SK50162010A3 - Method for producing optical display panels - Google Patents

Abstract

A process for producing an optical display panel by laminating an optical laminated sheet to an optical display element without fouling or marring the optical laminated sheet. A process for producing an optical laminated sheet is also provided which comprises: a step in which continuous optical sheets (1 and 3; and 11 and 13) are drawn out respectively of rolls (2 and 4; and 12 and 14); a first laminating step in which the optical sheets drawn are laminated to form a continuous optical laminated sheet; a second laminating step in which the optical laminated sheet is laminated as it is to an optical display element (7); and a cutting step in which the optical laminated sheet is cut. In the cutting step, the optical laminated sheet is cut into a size having an area which is larger than that of the display region of the optical display element and is smaller than that of the optical display element itself. The second laminating step may follow the cutting step.

Description

The invention relates to a method of manufacturing optical display panels.

BACKGROUND OF THE INVENTION

Continuous optical films with optical functions or optical strips as their laminates, such as polarizing plates for use in liquid crystal display mechanisms, have so far been continuously produced, being wound on rollers for optical element manufacturers.

For example, the polarizing plates thus produced are supplied by the panel manufacturers and are superimposed on liquid crystal display mechanisms (a liquid crystal display mechanism comprising two glass plates and a liquid crystal interposed therebetween, also called a liquid crystal cell).

In this way, liquid crystal panels are produced for use in liquid crystal display mechanisms.

Typically, continuous optical strips are cut into optical strips having the desired size by the manufacturer, a plurality of such optical strips being stacked and packaged by the optical element manufacturer when the optical elements, such as the above polarizing plates, are supplied by the panel manufacturers.

In addition, a clean working environment is required for optical element manufacturers to avoid dust or contamination of several optical elements of predetermined sizes during storage and packaging.

In addition, the packaging materials are carefully selected to avoid damage or cracking of the optical bands during transportation, while also carefully wrapping the optical bands.

On the other hand, it is very difficult for a panel manufacturer using such tightly packed optical strips for assembly purposes to carefully unpack the rigid packages of optical strips so as not to damage the optical strips, which is very problematic for the operator.

In order to solve the above problems, a method of direct layering of continuous optical strips to an optical display mechanism (see JP-A-1195028) and a method of cutting continuous optical strips and layering slit optical strips into an optical display mechanism on a continuous production line (see JP-A) -2007140 046).

JP-A-2002-196 132 discloses a method of manufacturing a polarizing plate, the method comprising the steps of superimposing the polarizing film and the first protective film together and winding the resulting laminate, and superimposing the second protective film on the surface of the polarizing film without any protective film.

There is another problem with large screen imaging mechanisms for televisions (for example, liquid crystal displays), that is, it is necessary to use optical bands with optical functions depending on the dimensions of the optical imaging mechanisms, since the sizes of the TVs vary from approximately 20 to 100 inches. .

For example, the polarizing plate typically comprises a polarizing film and a protective film layered on both sides of the polarizing film, wherein the pressure-sensitive adhesive layer is formed on the outer face of one of the protective films.

In a number of cases, such protective films have optical functions, for example a protective film placed on the visible side of the optical display can be treated on its surface (e.g., hard coating, anti-glare, anti-reflective, anti-pollution, anti-static or similarly), wherein the protective film for positioning between the polarizing plate and the optical display mechanism may be provided with a phase retardation function to adjust the visible angle, contrast and shade of the optical display.

color

The polarizing film is prone to rupture in the direction of its stretching, and therefore, generally, the protective film is laminated to the polarizing film immediately after its manufacture. In this way, a polarizing plate is formed.

In this case, in view of the production efficiency of the roll width for continuous optical strips for use in the polarizing plate, they have to be fixed to some extent.

When the roll widths are fixed, the continuous optical strips must be cut depending on a variety of different sizes of optical displays to produce polarizing plates.

As a result, in some cases, portions of the optical strips are larger, so that the ratio of optical strips for use in commercial products is greatly reduced.

The present invention has been developed to solve the above problems by providing a method for manufacturing optical display panels using optical films that are much cleaner and have less errors than known optical films.

It is a further object of the present invention to provide a method of manufacturing optical display panels with improved efficiency for utilizing optical films or optical strips in the form of laminates.

SUMMARY OF THE INVENTION

The present invention provides a method of manufacturing an optical display panel by laminating an optical web laminate with optical functions onto an optical display mechanism, the method comprising an extraction step for pulling continuous optical webs with optical functions or continuous optical strips as their laminates from a plurality of rollers. films or continuous optical strips wound, a first layering step of laminating the drawn continuous optical films or continuous optical strips together to obtain continuous optical film laminates, a second layering step of direct layering the continuous optical film laminates to the optical display mechanism, and a cutting step of cutting the optical film laminate from continuous optical web laminates to continuous optical web laminate and optical imaging laminate e. of a mechanism along an area that is not smaller than the display areas of the optical display panel, and no larger than the total area of the optical display panel (this method will hereinafter be referred to as the "first manufacturing method").

The present invention also provides a method of manufacturing an optical display panel by laminating optical web laminates with optical functions onto an optical display mechanism, the method comprising the pulling step of pulling continuous optical webs with optical functions or continuous optical strips as their laminates from a plurality of rollers. optical films or continuous optical strips wound, a first layering step of laminating the drawn continuous optical films or continuous optical strips together to obtain continuous optical ribbon laminates, a cutting step of cutting the optical ribbon from the continuous optical ribbon laminates, and laminates a second layering step of direct optical film lamination laminates for an optical display mechanism (this method will hereinafter be referred to as the "second manufacturing method").

In the case of the present invention, the above-mentioned "optical film" is essentially a single resin film having an optical function, and "optical film" is essentially a laminate of a plurality of optical films of different types, although there is no limiting difference in general terms between film and tape.

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For example, a base film having an optical layer formed thereon by coating or surface treatment is considered to be a single strip and is therefore in principle classified as an "optical film".

As described below, a resin film having a polarizing function (e.g., a polyvinyl alcohol resin film having a dichroic pigment that is adsorbed and oriented herein) is referred to as a "polarizing film, and a polarizing film having an additional optical film laminated thereon. as a protective film on at least one side is called a "polarizing plate".

The "polarizing film" is one type of "optical film", with the "polarizing plate" being one type of "optical strip".

In the first manufacturing method or the second manufacturing method of the present invention described above (hereinafter referred to collectively as the "manufacturing method of the present invention"), one of the continuous optical films or continuous optical strips for exposing the drawing step preferably comprises a polarizing film comprising a film of polyvinyl alcohol resin.

In the production method of the present invention, one of the continuous optical strips for exposing the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film and a protective film formed of a thermoplastic resin and superimposed on at least one surface of the polarizing film.

In the production method of the present invention, one of the continuous optical strips for exposing the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a pressure-sensitive adhesive layer formed on at least one face of the polarizing film, and a release film for protection a pressure-sensitive adhesive layer, wherein in the first or second lamination step, the release film is peeled off, and the exposed pressure-sensitive layer is laminated to another optical film or optical film or optical display mechanism.

foil formed on one surface

In the production method of the present invention, one of the continuous optical strips for subjecting to the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a thermoplastic resin protective layer and a layered polarizing film a pressure-sensitive adhesive layer formed on the other surface of the polarizing and a release film for protecting the pressure-sensitive adhesive layer, wherein in the first or second lamination step, the release film is peeled off and the exposed pressure-sensitive adhesive layer is laminated to a second optical film or optical web or optical display mechanism.

In addition, in the production method of the present invention, one of the continuous optical strips to be subjected to the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a thermoplastic resin protective film and a layered polarizing film an adhesive layer formed on the outer face of the protective film and a release film to protect the pressure-sensitive adhesive layer. Also in this case, in the first or second laminating step, the release film is peeled off and the exposed pressure-sensitive adhesive layer is laminated to the second optical film or the second optical web or optical display mechanism.

In the production method according to the invention, preferably one of the continuous optical films or continuous optical strips for subjecting to the pulling step comprises at least one film selected from the following films:

(a) a cyclooiephine resin sheet, (b) a cellulose ester resin sheet, (c) a polyethylene terephthalate resin sheet, (d) a (meth) acrylic resin sheet, and (e) a polypropylene resin sheet.

In the production method of the present invention, the use of an ultraviolet-curable adhesive is one of the preferred methods for laminating a continuous optical film or strip or another continuous optical film or strip in a first laminating step.

