into pieces. The elongated laminate in FIG. 3E includes a second base film 600 laminated on a glass member 200 with a second adhesive layer 700 interposed therebetween. In the elongated laminate shown in FIG. 3E, the first adhesive layer 300 is formed in the groove G, as in the case of FIG. 3D. In this case, the carrier film 400 and the first adhesive layer 500 are first peeled off. Next, the laser light L is irradiated from the glass member 200 side (in other words, the second base film 600 side), and the second base film 600 and the second adhesive layer 700 are cut. Next, by irradiating the laser light L through the groove G from the second main surface side of the first base film 100, the first adhesive layer 300 formed at the bottom of the groove G is formed. Upon removal, the glass member 200 is cut cleanly. In this way, by irradiating the laser light L from the top and bottom, a long laminated body can be divided, and a laminated body with a glass member separated into individual pieces can be easily manufactured. In addition, in FIG. 3E, this method is effective even when the first adhesive layer 300 as shown in FIG. 3C is formed in the groove G.

[Manufacturing method of long laminated body and laminated body]

Next, an example of a method for manufacturing a long laminated body (hereinafter referred to as 'manufacturing method A') will be described. For the components of the long laminated body, reference may be made to the description of the long laminated body.

Manufacturing method A can be roughly divided into three steps.

The first step is to prepare a long substrate laminate.

The second step is a step of preparing a long laminate from the base material laminate and the glass member.

The third step is to further process the long laminate.

<Step 1>

The first step includes preparing a substrate laminate. The base material laminate is a laminate in which a long first base film and a long carrier film are bonded together with a first adhesive layer. At this point, the first base film is in a state that does not include a plurality of frame-shaped grooves. The preparation process for the base material laminate is not particularly limited and may be performed by a roll-to-roll method.

The base material laminate is prepared, for example, by applying a first adhesive to one of the opposing surfaces of a long carrier film and a long first base film, forming a first adhesive layer, and bonding them to the other side. The first adhesive is applied to one main surface of the carrier film or the first base film using application or transfer. Alternatively, it may be prepared by purchasing a roll of a base material laminate in which a carrier film and a first base film are laminated with a first adhesive layer interposed therebetween.

This process may further include, for example, unwinding a long base material laminate wound into a roll shape by an unwinding unit. The unrolled base material laminate is supplied to the subsequent step (or process). In addition, it is not limited to this case, and the process of preparing the base material laminate may be performed as one of a series of processes for forming a long laminate.

<Step 2>

In the second step, a long-length laminate is formed using the base material laminate obtained in the first step. The second step includes a first step of forming a groove in the first base film of the base material laminate supplied from the first step, a second step of laminating a glass member, and a third step of forming a first adhesive layer. It may be included. The second step may further include a fourth step of laminating a second base film as needed. The fourth step may be performed in a roll-to-roll manner, if necessary. Additionally, the second step may, if necessary, include a fifth step of forming a surface coat layer on the glass member or the second base film.

(1st process)

In the first step, a plurality of frame-shaped grooves penetrating the first base film in the thickness direction are formed in the base material laminate. The grooves on the frame are not particularly limited and can be formed, for example, mechanically or using laser light in the first base film of the base material laminate. Each groove may be formed, for example, by cutting the first base film into a frame shape, forming two large and small frame-shaped slits, and forming a first base film between the slits (a frame-shaped first base film having a width between slits). It may be formed by removing . In the present disclosure, the latter method is advantageous because it forms grooves with a relatively large width. In particular, it is easy to form using half cut technology using laser light. Even if the first adhesive layer is cut through the first base film by half cutting, the first adhesive layer has fluidity, so the adhesiveness is not impaired while the first base film is maintained. Additionally, even if the first adhesive layer is partially damaged, it does not affect the product because it is later removed along with the carrier film.

The portion on the frame between the slits of the first base film can be removed, for example, by pushing the side end portion of the portion on the frame from below the carrier film to levitate it and pulling the levitated portion.

In the roll-to-roll method, grooves may be formed on a portion of the base material laminate while it is being unrolled and transported or when the transport is stopped. The base material laminate on which the first step has been performed may be initially wound into a roll shape by a winding unit. The base material laminate on which the first step has been performed may be further used in a subsequent step after being wound in the winding unit or without being wound.

(2nd process)

In the second step, after forming the groove in the first step, the first adhesive is applied to the first main surface of the first base film, and the glass member is laminated through the first adhesive. The second process may include a first sub-step of applying the first adhesive to the first base film and a second sub-step of laminating the glass member.

(Application of adhesive (first substep))

The first adhesive is applied so that a gap is formed between the end of the first main surface side of the groove and the glass member and at least one side of the groove. From this viewpoint, for example, it is preferable to apply the first adhesive to the area excluding the groove of the first main surface. In addition, the viscosity of the first adhesive is within the described range, or the thickness of the first adhesive layer between the first main surface of the first base film (region excluding the groove) and the glass member is within the described range. It is desirable to apply adhesive. In addition, the first adhesive is applied (e.g., application amount or coating film thickness) so that the minimum thickness of the first adhesive layer formed between the end of the first main surface side of the groove and the glass member and on at least one part of the groove is within the described range. It is also desirable to adjust .

For example, in the roll-to-roll method, the first adhesive is continuously or intermittently applied to the first main surface of the first base film of the base material laminate while the base material laminate after forming the groove is being transported or when the transport is stopped. You may apply.

For the type of the first adhesive, reference may be made to the description of the first adhesive forming the first adhesive layer of the elongated laminate. The type and composition of the first adhesive are such that the adhesive force between the first adhesive layer and the glass film and the adhesive force between the first adhesive layer and the first base film are, for example, 0.1 N/mm or more. It is advisable to choose

As a method of applying the first adhesive, a coating method, a printing method, etc. are used. Coating methods include air doctor coating, blade coating, knife coating, reverse coating, transfer roll coating, gravure roll coating, kiss coating, cast coating, spray coating, slot orifice coating, calendar coating, electrodeposition coating, and dip coating. , die coating, etc. Printing methods include emboss printing (flexographic printing, etc.), intaglio printing (direct gravure printing, offset gravure printing, etc.), flat printing (offset printing, etc.), and stencil printing (screen printing). etc.), etc. may be mentioned.

(Laminating of glass members (second substep))

Continuing from the first substep, the glass member is laminated on the first main surface of the first base film via the applied first adhesive. As described above, as a glass member, a long glass member (glass film, etc.) may be continuously superimposed on the first base film, or a plurality of base glass members may be arranged in a row on the first main surface of the first base film. do.

In the second sub-step, the glass member may be laminated alone on the first base film.

Alternatively, the glass member may be laminated on the first main surface of the first base film in a state in which it is previously laminated with the second base film via the second adhesive layer or the second adhesive layer. The laminate of the glass member, the second base film, and the second adhesive layer interposed between them is formed by, for example, applying the second adhesive to at least one of the opposing surfaces of the glass member and the second base film, It can be obtained by bonding the other side and curing the second adhesive to form a second adhesive layer. Application of the second adhesive can be performed by the application method described for the first adhesive, etc. For curing of the second adhesive, refer to the description of the third process described later. A laminate of a glass member, a second base film, and a second adhesive layer interposed between them may be formed, for example, by applying a second adhesive to at least one of the opposing surfaces of the glass member and the second base film. It can be formed by forming an adhesive layer and sticking the other side in contact with the second adhesive layer. Application of the second adhesive can be performed using application, transfer, or the like.

(Third process)

In the third step, the first adhesive layer is formed by curing the first adhesive applied in the second step. As a result, a long laminate is obtained in which a glass member is laminated through a first adhesive layer on a base laminate in which a plurality of frame-shaped grooves are formed in the first base film.

Curing of the first adhesive can be performed using heating or light irradiation, etc., depending on the type of the first adhesive. Since the glass member is transparent, a photocurable first adhesive can be used, and curing can be performed efficiently. When using an ultraviolet curing type first adhesive, the first adhesive layer is formed by irradiating ultraviolet rays to the first adhesive through a glass member.

The long laminated body or its precursor obtained in the third step may be initially wound into a roll shape by a winding unit. The long laminate on which the third process has been performed may be subjected to a subsequent process or step (e.g., the fourth process, the fifth process, or the third step) after being wound on the winding unit or without being wound. do. When the precursor is obtained in the third process, the elongated laminate may be completed by performing the fourth process and/or the fifth process.

Fig. 5 is an explanatory diagram showing an example of a method for manufacturing a long laminated body. The method for manufacturing a long-length laminate is a roll-to-roll method and proceeds sequentially in the direction of the arrow in FIG. 5. Figure 5(a) schematically shows at least a part of the process of preparing the base material laminate in the first step, and involves unwinding the roll-shaped base layer laminate 456 by the unwinding unit 1. It may be included. The base material laminate 456 is a laminate in which a long carrier film 400 and a long first base film 100 are bonded together with a first adhesive layer 500. The unrolled base material laminate 456 is supplied to the first process of the subsequent second stage.