One typical example of a display panel produced by the method of manufacture of the present invention is a liquid crystal panel.

In this case, the optical display mechanism is a liquid crystal display mechanism.

When the optical display mechanism is a liquid crystal display mechanism, generally the films laminated to the surface and the back (i.e., the visible side and the back side) of the liquid crystal display mechanism are different from each other.

However, there is an advantage that some of the films, such as polarizing films, can be used together between the surface and the back of the liquid crystal display mechanism.

In particular, the polarizing plate on the visible side of the liquid crystal display mechanism is subjected to a surface treatment such as anti-glare treatment or anti-reflection treatment, and the polarizing plate on the back may have a specific function, such as light scattering or lighting enhancement.

Until now, optical films or optical strips meeting such requirements are laminated by the optical element manufacturer prior to delivery by the panel manufacturers.

However, a different approach is also possible. That is, polarizing films of the same type are used for polarizing plates and superimposed on the surface and back surface of the liquid-crystal display mechanism, wherein the different optical films or optical strips required on the surface and back surface of the liquid-crystal display mechanism are respectively superimposed for polarizing films, and the respective laminates are laminated to the surface and back surfaces of the liquid crystal display mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be explained in more detail by way of examples of specific embodiments thereof, the description of which will be given with reference to the accompanying drawings, in which:

Fig. 1 schematically illustrates preferred exemplary

carrying out the first method production from ways manufacturing optical display panels according to this invention. Fig. 2 consists of FIG. 2 (a .) and FIG. 2 (b), whereby Fig. 2 (a) shows schematic view in section

for the continuous optical strip 1, pulled from the roll 2 shown in FIG. 1, and FIG. 2 (b) shows a schematic cross-sectional view of a continuous optical strip 3 withdrawn from the roll 4.

Fig. 3 schematically illustrates another preferred exemplary embodiment of the first manufacturing method of the present invention.

Fig. 4 schematically illustrates another preferred exemplary embodiment of the first manufacturing method of the present invention.

Fig. 5 schematically illustrates the first half of a preferred exemplary embodiment of the second manufacturing method of the optical display panel manufacturing methods of the present invention.

Fig. 6 schematically illustrates the second half of a preferred exemplary embodiment of the second manufacturing method of the optical display panel manufacturing methods of the present invention.

Fig. 7 illustrates a perspective and schematic view of an operation of laminating an optical tape laminate to one face of an optical display mechanism, reversing the optical display mechanism from top to bottom, while rotating the conveying direction by 90 °, and layering another optical tape laminate on the other face of the optical display mechanism.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides a method of manufacturing an optical display panel by laminating optical ribbon laminates with optical functions onto an optical display mechanism, the method being roughly divided into a first manufacturing method and a second manufacturing method.

Examples of an optical display panel that is manufactured according to the present invention include a liquid crystal panel, an organic EL panel, etc., wherein such an optical display panel is used to produce an optical display, such as a liquid crystal display, an organic EL display, or the like.

In the following, the manufacture of a liquid crystal panel will be described as a preferred example of an optical display panel, although the optical display panels that can be manufactured according to the present invention are not limited to this example.

Fig. 1 schematically shows a preferred example of a first manufacturing method of all the methods of manufacturing panels according to the invention.

The first manufacturing method according to the invention comprises a drawing step in which at least two continuous optical films with optical functions or continuous optical strips superimposed thereon from a plurality of rollers on which the continuous optical films or continuous optical strips are wound, the first laminating step for laminating a plurality of continuous optical films or continuous optical strips that have been pulled together to obtain a continuous optical film laminate, a second laminating step for laminating the continuous optical film laminate as on the optical display mechanism, and a cutting step for cutting the optical film laminate from a continuous optical web laminate in a continuous optical web laminate laminate and an optical display mechanism along an area that is not less than the display area of the resulting optical display panel 1 and not greater than the total area of the optical display panel.

The first manufacturing method of the present invention will now be explained with reference to FIG. First

In the extraction step as shown in FIG. 1, first the continuous optical strips 1 and 11 as laminates, each consisting of at least two continuous optical films with optical functions, are respectively drawn from rollers 2 and 12, on which the continuous optical strips 1 and 11 are wound, the other continuous the optical strips (3 and 13 as laminates, each consisting of continuous optical films with optical functions) are drawn respectively from rollers 4 and 14.

Fig. 2 (a) shows the continuous optical band shown in FIG. First

a schematic sectional view 1 taken out of the cylinder 2,

Fig. 2 (b) shows a schematic cross-sectional view of a continuous optical strip withdrawn from the roll 4.

There is no particular limitation on the choice of continuous optical films or continuous optical strips as laminates for use in the present invention.

For example, as continuous optical optical continuous films or strips for use in forming a continuous optical film laminate to be laminated to one surface of the optical display mechanism 7, the continuous optical and continuous optical web 2 of the continuous optical web 1 of FIG. 2 (a) of FIG. 2 (b), having a laminate structure of a polarizing film 8, a protective film 9 and a pressure-sensitive adhesive layer 10, and a continuous optical web 2 having a laminate structure of a surface-treated film 17 and a pressure-sensitive adhesive layer 18.

As a continuous optical film or continuous optical strips for use in forming a continuous optical film laminate to be laminated to a second surface of the optical display mechanism, for example, a continuous optical film 11 having a laminated polarizing film, protective film and pressure-sensitive adhesive layer is the layered structure of FIG. 2 (a), and a continuous optical web 13 having a laminated protective film structure and a pressure-sensitive adhesive layer.

In the following first laminating step, the continuous optical film 1 and the continuous optical film 3, as outlined above, are superimposed on each other, and the continuous optical film 11 and the continuous optical film 13, outlined above, are superimposed on each other on itself to obtain respective continuous optical web laminates.

As can be seen in FIG. 1, the first laminating rollers 5 are used to laminate the continuous optical belt 1 to the continuous optical belt 3 under pressure, the other first laminating rolls 15 are used to laminate the continuous optical belt 11 to the continuous optical belt 13 under pressure.

When using continuous optical strips with the structure of FIG. 2, the pressure-sensitive adhesive layer 18 of the continuous optical web 3 is positioned against the polarizing film 8 of the continuous optical web 1, and both continuous optical webs are subjected to a first laminating step to obtain a continuous optical web laminate in which the surface treated film 17 is pressurized. the sensitive adhesive layer 18, the polarizing film 8, the protective film 10, and the pressure-sensitive adhesive layer 10 are superimposed in this order.

Conversely, the pressure-sensitive adhesive layer of the continuous optical web 13 is positioned against the polarizing film of the continuous optical web 11, both continuous optical webs being subjected to a first laminating step to obtain a continuous optical web laminate in which the protective film, the pressure sensitive adhesive layer, the polarizing film , the protective film and the pressure-sensitive adhesive layer are laminated in this order.

Further, in a second laminating step, the continuous optical web laminate of the continuous optical strips 1 and 3 and the continuous optical web laminate of the continuous optical strips 11 and 13 are laminated respectively to the optical display mechanism 7.

As shown in FIG. 1, the second laminating roll 6 is used to laminate the continuous optical web laminate from the continuous optical strips 1 and 3 to one side of the optical display mechanism under pressure, and the other second laminating roll 16 is used to laminate the continuous optical web laminate from the continuous optical strips 11 and 13 to the other side of the optical display mechanism 11P ^{from the} pressure.

If continuous optical strips having the structure of FIG. 2, the continuous optical web laminate for lamination to one side of the optical display mechanism 7 has a layered structure in the surface-treated film 17, a pressure-sensitive adhesive layer 18, a polarizing film 8, a protective film 8 and a pressure-sensitive adhesive layer 10, side pressure-sensitive adhesive layer 10 of the continuous optical sheet laminate is positioned against the optical imaging device 2 ^and j ^e superimposed on them.

Similarly, the continuous optical sheet laminate the layered on the other side of the optical display mechanism, ^{characterized} plated layer structure in the order of the protective film, the pressure-sensitive adhesive layer, a polarizing plate, protective film and the pressure-sensitive adhesive layer, wherein the side of the outer pressure-sensitive adhesive layer of the of the continuous optical web laminate is positioned against and superimposed on the optical display mechanism 7.