Figure 5(b) schematically shows at least part of the first process in the second stage, and first shows a slit S being formed by the half cut device 2 using a laser beam. there is. The slits S are formed to draw a rectangular set on two large and small frames. A plurality of such frame-shaped rectangular sets are formed in succession in the longitudinal and width directions of the base material laminate 456. Then, a plurality of frame-shaped grooves G are formed by removing the portion (frame-shaped portion) 100a between the two large and small frame-shaped slits S of the first base film 100.

Figure 5(c) schematically shows at least part of the second process and shows the application of the first adhesive 300a in the first sub-step. In the cross-sectional schematic diagram, the first adhesive 300a is applied to portions other than the grooves G on the first main surface of the first base film 100.

FIG. 5(d) schematically shows at least a part of the second process and shows how the long glass members 200 are stacked in the second sub-step. The roll-shaped glass member 200 is unwound from the unwinding section 4 and laminated on the base material laminate in which the frame-shaped groove G is formed. Then, by curing the first adhesive 300a, a long laminated body 10C as shown in the cross-sectional schematic diagram is formed. By irradiating ultraviolet rays to the first adhesive 300a through the glass member 200, the first adhesive 300a is cured to form the first adhesive layer 300. In this way, the long laminated body 10C is formed. The base material laminate on which the glass member 200 is laminated may be passed through the nip of a pair of nip rollers 3a and 3b, and the glass member 200 may be pressed against the first adhesive.

The long laminated body 10C may be wound into a roll shape by the winding unit 5, as shown in FIG. 5(e). In this case, from the viewpoint of securing the glass member 200, it is preferable to wind the roll so that the inside of the roll becomes the glass member 200.

In the illustrated example, an example is shown in which the longitudinal direction of the rectangular glass member 200 and the MD direction of the elongated carrier film are parallel, but the relationship between the longitudinal direction of the glass member 200 and the MD direction is not limited to this.

Fig. 6 is a plan view showing an example of arrangement of grooves G on a plurality of frames in the base material laminate. Figure 6(a) shows an arrangement similar to the substrate laminate 456 shown in Figure 5. Figure 6(b) shows an example in which the longitudinal direction of the groove G on the rectangular frame is parallel to the TD direction of the long carrier film. Figure 6(c) shows an example in which the longitudinal direction of the groove G on the rectangular frame and the TD direction of the long carrier film are inclined at a predetermined angle.

In the case of an optical laminated body used as a display panel of a flexible flat panel display (FPD), the glass film is required to be rounded or curved. When the direction in which the glass film is rounded or bent (i.e., the circumferential direction of the circumferential surface formed when the glass film is rounded or bent) is set as the first direction, the first direction and the MD direction are parallel (the first direction is parallel to the MD direction). The arrangement direction of the grooves G on the frame in the long laminated body may be determined so that the direction and the TD direction are perpendicular.

(4th process)

The second step may further include a fourth step of laminating a second base film as needed. When the second base film is not provided, or when the laminated body containing the glass member and the second base film is laminated in the second process, there is no need to specifically provide this process. However, this is not limited to this case, and even when a laminate including a glass member and a second base film (more specifically, a partial layer of the second base film) is laminated in the second process, in the fourth process, Furthermore, the second base film (more specifically, partial layers of the second base film) may be laminated to form the entire second base film into a multilayer film.

In the fourth process, a long second base film is usually laminated on the main surface of the glass member opposite to the first base film side via a second adhesive layer or a second adhesive layer. For lamination of the second base film, reference can be made to the explanation in the case of laminating the second base film on the glass member in the second process. In addition, in accordance with this case, some layers of the second base film can be further laminated on some layers of the second base film. When the layers constituting the second base film are laminated without an adhesive layer or adhesive layer, multilayering is performed, for example, by applying a coating agent constituting the layer to the laminated layer and solidifying it.

(5th process)

For example, when forming a surface coating layer on the surface of a glass member or a second base film in a long laminate, the surface coating layer may be formed in the fifth step. For the surface coat layer, reference may be made to the description of the surface coat layer formed on the surface of the glass member. The surface coat layer can be formed, for example, by applying a coating agent as a material to at least part of the surface of the glass member or the second base film and solidifying it.