Although not shown in the figure, a release liner is generally laminated to a surface such as a pressure sensitive adhesive layer to protect the surface of a pressure sensitive adhesive layer, such as a continuous optical web laminated to another material in the following case: in the case where the continuous optical films or continuous optical strips to be subjected to the first laminating step have pressure sensitive adhesive layers for lamination for the further continuous optical films or strips in the first laminating step, or have pressure sensitive adhesive layers for the optical lamination the imaging mechanism 2 ^{in the} second lamination step, for example, in the case where the continuous optical strip 1 of FIG. 2 (a) has a pressure-sensitive adhesive layer 10, or a continuous optical strip 3 of FIG. 2 (b) has a pressure-sensitive adhesive layer 18.

The release film is obtained by coating a surface of a transparent resin film, such as polyethylene terephthalate film, with a release agent containing a silicone resin.

This release film is peeled prior to laminating the continuous optical web onto another material.

A special example of a release film peeling method will be described below with reference to FIG. 6th

In the first manufacturing method of the present invention, in a subsequent cutting step, the optical ribbon laminate is cut from the continuous optical ribbon laminate, laminating the continuous optical ribbon laminate and the optical display mechanism 2 'obtained in the second laminating step, along an area not less than the display area of the resulting optical display panel, and not greater than the total area of the resulting optical display panel, to obtain the optical display panel as the final product (not shown).

In the first manufacturing method of the present invention, the types and number of continuous optical films, stacked structures, and number of rollers for withdrawing continuous optical films or strips are in no way limited to the details shown in FIG. First

Another example of a first manufacturing method according to the invention is schematically shown in FIG. Third

Fig. 3 is similar to FIG. 1, but with some differences, wherein the same reference numerals are used to designate the same components as in FIG. 1, for the purpose of saving in describing them.

As can be seen in FIG. 3, the continuous optical web is withdrawn from the roll 4 in the same manner as in FIG. 1, the continuous optical film 21 is pulled out of the roller 22, another continuous optical film 23 is pulled out of the roller 24, and another continuous optical film 25 is pulled out of the roller 26.

In this case, for example, a polarizing film (e.g., a polarizing film from which a release film having pressure-sensitive pressure-sensitive adhesive properties has been peeled as described below) is utilized as a continuous optical film 21, an adhesive layer laminate formed from ultraviolet-curable resin adhesive; and the protective film is used as a continuous optical film 23, and the pressure-sensitive film is used as a continuous optical film 25.

In the example of FIG. 3, in the first laminating step, the continuous optical film 25 drawn from the roll 26 and the continuous optical film 23, first laminated with each other by the first of the layering rolls 27 drawn from the roll 24 are pressurized together, the laminate and the continuous optical film 21 from the roll 22, are laminated to each other under pressure by means of the first first layering rollers 28, and the laminate and the continuous optical strip 3 withdrawn from the roll 4 are further superimposed on each other under pressure by the other first layering rollers 5.

A continuous optical web laminate is thus obtained.

In this case, the continuous optical web laminate is, for example, a laminate of a surface-treated film, a pressure-sensitive adhesive layer, a polarizing film, an adhesive layer, a protective film, and a pressure-sensitive film respectively, the pressure-sensitive film side facing the optical display mechanism. 7 and is then superimposed on one side of the optical display mechanism 6 in a second laminating step.

In the example of FIG. 3 is the same as in FIG. 1, a continuous optical belt 13 withdrawn from the roll 14,

The continuous optical film 31 is pulled out of the roll 32 and another continuous optical film 33 is pulled out of the roll 34.

In this case, for example, a polarizing film (e.g., a polarizing film from which a release film having peel-off pressure-sensitive adhesive properties, as described below) has been peeled, is used as a continuous optical film 31, and the pressure-sensitive film is used as another continuous optical film. 33rd

As can be seen in FIG. 3, and in the first lamination step, the continuous optical film 33 pulled out of the roll 34, and the continuous optical film 33 pulled out of the roll 32 are first laminated to each other under pressure by the first laminating rolls 35, and the laminate and the continuous optical belt. 13, drawn from the cylinder 14, are superimposed on each other under pressure by means of further first cylinders 15.

A continuous optical web laminate is thus obtained.

In this case, the continuous optical web laminate is, for example, a laminate of a protective film, a pressure-sensitive adhesive layer, a polarizing film and a pressure-sensitive film respectively, the side of the adhesive layer of the laminate facing the optical display mechanism V. a. then is superimposed on the other side of the optical display mechanism 2 ^{in a} second laminating step.

Another preferred example of the first manufacturing method of the present invention is schematically shown in FIG. 4th

Fig. 4 is similar to FIG. 1 and FIG. 3, but with some differences, wherein the same reference numerals are used to designate the same components as in FIG. 1 and FIG. 3, for the purpose of saving in describing them.

In the example of FIG. 4 is a continuous optical web laminate for lamination to one side (the upper side of the optical display mechanism is obtained in the same manner as in FIG. 3).

However, the continuous optical web laminate to be laminated to the other side (underside) of the optical display mechanism 11 is obtained in a different manner by further utilizing another continuous optical web 41 pulled from the roll 42.

In this case, for example, a laminate of an adhesive layer consisting of an ultraviolet ray curable resin adhesive and a protective film is used as a continuous optical web 41.

In the example of FIG. 4, the continuous optical film 33 pulled out of the roll 34, and the continuous optical strip 41 pulled out of the roll 42 are first laminated to each other under pressure by the first of the laminating rolls 43, the laminate and the continuous optical strip 31 pulled out of the roll 32; are laminated to each other under pressure by means of the first first laminating rollers 35, and the laminate and the continuous optical web 13 pulled from the roll 14 are laminated to each other under pressure by the first laminating rollers 15.

A continuous optical web laminate is thus obtained.

In this case, the continuous optical web laminate is, for example, a laminate of a protective film, an adhesive layer, a polarizing film, an adhesive layer, a protective film and a pressure-sensitive film respectively, the pressure-sensitive film laminate side facing the optical display mechanism 7. then superimposed on the other side of the optical display mechanism 7 in a second laminating step.

Although not shown in the figure, generally the areas of these pressure-sensitive adhesive layers or pressure-sensitive films are laminated with the same release films as described above in order to protect the areas of the adhesive layers or films, such as continuous optical films or strips laminated to other materials in the following case: that is, when the continuous optical films or continuous optical strips to be subjected to the first laminating step have pressure sensitive adhesive layers for laminating to the further continuous optical films or strips in the first laminating step, or having pressure-sensitive adhesive layers for lamination to the optical display mechanism in the second laminating step, or when the self-pressure-sensitive film forms a single continuous optical film.

For example, layers equivalent to the above-described pressure-sensitive adhesive layers or pressure-sensitive films are formed by a pressure-sensitive adhesive layer formed in the form of a continuous optical web 3 to allow the web to be superimposed on the continuous optical film 21 (polarizing film). a layer formed in the form of a continuous optical web 13 to allow the web to be superimposed on the continuous optical film 31 (polarizing film), and pressure sensitive films that are formed as the continuous optical film 25 and 33 of FIG. 3 and FIG. 4th

The release films arranged on the surfaces of the pressure-sensitive adhesive layers or the pressure-sensitive films are peeled off before the continuous optical web is laminated to another material.

A specific example of a method of peeling release films will be described below with reference to FIG. 6th

In this respect, a layer of UV-curable resin adhesive is usually applied immediately prior to the adhesive treatment.

A preferred example of the last half of the second manufacturing method of the optical display panel manufacturing methods of the present invention is schematically shown in FIG. 5th

A preferred example of the last half of the second production method is shown schematically in FIG. 6th

The second manufacturing method according to the present invention comprises the drawing step of drawing continuous optical films or optical optical strips in the form of laminates from a plurality of rollers on which the films or strips are wound, a first laminating step of laminating continuous optical films or continuous optical strips drawn as above, to each other to obtain a continuous optical web laminate, a cutting step of cutting the optical web laminate from the continuous optical web laminate, and a second laminating step of laminating the optical web laminate to the optical display mechanism.

Now, the second manufacturing method described with reference to FIG. 5 and FIG. 6th

The drawing step and the first layering step of the second manufacturing method of the present invention are similar to the drawing step and the first layering step of the first manufacturing method described above.

As shown in FIG. 5, the continuous optical web 1 pulled out of the roll 2 and the continuous optical web 3 pulled out of the roll 4 are laminated to each other under pressure by first laminating rollers 15 to obtain a continuous optical web laminate, and the web 11 pulled out of the roll.

and the continuous optical strip 13 pulled from the laminated under pressure simultaneously the continuous optical rollers 12, the rollers 14 are stacked on top of each other through the first first laminating rollers 15 to obtain a continuous optical band laminate, as in the example of FIG. First

Since the continuous optical films or continuous optical strips as their laminates are intended for use in the second manufacturing method of the present invention, the same continuous optical films or the same continuous optical strips as described for the first manufacturing method can be used.

In the second manufacturing process of the present invention, the continuous optical web laminates obtained in the first laminating step are cut in a subsequent cutting step to obtain the optical web laminates.

Fig. 5 shows an example of the steps for obtaining optical ribbon laminates: that is, the continuous optical laminate from the continuous optical strips 1 and 6 is cut by means of cutting means 53 to obtain the optical ribbon laminate 51, and the continuous optical laminate from the continuous optical strips 11 and 13 is cut off by means of cutting means 54 to obtain the optical web laminate 52.

In a second laminating step of the second manufacturing method, the optical ribbon laminates obtained in the cutting step are laminated on both sides of the optical display mechanism to obtain the optical display panel as the final product.

In FIG. 6 is the optical web laminate 51 obtained in the cutting step of FIG. 5, superimposed on one side of the optical display mechanism under pressure by means of the second layering roller 55, and at the same time, the optical web laminate 52 is superimposed on the other side of the optical display mechanism 7 under pressure by another second layering roller 56.

As described above, the pressure-sensitive adhesive layers are respectively formed on the surface of the optical web laminate to be laminated to the optical display mechanism 11 and the surface of the optical web laminate 52 to be laminated on the optical display mechanism a, and the surfaces of the adhesive layers are usually protected by release films.

In FIG. 6, it is shown that the optical web laminates 51 and 52 are laminated on both sides of the optical display mechanism 7 after peeling off release films from these optical web laminates.

In this example, the release film 59 is peeled off from the surface of the optical web laminate 51 to be laminated to the optical display mechanism f by the peel roller 57, and then a pressure-sensitive adhesive layer of the optical web laminate is laminated to one side of the optical display mechanism 2. under pressure by the second laminating roller 55, while at the same time the release film 60 is peeled off from the surface of the optical web laminate 52 to be superimposed on the optical display mechanism by the further peeling roller 58, and then a pressure sensitive adhesive layer of the optical web laminate superimposed on the other side of the optical display mechanism 7 under pressure by means of a second laminating roll 56.

The peel-off release films are wound on regeneration rollers 61 and 62 if desired.

The white arrow shown in FIG. 6, for the optical display mechanism, laminates 51 and 52.

indicates the direction of transport 7 and the optical track

Also, in the second manufacturing method of the present invention, the types and number of continuous optical films, laminates, and number of rollers for drawing continuous optical films or strips are not limited to the details shown in FIG. 5 and FIG. 6th

For each first manufacturing method and the second manufacturing method of the present invention, the respective steps are performed sequentially.

According to the first manufacturing method or the second manufacturing method, the optical films laminated to the optical display panel are much cleaner, the number of errors being reduced, since it is possible to save the laminating step, the cutting step and the packaging step for the films, and delivering (or transporting) such films. to the panel manufacturer, since all of these steps were carried out by the optical element manufacturer.

In addition, the yield of optical films or optical strips as their laminates is improved, as is the availability of products.

Although not shown in FIG. 1 and FIG. 3 to FIG. 5, the polarizing films in the optical sheet laminate superimposed on one side of the optical display mechanism and the polarizing films in the optical sheet laminate superimposed on the other side of the optical display mechanism must have a position relative to each other such that their light transmission axes are spaced from each other vertical.

For example, a polarizing plate lamination is used to achieve this relationship in the first manufacturing method or the second manufacturing method of the present invention, as shown in FIG. 6 of JP-A-2005-37417, for laminating a continuous optical web laminate (in the case of the first manufacturing method) or an optical web laminate (in the case of the second manufacturing method) on one side of the optical display mechanism that is fed and conveyed from the feed section in the first conveying area, then the continuous optical film laminate is cut off in the case of the first manufacturing method, then the optical display mechanism fed from the first conveying area is turned upside down at the turning point so that the end surface of the optical display mechanism in the conveying direction can be perpendicular to the conveying direction, and then the optical display mechanism is fed to a second conveying region, wherein the continuous optical ribbon laminate or optical ribbon laminate is laminated to the other side of the optical display mechanism that is conveyed in a direction perpendicular to the conveying direction you in the first transport area.

This procedure is shown schematically in FIG. 7th

Fig. 7 is a perspective and schematic representation of the process of FIG. 1, wherein the optical film laminate is laminated on one side of the optical display mechanism,

Then, the optical display mechanism is rotated from top to bottom while being rotated 90 ° in the transport direction, and another optical ribbon laminate is laminated to the other side of the optical display mechanism.

In FIG. 7 are components having the same configuration as those of FIG. 1, with the same reference numerals in order to save their detailed description.

As can be seen in FIG. 7, in the first conveying region 71, the optical display mechanism 7 is conveyed in one direction, and at the same time the continuous optical film laminate obtained in the first laminating step according to the present invention is laminated to one side (top side of the figure) of the optical display mechanism 7. in a second layering step.

Then, the resulting continuous optical web laminate is cut to size according to the size of the optical display mechanism 7 by cutting means 74 to obtain the optical web laminate, then the optical web laminate is laminated to one side of the optical display mechanism 7.

Subsequently, the optical display mechanism 7 is turned from top to bottom at the turning point 77 without rotation in the plane, and is then conveyed in the second transport area 72.

In this way, in the second conveying region 72, the side of the optical display mechanism 7 on which the optical web laminate is laminated, and its second side to which no optical web laminate is laminated, have the opposite relationship to that in the first transport region 71.

In this example, the optical sheet laminate is laminated to the top side of the optical display mechanism 7 in the first transport region 71, and the optical display mechanism is then turned upside down so that the same side having the optical sheet laminate thereon is seen as the underside of the optical display mechanism. 2 ^{in the} second transport area 72.

In the second transport region 72, the transport direction of the optical display mechanism 7 is rotated 90 ° in a plane relative to the transport direction in the first transport region 71.

That is, the end surface of the optical display mechanism 7 in the transport direction in the first transport region 71 is perpendicular to the transport direction in the second transport region 72 after inverting the optical display mechanism from top to bottom and transporting it to the second transport region 72.

In the second conveying area 72, a second second laminating step is performed, wherein the continuous optical web laminate obtained in the first laminating step of the present invention is laminated again to the other side of the optical display mechanism 7 (i.e. to its side to which there was no continuous optical a sheet laminate laminated in the first conveying region 71).

Thereafter, the thus obtained continuous optical film laminate is cut by size cutting means 75 according to the size of the optical display mechanism 2 'so that the optical film laminates are superimposed on both sides of the optical display mechanism 7.

As can be seen in FIG. 7, and in the first conveying region 71, the continuous optical strip 1 withdrawn from the roll 2, and the continuous optical strip 3 withdrawn from the roll 4 are laminated to each other under pressure by means of laminating rolls, the resulting continuous optical ribbon laminate being fed to one side. optical display mechanism 7.

Up to this point, the above-described step is the same as shown in connection with the top side of FIG. First

In the second conveying region 72, the continuous optical web 11 pulled out of the roll 12 and the continuous optical web 13 pulled out of the roll 14 are laminated to each other under pressure by other first laminating rolls 15, the resulting continuous optical web laminate being fed to a second side of the optical display mechanism].

Up to this point, the above-described step is the same as shown in connection with the underside of FIG. First

In the case where the optical display mechanism 7 is a liquid crystal display mechanism (or a liquid crystal cell), the optical ribbon laminates each containing a polarizing film are superimposed on both sides of the liquid crystal display mechanism, as in the example of Fig. 1, wherein each of the continuous optical bands 1 and 11 comprises a polarizing film.

In many cases, the polarizing films placed on the front and opposite surfaces of the liquid crystal display mechanism have such a relationship that their absorption axes are mutually perpendicular.

When the system of FIG. 7, the polarizing films disposed on both sides of the liquid crystal display mechanism may have such a relationship that their absorption axes are perpendicular to each other.

In FIG. 7 the white arrow indicates the directions of transport.