The fifth step may be performed on the laminated glass member after the glass member is laminated on the substrate laminate in the second substep of the second step, or after the third step. Additionally, after laminating the second base film in the fourth process, the fifth process may be performed on the second base film. However, it is not limited to these cases. From the viewpoint of protection of the glass member or workability, etc., it is preferable to previously form a surface coat layer on the glass member in the fifth step before laminating the glass member to the base material laminate in the second step. In addition, when forming a surface coat layer on a second base film, from the viewpoint of workability, it is preferable to previously form a surface coat layer on the second base film through the fifth step before lamination in the fourth step.

<Step 3>

In the third step, the elongated laminate obtained in the second step is further processed. More specifically, the long laminate is processed to form a plurality of laminates with glass members each containing a plurality of individual glass members.

The third step includes, for example, a sixth step of peeling off the carrier film, a seventh step of dividing the glass member, an eighth step of dividing the second base film, etc., depending on the configuration of the long laminate. If necessary, the ninth step of forming a surface coat layer on the surface of the glass member or the second base film may be performed.

Before separating the glass members into individual pieces in the seventh step, a tenth step of forming a base sheet including a portion of grooves on a plurality of frames may be performed.

(6th process)

In the sixth step, the carrier film and the first adhesive layer are removed from the long laminated body. From the viewpoint of reducing the risk of damage to the individualized glass ends, the sixth process is preferably performed before the seventh process. The sixth step and the eighth step may be performed either first. For example, the sixth step may be followed by the eighth step, and the eighth step may be followed by the seventh step.

When the long laminated body is wound into a roll, the sixth step may include, for example, unwinding the long laminated body wound into a roll by an unwinding unit.

The carrier film removed in the sixth step may be wound into a roll by a winding unit together with the first adhesive layer.

(7th process)

In the seventh step, a laser beam is beamed from the glass member side or the first base film side to the area corresponding to the groove of the long laminate (more specifically, the laminate obtained by removing the carrier film and the first adhesive layer from the long laminate). irradiated to divide the glass member. By irradiating the glass member with laser light, the glass member is divided (or cut) into a shape surrounded by a frame along the groove. When the long laminated body does not contain a second base film, the glass member can be cut by irradiating a laser beam from the glass member side, as shown in FIGS. 3A to 3D. Since the glass member can be cut by irradiating the laser beam to the area corresponding to the groove of the long laminated body, damage to the first base film by the laser beam is suppressed. Furthermore, as shown in FIGS. 3A to 3D, even if the first adhesive layer is formed by invading the groove, a gap is formed in the groove, so even if the first adhesive layer exists in the optical path of the laser beam, the glass is not formed. When cutting a member, it can be easily removed. Therefore, a laminate including the separated glass member and the first base film can be easily formed with a clean cut surface. In addition, even when the elongated laminate does not include the second base film, the carrier film and the first adhesive layer are first removed in the sixth step, and laser light is irradiated from the first base film side to the area corresponding to the groove. , the glass member can be divided. In this case, more specifically, the laser light passes through the groove and is irradiated to the glass member. In addition, in this specification, the laminated body after removing the carrier film and the first adhesive layer from the long laminated body may also be referred to as a long laminated body for convenience.

When the elongated laminate includes a second base film, for example, after removing the carrier film and the first adhesive layer in the sixth step, preferably the eighth step is performed, and then in the seventh step from the first base film side. By irradiating laser light to the area corresponding to the groove, the glass member can be divided. In this case, in the seventh step, the laser light passes through the groove and is irradiated to the glass member. An example of this case is shown in Fig. 3E. In the present disclosure, even if the first adhesive layer is formed in the groove as shown in FIG. 3E, since there are many voids in the groove and the thickness of the first adhesive layer is small, it is easily removed by the irradiated laser light, forming the glass member. It can be cut cleanly.

Even when a long laminate includes a second base film and a second adhesive layer, when the second base film and the second adhesive layer are removed, after performing the substep of removing the second base film and the second adhesive layer. 3A to 3D, the glass member may be cut by irradiating laser light from the glass member side to the area corresponding to the groove.

After irradiating the laser light from the glass member side, if the first adhesive layer remains in the groove, the laser light may be irradiated through the groove from the first base film side, if necessary. As a result, the first adhesive layer remaining in the groove can be removed and the first base film can be divided again.

In the seventh step, the type of laser light is not particularly limited, and depending on the medium of laser light oscillation, for example, a semiconductor laser, gas laser (CO ₂ laser, etc.), solid-state laser (YAG laser, ultraviolet laser), etc. It's okay too. The irradiation conditions of the laser light are determined, for example, depending on the thickness and composition of the glass member and the first adhesive layer.