The above description with reference to FIG. 1a; FIG. 3 to FIG. 7 was performed when the optical display mechanism 2 is a liquid crystal display mechanism (or liquid crystal cell), wherein the optical ribbon laminates are laminated on both sides thereof.

However, for those skilled in the art will appreciate that when the optical imaging mechanism yj ^e EL display device and optical sheet laminate is superimposed on the one hand, it is the visible display of the imaging mechanism EL.

In the previous manufacturing process according to the invention, preferably the continuous optical films or the continuous optical strips drawn in the drawing step comprise polarizing films comprising respective films of polyvinyl alcohol resin.

The polyvinyl alcohol resin is obtained by saponification of the polyvinyl acetate resin.

As polyvinyl acetate resin there are given copolymers of vinyl acetate and other monomers copolymerizable with vinyl acetate, in addition to polyvinyl acetate as homopolymer of vinyl acetate.

Other monomers copolymerizable with vinyl acetate include, for example, unsaturated carboxylic acids, olefins such as ethylene and propylene, vinyl ethers, unsaturated sulfonic acids, acrylamides having ammonium groups, and the like.

The degree of saponification of the polyvinyl alcohol resin is usually from 85 to 100 mol%, preferably 98 mol% or more.

The polyvinyl alcohol resin can be modified so that it can be used, for example, as polyvinylformal, polyvinyl acetal and polyvinylbutylal, each modified with an aldehyde.

The degree of polymerization of the polyvinyl alcohol resin is usually from 1,000 to 10,000, preferably from 1,500 to 5,000.

A film formed of such a polyvinyl alcohol resin is used as a film of material for the polarizing film.

The polyvinyl alcohol resin can be formed into a film by any of the known and suitable processes.

Although the thickness of the film material formed from the polyvinyl alcohol resin is not limited, it is, for example, from about 10 μπι to about 150 μπι.

The polarizing film is typically formed by a process comprising the steps of dyeing a polyvinyl alcohol resin film with a dichromatic pigment to absorb a dichromatic pigment (dye processing), treating the polyvinyl alcohol resin sheet with a dichromatic pigment absorbed with an aqueous boric acid solution (treatment with boric acid) foil with water after treatment with aqueous boric acid solution (treatment with water rinsing).

Typically, the polyvinyl alcohol resin film is stretched in a single axis direction to form a polarizing film. Stretching in a single axis direction may be performed before, during or after dyeing.

If the single-axis stretching is performed after dyeing, the single-axis stretching may be performed before or during the boric acid treatment.

It is also possible to perform stretching in the direction of a single axis by means of a plurality of steps.

Stretching in the direction of a single axis can be effected between rollers of different peripheral speeds or using heated rollers.

Alternatively, the resin film may be subjected to a dry stretching in which the film is stretched in air, or wet stretching in which the stretched film is impregnated with a solvent. The stretching ratio is usually from about 3 to about 8.

The dyeing of the polyvinyl alcohol resin film with a dichromatic pigment in the dyeing step is performed, for example, by immersing the polyvinyl alcohol resin film in a dichromatic pigment.

aqueous solution

As the dichromatic pigment, for example, iodine, a dichromatic dye, and the like are used. Examples of a dichromatic dye are a dichromatic direct dye containing a disazo component such as C.I. DIRECT RED 39, and a dichromatic direct colorant containing a component such as trisazo, tetrakisazo or the like.

Preferably, the polyvinyl alcohol resin sheet is immersed in water prior to dyeing.

When iodine is used as the dichromatic pigment, the polyvinyl alcohol resin sheet is usually immersed in an aqueous solution containing iodine and potassium iodide for dyeing.

The iodine content of the aqueous solution is usually from 0.01 to 1 part by weight per 100 parts by weight of water, while the potassium iodide content is usually from 0.5 to 20 parts by weight per 100 parts by weight of water.

The temperature of the aqueous solution to be used for dyeing is usually from 20 to 40 ° C, while the immersion time (dyeing time) is usually from 20 to 1800 seconds.

If, on the other hand, a dichromatic dye is used as the dichromatic pigment, the polyvinyl alcohol resin film is usually immersed in an aqueous solution containing the dichromatic dye for dyeing.

The content of the dichromatic dye in this aqueous solution is generally from 1 x 10 ^-4 to 10 parts by weight, preferably from 1 x 10 ³ to 1 part by weight, in particular from 1 x 10 ³ to 1 x 10 ² parts by weight per 100 parts by weight water.

This aqueous solution may contain an inorganic salt, such as sodium sulfate, as a dye auxiliary.

The temperature of the aqueous solution to be used for dyeing is usually from 20 to 80 ° C, while the immersion time (dyeing time) is usually from 10 to 1800 seconds.

The boric acid treatment step is performed by dipping a polyvinyl alcohol resin film dyed with a dichromatic pigment in an aqueous solution containing boric acid.

The amount of boric acid in this aqueous solution is usually from 2 to 15 parts by weight, preferably from 5 to 12 parts by weight per 100 parts by weight of water.

Again, when iodine is used as the dichromatic pigment in the above dyeing step, preferably an aqueous solution containing boric acid for use in boric acid treatment comprises potassium iodide.

In this case, the amount of potassium leaving in the boric acid-containing aqueous solution is usually from 0.1 to 15 parts by weight, preferably from 5 to 12 parts by weight, per 100 parts by weight of water.

The immersion time is usually from 60 to 1200 seconds, preferably from 150 to 600 seconds, and even more preferably from 200 to 400 seconds.

The temperature of the aqueous solution is usually 50 ° C or higher, preferably from 50 to 85 ° C, and even more preferably from 60 to 80 ° C.

In the next water washing step, the polyvinyl alcohol resin sheet, treated with boric acid, is immersed, for example, in washing water.

The water temperature in this treatment is usually from 5 to 40 ° C, with the immersion time usually from 1 to 120 seconds. The film is usually dried after washing with water. A polarizing film is thus obtained.

The hot air dryer or infrared heater is preferably used for drying. The drying temperature is usually from 30 ° C to 100 ° C, preferably from 50 ° C to 80 ° C.

The drying time is usually from 60 to 600 seconds, preferably from 120 to 600 seconds.

During the manufacturing process of the present invention, the continuous optical films or continuous optical strips which are intended to carry out the drawing step comprise the above polarizing films.

Examples of a continuous optical strip comprising a polarizing film (or polarizing plate) include the following:

(A) a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film and a protective film formed of a thermoplastic resin and superimposed on at least one surface of the polarizing film; (B) a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol film. , a pressure-sensitive adhesive layer formed on at least one surface of the polarizing film, and a release film for protecting the pressure-sensitive adhesive layer, (C) a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a protective film formed of thermoplastic resin and superimposed on at least one surface of the polarizing film, a pressure sensitive adhesive layer formed on the second surface of the polarizing film, and a release film for protecting the pressure sensitive adhesive layer, and (D) a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol film ice, a protective film formed of a thermoplastic resin and superimposed on at least one surface of the polarizing film, a pressure-sensitive adhesive layer formed on the second surface of the protective film, and a release film for protecting the pressure-sensitive adhesive layer.

In the case of any of the polarizing plates (B) to (D) having release sheets, the release sheet is peeled off in the first or second lamination step such that the exposed pressure-sensitive adhesive layer is laminated to another optical film or another optical web, or an optical display mechanism.

In any of the polarizing plates described above, the protective film may be formed of a thermoplastic resin from any of the following films:

(a) a cycloolefin resin film, (b) a cellulose ester resin film, (c) a polyethylene terephthalate resin film, (d) a methacrylic resin film, and (e) a polypropylene resin film.

Any of these thermoplastic resin films may be laminated on at least one surface of the polarizing film so that the thermoplastic resin film in the form of a continuous optical strip (or polarizing plate) may be subjected to a stretching step.

Alternatively, any of these thermoplastic resin films in the form of a continuous optical film of the same resin film may be separately subjected to a stretching step, and may be laminated to at least one surface of the polarizing film in a first laminating step.

These thermoplastic resin films will now be described in more detail below.

(a) Cycloolefin resin sheet

A cycloolefin resin for use in the process of the invention is, for example, a thermoplastic resin having a monomer unit containing a cyclic olefin (or cycloolefin) such as norbornene and a polycyclic norbornene monomer (or a so-called thermoplastic cycloolefin resin).

According to the invention, the cycloolefin resin may be a ring-opening polymerization of a cycloolefin, or a hydrogenated product of a copolymer of one or more cycloolefins resulting from a ring-opening polymerization, or an addition polymer of a cycloolefin and an aromatic chain containing olefin with vinyls. .

It is also possible to effectively use a cycloolefin resin having a polar group introduced.

When a copolymer of cycloolefin and an aromatic compound containing a chain olefin and / or a vinyl group is used, ethylene, propylene and the like are used as the olefin with a chain, and as the aromatic compounds containing vinyl group, styrene, α-methylstyrene, styrene alkyl -substituted at the core and the like.

Such a copolymer may contain 50 mole% or less (preferably 15 to 50 mole%) of a monomer unit comprising a cycloolefin.

Particularly when a ternary copolymer of a cycloolefin and an aromatic compound containing a chain olefin and a vinyl group are used, the amount of the monomeric unit comprising the cycloolefin can be reduced to a relatively small amount as described above.

In such a ternary copolymer, the amount of the monomer unit comprising the chain olefin is usually from 5 to 80 mol%, the amount of the monomer unit containing the aromatic compound having a vinyl group is usually from 5 to 80 mol%.

As the cycloolefin resin, commercially available products such as Topas (from Ticona), ARTON (from JSR), ZEONOR (from Zeon Corporation), ZEONEX (from Zeon Corporation), APL (from MITSUI CHEMICALS) can be used advantageously. , IC.), Etc.

When such a cycloolefin resin is used to form a film, any of the known methods, such as solvent casting, melt extrusion, and the like can be suitably used.

Commercially available cycloolefin resin films such as S-SINA (from Sekisui Chemical Co., Ltd.), SCA40 (from Sekisui Chemical Co., Ltd.), ZEONOR (from OPTES), etc. can be used.

The cycloolefin resin may be uniaxially or biaxially stretched. By stretching, the cycloolefin resin can have its desired optional phase retardation value.

The film is continuously stretched as it is pulled out of the roll. The film is stretched in the feed direction from the roll, in a direction perpendicular to the feed direction from the roll, or in both directions, in a heated furnace.

The transition temperature in the heated furnace is a cycloolefin temperature of + 100 ° C.

usually from glass resin to glass

The stretching ratio is usually from 1.1 to 1.1 to 3.5.

6, preferably

When the cycloolefin resin film is held to be wound onto a roll, the layers of film on the roll adhere to each other to form a block. Therefore, usually the protective film is laminated to the cycloolefin resin film, wherein the cycloolefin resin film with the laminated protective film is wound onto a roll.

The cycloolefin resin film having generally weak surface activity is preferably subjected to a surface treatment such as plasma treatment, corona treatment, ultraviolet treatment, flame treatment, saponification treatment or the like to treat the side of the cycloolefin resin film which is in contact with the polarizing film.

In particular, plasma treatment or corona treatment is advantageous because it is a relatively simple operation.

When such a cycloolefin resin film is used in a polarizing plate, the polarizing plate has a structure similar to that of a conventional optical display panel such as a liquid crystal panel or the like, but the quality and availability of the resulting optical display panel are improved. .

(b) Cellulose ester resin film

The cellulose ester resin film for use in the process of the present invention is a film obtained partially or wholly by esterification of cellulose.

Examples of such films are those formed from cellulose acetate, propionate and butylate and mixtures thereof.

Specific examples are cellulose triacetil films, cellulose diacetil films, cellulose propionate acetate films, and cellulose acetate butylate films.

Commercially available products such as FUJITAC TD80 (from FUJI FILM), FUJITAK TD80UF (from FUJI FILM), FUJITAK TD80UZ (from FUJI FILM), KC8UX2M (from KONICA MINOLTA) can be advantageously used as such cellulosic resin films. and KC8UY (from KONICA MINOLTA).

Preferably, a cellulose ester resin film having phase retardation is used in the process of the present invention.

Examples of the cellulose ester resin film include commercially available products such as WV BZ 438 (from FUJI FILM) and KC4FR-1 (from KONICA MINOLTA). In addition, the cellulose ester resin film having a negligibly low phase retardation value in its plane and / or thickness direction can be advantageously used.

Examples of a substantially non-oriented cellulose ester resin film include a commercially available product such as KC4UEW (from KONICA MINOLTA), etc.

When such a cellulose ester resin film is used in a polarizing plate, the polarizing plate has a structure similar to that of a conventional optical display panel, such as a liquid crystal panel or the like, but the quality and availability of the resulting optical display panel are improved. .

(c) Polyethylene terephthalate resin sheet

Polyethylene terephthalate is a resin having repeating units of which 80 mol% or more is ethylene terephthalate.

Further copolymerizable components are, for example, isophthalate, β-β-oxyethoxybenzoic acid, dicarboxylic acid components such as 4,4 'dicarboxydiphenyl, 4,4' dicarboxybenzophenone, bis (4-carboxyphenyl) ethane, adipic acid, sebacic acid, 5- sodium sulfoisophthalic and 1,4-dicarboxycyclohexane, and diol components such as propylene glycol, butanediol, neopentyl glycol, diethylene glycol, cyclohexanediol, bisphenol A ethylene oxide, polyethylene glycol, polypropylene glycol and polytetramethylene glycol.

If desired, two or more components selected from dicarboxylic acid components and glycol components may optionally be used in combination.

4.Ί

In addition, an oxycarboxylic acid, such as p-oxybenzoic acid, may be used in combination with a dicarboxylic acid or glycolic component.

Such a copolymerizable component may comprise a composition comprising a small amount of an amide binder, amide linkages, urethane linkages, ether linkages, carbonate linkages, or the like.

Both the process for the production of polyethylene terephthalate, the so-called direct polymerization process for the direct reaction of terephthalic acid with ethylene glycol, and the so-called ester exchange reaction between dimethyl terephthalic acid ester and ethylene glycol, or the like, may optionally be employed.

In addition, known additives can optionally be added.

Examples of additives include lubricants, antiblocking agents, heat stabilizers, antioxidants, antistatic agents, light protection agents, anti-shock agents, and the like.

However, the amount of additives should be as low as possible, as transparency is required for optical use.

Although the process for producing polyethylene terephthalate is not limited to the present invention, a process comprising the steps of melting polyethylene terephthalate as a resin material, extruding a melt strip to form an undirected film, stretching the undirected film in a lateral direction at a temperature not lower, such as glass transition temperature, and thermal fixation of the stretched film.

The stretching temperature is from 80 to 130 ° C, preferably from 90 to 120 ° C, with a stretching ratio of from 2.5 to 6, preferably from 3 to 5.5.

A lower stretching ratio is not recommended as the transparency of the film would be poor.

In order to reduce the deformation of the main orientation axis of the polyethylene terephthalate film, it is advantageous to relax the film in the longitudinal direction before lateral stretching and thermal fixing of the film.

The relaxation temperature of the film is from 90 to 200 ° C, preferably from 120 to 180 ° C.

Since the amount of relaxation of the film from the side stretching conditions, the film and the temperature are selected such that the shrinkage of the relaxed film can be a temperature of 150 ° C.

The thermal fixation temperature is

250 ° C, preferably from 200 to 245 ° C.

varies depending on the amount of relaxation percentage thermal 2% or less at usually from

180 to

The thermal fixation of the film is carried out as follows: First, the fixed-length film is processed at the above temperature, and then it is relaxed so that the relaxation ratio of the film in the width direction can be from 1 to 10% (preferably from 2 to 10%).

%).

In this way, the deformation of the main orientation axis of the film is reduced. A uniaxially stretched polyethylene terephthalate film having excellent heat resistance properties is thus obtained.

In the present invention, a polyethylene terephthalate film whose maximum deformation at its major orientation axis is 10 ° or less, preferably 8 ° or less, even more preferably 5 ° or less, may be advantageously used.

If the polyethylene terephthalate film, whose maximum deformation value of its principal orientation axis exceeds 10 °, is used in a polarizing plate, and if such a polarizing plate is superimposed on a liquid crystal display screen, the color failure of the screen tends to increase.

The maximum deformation value of the major orientation axis of the polyethylene terephthalate film can be measured, for example, using a phase retarded film inspection device such as a RETS system (from Otsuka Electronics Co., Ltd.).

The film thickness of the polyethylene terephthalate is from about 20 to about 60 microns. The R0 value of the phase retardation in the plane of the film is preferably 1000 nm or more, more preferably 3000 nm or more.