(8th process)

When a long laminate includes a second base film, suitable irradiation conditions are often different for the second base film and the glass member, so the second base film has a glass member side (more specifically, as shown in FIG. 3E). It is preferable to irradiate a laser beam from the second base film side) to cut the second base film and the second adhesive layer or the second adhesive layer. Additionally, since the second adhesive layer can be removed without irradiating laser light, when removing the second base film and the second adhesive layer, the second base film may be removed by irradiating only the second base film with laser light.

In the eighth process, the type of laser light is not particularly limited, and includes the laser used in the seventh process. The irradiation conditions of the laser light are determined, for example, depending on the thickness and composition of the second base film, the second adhesive layer or the second adhesive layer, the layer structure of the second base film, etc.

When it is necessary to perform both the seventh and eighth steps, the other step may be performed after performing one step, or both steps may be performed in parallel, but the eighth step may be performed before the seventh step. It is desirable. When the 8th process is performed before the 7th process, the 6th process may be performed before or after the 8th process, but is preferably performed before the 7th and 8th processes.

When the long laminated body is wound into a roll before laser irradiation, the eighth step may include unwinding the long laminated body wound into a roll by, for example, an unwinding unit.

(9th process)

The surface coat layer may be formed in the fifth step in the manufacturing process of the elongated laminate in the second step, or may be formed in the ninth step in the third step. When forming the surface coat layer in the third step, from the viewpoint of workability, it is preferable that the ninth step is performed after the sixth step and before the seventh and eighth steps. Additionally, after the seventh and eighth processes, a surface coat layer may be formed on the surface of the separated glass member or the second base film in the ninth process, if necessary. For formation of the surface coat layer, reference may be made to the description of the fifth step.

(Process 10)

The tenth process is performed before the glass member is separated into pieces (that is, before the seventh process). When performing the 8th process, the 10th process may be performed before the 8th process. The tenth process may be performed before the sixth process or after the sixth process.

In the tenth step, the long laminate is cut outside the grooves on the frame of the long laminate, and a base sheet including a portion of a plurality of grooves on the frame is formed. Before or after the 10th process, after performing the 6th process, a base sheet (more specifically, a base sheet from which the carrier film and the first adhesive layer have been removed) is supplied to the 7th process, and a glass member is supplied in the 7th process. is reorganized. The 7th process and the 8th process may be performed in parallel using a base sheet, but from the viewpoint of reducing damage to the glass member, the base sheet is supplied before the 8th process and supplied to the 7th process after the 8th process. It is desirable. When performing the 9th process, for example, the 9th process is performed on the base sheet from which the carrier film and the first adhesive member layer have been removed, before the 8th process and the 7th process, or the 9th process is performed after the glass member is divided. It is preferable to perform the ninth process on the converted laminate.

Figure 7 is an explanatory diagram showing an example of a series of processes in which a laminated body is separated into individual pieces from a long laminated body. In the illustrated example, first, the base sheet 10E including a plurality of frame-shaped grooves is cut out from the long laminated body 10C. Before or after this cutting, the carrier film and the first adhesive layer are removed by the sixth process. Then, using the base sheet from which the carrier film and the first adhesive layer have been removed, the glass member 200 is divided in the seventh step, and the divided laminate 10 with the glass member is obtained.

More specifically, the base sheet 10E is formed by cutting the long laminated body 10C along the cutting line LB that passes outside the groove G on the frame of the long laminated body 10C. In the illustrated example, the cutting line LB is set at a portion that does not cross the groove G on the frame from one end to the other end in the width direction of the long stacked body 10C (FIG. 7(a)).

And, the long laminated body 10C includes a first base film 100 that is cut along the cutting line LB and has a glass member 200 and a plurality of frame-shaped grooves G (nine in the illustrated example) formed therein; A base sheet 10E including the first adhesive layer 300 interposed between them is formed (FIG. 7(b)). The length of the base sheet 10E is arbitrarily selected in consideration of ease of handling.

Then, in the sixth step, the carrier film and the first adhesive are removed from the base sheet 10E. By irradiating laser light to the area corresponding to the groove G of the obtained base sheet in the seventh step, the glass member 200 is cut at the cutting line LA along the frame shape of the groove G. As a result, the laminate 10 with glass members separated into pieces from the base sheet is obtained (FIG. 7(c)).