Meanwhile, the polyethylene terephthalate sheet may be provided with a smoky tinge.

For example, as a smoke-treating method, fine inorganic or organic particles are mixed into the resin material, or a coating liquid, such as a mixture of fine inorganic or organic particles with a binder, is applied in a layer to the surface of the film.

However, the method is not limited to this procedure.

Typical examples of fine inorganic particles include silica, colloidal silica, alumina, alumina salt, aluminosilicate, alumina / silica composite oxide, kaolin, talc, mica, calcium carbonate, and calcium phosphate.

Refractory resin particles such as cross-linked polyacrylic acid particles, cross-linked polystyrene particles, cross-linked polymethyl methacrylate silicone resin particles, and polyimide particles can be used as fine organic particles.

The polyethylene terephthalate resin film having the above properties is excellent as a whole in terms of mechanical properties, solvent resistance, scratch resistance, and inexpensive cost.

When such a polyethylene terephthalate resin sheet is used in a polarizing plate, the polarizing plate may have a strength that is equal to or higher than the strength of the polarizing plate for use with a known optical display panel, such as a liquid crystal display panel, not smoothing. to its reduced thickness.

In this context, a surface treatment such as anti-glare treatment, hard coat treatment, antistatic treatment or the like can be performed on the surface of the polyethylene terephthalate resin sheet facing the surface to be laminated to the polarizing film.

In addition, the coating layer of the liquid crystalline component or its polymeric component may be formed on the surface of such a film.

Instead of polyethylene terephthalate film, polyethylene naphthalate film may be used.

(d) (meth) acrylic resin sheet

Examples of the (meth) acrylic resin film include a film that is formed by melting in the molten state of the acrylic resin or methacrylic resin alone or both in combination, and optionally acrylic rubber particles, to obtain the acrylic rubber material, and extruding the acrylic resin material for foil shaping.

The (Met) acrylic resin may contain known additives such as an ultraviolet absorber, an organic dye, a pigment, an inorganic pigment, an antioxidant, an antistatic agent, a surfactant, and the like.

The (meth) acrylic resin film may have a multilayer structure having an inner light diffusing layer and an outer light diffusing layer in combination.

To achieve light scattering properties, the fine particles are mixed in a (meth) acrylic resin, then the mixture is kneaded in the molten state.

When the (meth) acrylic resin film is placed on the visible side of the liquid crystal panel, the resin film surface is preferably subjected to a surface treatment (to form a hard coating layer, glare shielding layer, antireflective layer, dirt protection layer, antistatic layers or the like).

A polarizing plate comprising such a (meth) acrylic resin film is excellent in terms of surface hardness and stiffness relative to polarizing plates for use in known optical display panels, such as liquid crystal panels.

(e) Polypropylene resin sheet

Polypropylene resin for use in the process of the present invention a propylene unit, crystalline.

is a resin having in particular wherein the resin is generally

The polypropylene homopolymer or copolymerizable with the propylene copolymer may be propylene and a propylene comonomer,

Examples of a comonomer copolymerizable with propylene include ethylene and C _4-20 alpha olefins.

The xylene soluble portion of the polypropylene resin film at 20 ° C, if used, is 1% or less, preferably 0.8% or less, more preferably 0.5% or less.

If the xylene soluble portion of the polypropylene resin film exceeds 1% by weight, the polypropylene resin film becomes belastic when the polarizing plate containing such a resin film is exposed to high temperature, thereby significantly reducing the patency of the polarizing plate.

It is believed that bleaching the surface area of the polypropylene resin film at such high temperature conditions can cause the low molecular weight components to flow in the resin film.

Typical examples of such low molecular weight components include, but are not limited to, low molecular weight oligomers.

The xylene soluble portion (in% by weight per unit) of the polypropylene resin film is measured as follows.

Polypropylene resin film (5 g) is added to the variation xylene (500 mL) and completely dissolved therein, then the resulting solution is cooled to 20 ° C and kept at 20 ° C for 4 hours.

Then, the xylene solution is filtered to separate the solution into a precipitate and a filtrate, the solvent is removed from the filtrate, and the residue is dried at 70 ° C under reduced pressure to obtain a xylene-soluble solid.

The xylene soluble moiety is determined by the following equation:

Xylene soluble part [% by weight] = (weight [g] of xylene soluble dry solid) / (5 [g]) x 100.

As the polypropylene resin forming the aforementioned polypropylene resin film, a polypropylene resin having a soluble part in xylene is preferably 1% by weight or less, more preferably 0.8% by weight or less, even more preferably 0.5% by weight or less.

The method of measuring the xylene soluble portion of the polypropylene resin is the same as that of the polypropylene resin film.

The polypropylene resin may be a polypropylene resin consisting of a propylene homopolymer or a copolymer of propylene and another propylene copolymerizable monomer, but both may be used in combination as a polypropylene resin.

Examples of another monomer copolymerizable with propylene include ethylene and α-olefins.

Preferred examples of α-olefins include alpha-olefins, each having four or more carbon atoms, preferably _C4-IO a-olefins.

Specific examples of C ₄ _i ₀ α-olefins include linear monoolefins such as 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene and 1-decene, branched monoolefins such as 3-methyl-lbutén 3- methyl-1-pentene and 4-methyl-1-pentene, and vinylcyclohexane.

The propylene copolymer and the other propylene copolymerizable monomer may be a random copolymer or a block copolymer.

When the copolymer described above is used as a polypropylene resin, it is relatively easy to obtain a polypropylene resin having a xylene soluble part of 1% by weight or less.

Therefore, the proportion of the additional monomer in the copolymerization with propylene is preferably set to 8 wt% or less, more preferably to 4 wt% or less.

The content of the constitutional unit derived from another monomer in the copolymer can be determined by infrared spectral measurement according to the procedure described on page 616 of the "Kobunshi Bunseki Handbook, published by KINOKUNIYA COMPANY LTD., 1995.

In particular, propylene homopolymer, propylene-ethylene random copolymer, propylene-1-butene random copolymer and propylene-ethylene-1-butene random copolymer are preferably used as the polypropylene resin forming the polypropylene resin film.

It is relatively easy to obtain a polymer having a reduced xylene soluble portion from any of these homopolymers or copolymers by selecting a suitable polymerization catalyst.

If a propylene homopolymer is particularly used, it is easy to obtain a polymer having a reduced xylene soluble portion.

The stereoregularity of the propylene resin forming the polypropylene resin film is preferably substantially isotactic or syndiotactic.

A polypropylene resin film formed from a polypropylene resin having substantially isotactic or sindiotactic stereoregularity is relatively good in terms of ease of handling while having excellent mechanical strength at high temperature.

Polypropylene resin having such stereoregularity has a relatively low incidence of low molecular weight components that can cause the polarizing plate to be whitened in the polymerization step.

Thus, a polarizing plate in which high-temperature throughput reduction is suppressed is readily obtainable when the polypropylene resin film is utilized in the polarizing plate.

Although the method of reducing the xylene soluble portion of propylene resin to 1% by weight or less is not limited, for example, the following methods are provided:

a method of increasing the degree of polymerization of a propylene resin in a polymerization step to proportionally reduce a portion of the low molecular weight component, a method of removing a solvent soluble component, such as the low molecular weight component, by washing the polypropylene resin obtained by polymerization in a solvent; are generally known to those skilled in the art.

In this context, the treatment to reduce the xylene soluble portion of the propylene resin obtained by polymerization is not always necessary in the following case, such as the case where the xylene soluble portion of the resulting polypropylene resin is reduced to 1% by weight or less by controlling the stereoregularity of the polypropylene resin. such that it is isotactic or syndiotactic, through the choice of a suitable polymerization catalyst, and / or through homopolymerization propylene.

Despite propylene, the method of forming the resin sheet is not limited, but examples thereof include extrusion using molten resin, a method of casting in a solvent by pouring a solution of a resin in an organic solvent onto a flat plate, and removing solvent from the resulting film forming layer, and the like. .

wherein the extrusion method is advantageous in terms of productivity.

In this case, the polypropylene resin exhibits a melt flow rate (MFR) of preferably from 0.1 to 200 g / 10 min, more preferably from 0.5 to 50 g / 10 min, measured at 230 ° C under a load of 21.18 N in in accordance with JIS K 7210.

The use of a polypropylene resin having an MFR in this range is effective to produce a uniform polypropylene resin film without much load on the extruder.