FIG. 8 is a schematic cross-sectional view of the separated laminate 10 with glass members in FIG. 7(c) cut along the line VIII-VIII, as seen from the direction of the arrow. Since the laminate 10 is obtained by dividing the glass member 200 in a state in which the groove G is previously formed in the first base film 100, the cross section of the glass member 200 has the divided first It is in a state that extends outward from the cross section of the base film 100.

Fig. 9 shows an example of a process chart for forming a laminate with glass members separated into individual pieces from a long laminate. Figure 10 is another example of a process chart for forming a laminate with glass members separated into pieces from a long laminate.

In Fig. 9, for example, in the sixth step, the carrier film and the first adhesive layer are removed from the elongated laminate unwound from the unwinding unit (S6). Next, in the seventh step, laser light is irradiated from the glass member side to the area corresponding to the groove of the long laminate from which the carrier film and the first adhesive layer were removed, and the glass member is broken into pieces (S7). Subsequently, by this, a laminate with a glass member separated into individual pieces is obtained.

In Fig. 10, for example, in the sixth step, the carrier film and the first adhesive layer are removed from the long laminate including the second base film unwound from the unwinding unit (S6). Next, in the eighth step, laser light is irradiated from the glass member side (more specifically, the second base film side) to the area corresponding to the groove in the long laminate from which the carrier film and the first adhesive layer have been removed. , the second base film is cut (S8). At this time, the second adhesive layer or the second adhesive layer may be cut with a laser beam along with the second base film. After the eighth step, in the seventh step, laser light is irradiated from the first base film side through the groove to the glass member in the area corresponding to the groove of the long laminate from which the carrier film and the first adhesive layer were removed, The glass member is cut (S7). In this way, a laminate with individual glass members is obtained.

Although the present invention has been described in terms of presently preferred embodiments, such disclosure should not be construed as limiting. Various modifications and variations will no doubt become apparent to those skilled in the art upon reading the above disclosure. Accordingly, the appended claims should be construed to include all modifications and changes without departing from the true spirit and scope of the present invention.

The present disclosure can contribute to improving the performance and productivity of optical laminates used in, for example, display panels of flat panel displays (FPD).

10: Reorganized glass member attached laminate
10C: Long laminate
10E: Base plate sheet
100, 1100: first base film
110: Polarizing film
120: Separator
130: Adhesive layer
200: glass film
300: first adhesive layer
L: Laser light
300a: first adhesive
456: Substrate laminate
400: Carrier film
500: first adhesive layer
600: second base film
700: second adhesive layer
800: Second adhesive layer
G: Home
1, 4: Unwinding part
2: Half cut device
3a, 3b: Nip roller
5: winding part
S: slit

Claims (9)

a long first base film including a first main surface and a second main surface opposite to the first main surface;
A glass member laminated on the first main surface side of the first base film,
a long carrier film laminated on the second main surface side of the first base film;
a first adhesive layer interposed between the first base film and the glass member;
It includes a first adhesive layer interposed between the first base film and the carrier film,
A plurality of frame-shaped grooves are formed in the first base film, penetrating the first base film in the thickness direction,
A long laminate in which a gap is formed in the groove. According to paragraph 1,
The first adhesive layer is formed in a portion of the groove,
A long laminate wherein the minimum thickness of the first adhesive layer formed in a portion of the groove is 0 μm or more and 3 μm or less. According to claim 1 or 2,
A long laminate in which at least a part of the cross section of the first base film is covered with the first adhesive layer in the groove. According to any one of claims 1 to 3,
A long laminate wherein the width of the groove is 5 mm or more. According to any one of claims 1 to 4,
A long laminate wherein the adhesive force between the first adhesive layer and the first base film and the adhesive force between the first adhesive layer and the glass member are both 0.1 N/mm or more. According to any one of claims 1 to 5,
The first adhesive forming the first adhesive layer is an ultraviolet curing type, a long laminate. According to any one of claims 1 to 6,
A long laminate wherein the viscosity at 25°C of the first adhesive forming the first adhesive layer is 0.1 mPa·s or more and 100 mPa·s or less. According to any one of claims 1 to 7,
A long laminate wherein the thickness of the first adhesive layer interposed between the portion of the first base film excluding the groove and the glass member is 0.5 μm or more and 5 μm or less. According to any one of claims 1 to 8,
a long second base film laminated on a main surface of the glass member opposite to the first base film side;
A long laminate further comprising a second adhesive layer or a second adhesive layer interposed between the second base film and the glass member.