The polypropylene resin film for use in the present invention should preferably have a high transparency, in particular the total smoke smell of the film, measured in accordance with JIS K 7105, is 10% or less, preferably 7% or less.

The thickness of the protective film comprising the polypropylene resin film is preferably from about 5 to about 200 μm, more preferably 10 μπ or more and 150 μπ or less.

The polypropylene resin film may be uniaxially or biaxially stretched. The stretching allows to achieve the desired optional phase retardation values for the polypropylene resin film.

The stretching is usually carried out continuously when the film is withdrawn from the roll, the film being stretched in the feed direction from the roll or in a direction perpendicular to the feed direction or both in the heated furnace.

The internal temperature of the heated furnace is usually set to a temperature of about the glass transition temperature of the polypropylene resin to ± 100 ° C glass transition temperature.

The stretching ratio is usually from 1.1 to 6, preferably from 1.1 to 3.5.

When the polypropylene resin film is held in a rolled state, the film layers on the roll adhere to each other to form a block. Therefore, usually the protective film is laminated to the polypropylene resin film before winding the polypropylene resin film onto the roll.

Meanwhile, the cycloiefin resin film, which has generally weak surface activity, is preferably subjected to a surface treatment, such as plasma treatment, corona treatment, ultraviolet treatment, flame treatment, saponification treatment, on its surface for contacting the polarizing film.

In particular, plasma treatment and corona treatment are advantageous, since this is a relatively simple operation.

When such a polypropylene resin film is used in a polarizing plate, the polarizing plate has a similar structure to that of a conventional liquid-crystal panel or other optical display panel, but the quality and availability of the resulting optical display panel are improved.

The above-described cycloolefin resin films, cellulose ester resin films, polyethylene terephthalate resin films, (meth) acrylic resin films or polypropylene resin films are preferably used as protective films for polarizing films.

In addition, polycarbonate resin films or polypropylene resin films can also be used as protective films for polarizing films.

In the manufacturing method of the present invention, the release film having its own pressure-sensitive tack may be pre-laminated to at least one surface of the polarizing film and may be peeled from the polarizing film before using the polarizing film.

Examples of the release film include films formed from polyethylene resins, polypropylene resins, or the like.

As commercially available products for the use of such a separately pressure-sensitive release film, products such as "TORETEC, containing polyethylene resin, and manufactured by Toray Industries, Inc.," Sanitect, manufactured by Sun A. Kaken Co., Ltd. are preferably used. , etc.

In this regard, a release film having a small defect, such as the final eye, is optionally preferred. When a release film having such an error is used, the shape of the error is transmitted to the polarizing film, which can induce the error of the resulting polarizer.

Also, in the production method of the present invention, an optical film or optical strip having a function such as anti-glare function, anti-reflection function, hardness enhancing function, illumination enhancing function or the like can be superimposed on one side of the polarizing plate opposite its side. optical display mechanism.

Examples of continuous optical films or continuous optical strips having such optical functions include an optical compensation film comprising a liquid-crystal component layered and oriented on the substrate surface, a reflective-type polarizing film that carries certain polarizing light rays and reflects polarizing light rays having opposite properties, a phase retardation film comprising a polycarbonate resin, a phase retardation film comprising a cyclopolyolefin resin, a glare shielding film having non-uniform surface area formed on its surface antireflective film, a reflective film that reflects the film it has both a reflective function and a function in terms of light transmission, etc.

Commercially available products, equivalent to an optical compensation film comprising a liquid-crystal component applied and substrate oriented are WV films (manufactured by FUJI FILM), NH films (manufactured by Nippon Oil Corporation), NR films (manufactured by Nippon Oil Corporation) ) etc.

Commercially available products, equivalent to a reflective-type polarizing film that carries certain polarizing light rays and reflects polarizing light rays having opposite properties, are DBEF (manufactured by SUMITOMO 3M)

LIMITED), APF (manufactured by SUMITOMO 3M LIMITED), etc.

Commercially available products, equivalent to a phase retardation film that contains a cyclopolyolefin resin, are ARTON films (manufactured by JSR), S-SINA (manufactured by Sekisui Chemical Co., Ltd.), ZENOR films (manufactured by OPTES), and the like.

Further, in the production method according to the invention, preferably at least one of the continuous optical films for lamination comprises a pressure-sensitive film and / or an adhesive film.

The coating device may be used to form a pressure-sensitive adhesive layer and / or adhesive layer on a continuous optical film, continuous optical web or continuous optical film laminate prior to the first laminating step or the second laminating step.

Although the pressure-sensitive adhesive for use in the pressure-sensitive film or pressure-sensitive adhesive layer is not limited to the production method of the present invention, conventional pressure-sensitive adhesives containing acrylic resins, urethane resins, resins made of natural or synthetic gums, vinyl ether resins or silicone resins as the main constituents, among which pressure-sensitive adhesives containing acrylic resins or urethane resins as the main constituents are advantageous because of their excellent resistance to environmental influences, whereas the pressure-sensitive adhesive containing acrylic Resins as the main constituents are particularly preferred.

Although the adhesive for use in the pressure-sensitive film or adhesive layer is not limited to the production method of the present invention, adhesives containing photocurable resins, ultraviolet-curable resins, heat-curable resins or moisture-curable resins, among which ultraviolet light are used curable resin adhesives are advantageous because of their excellent cure rate properties, and can be manufactured using a relatively simple device.

Examples of particularly preferred ultraviolet curable resin adhesives for use in the process of the present invention are those obtained by adding radical polymerization initiators and / or cationic polymerization initiators to epoxy resins, acrylic resins, oxtacene resins, urethane resins or polyvinyl alcohol.

An adhesive obtained by adding a cationic polymerization initiator to a mixture of an alicyclic epoxy resin and an epoxy resin having no alicyclic structure is preferred.

To form an ultraviolet curable resin adhesive layer, the ultraviolet curable resin adhesive in the uncured state is applied to the thermoplastic resin film for use as a protective film to form an adhesive-coated surface on the thermoplastic resin film or the ultraviolet curable adhesive is between the polarizing film and the protective film and is evenly distributed by rollers or the like to press the two films against each other.

Although the means for applying the UV-curable resin adhesive to the protective film is not limited, various means such as a scraper blade, wire rod, dye applicator, gravure coating device, etc. may be used.

If the polarizing film and the protective film between which the UV-curable resin adhesive is dripped, pass between the rollers and are compressed to uniformly distribute the adhesive, the rollers may be made of metal or rubber.

The two film compression rollers on both sides may be of the same material or of different materials.

The respective steps of the first production method or the second production method according to the invention can be carried out using a combination of devices commonly used in the art.

The apparatus for drawing continuous optical films or continuous optical strips in the drawing step is not limited in any way and may be constituted by a conventional and suitable device.

In order to prevent the formation of static electricity on the continuous optical films or continuous optical strips being pulled out, a device provided with a static electricity eliminator is preferably used.

In the first laminating step of the first manufacturing method or the second manufacturing method of the present invention, two or more continuous optical film laminates having pressure or adhesive sensitivity must be aligned in the width direction before being laminated.

If the optical display mechanism is a liquid crystal display mechanism, and if the continuous optical film laminates described above are superimposed on both sides of the liquid crystal display mechanism, at least two first layering rolls in the first layering step are necessary.

In this case, two or more first laminating rollers may be used only to obtain a continuous optical web laminate to be laminated to one side of the optical display mechanism.

Typically, the continuous optical films or continuous optical strips aligned in the width direction are suitably laminated to each other in accordance with the desired structure, then pass between the first laminating rollers and are pressed against each other.

In the first laminating step, 2 to 4 continuous optical films are usually laminated to one another at the same time.

The surfaces of the continuous optical film laminate obtained in the first laminating step may be surface treated by means of a surface modification device for corona treatment, plasma treatment, flame treatment or the like.

A corona treatment surface modification device which is excellent in terms of surface modification effect and which is easy to adjust is preferred.

In a second laminating step in a first manufacturing method or a second manufacturing method according to the present invention, a laminating device having rollers (second laminating rollers) is used to superimpose the polarizing plate and the liquid crystal display mechanism on top of each other. crystals.

The laminating mechanism for use in the second laminating step is preferably provided with, for example, a mechanism for precisely positioning the continuous optical ribbon laminates or optical ribbon laminates along one side of the optical display mechanism, or a release film peeling mechanism that is laminated to a pressure-sensitive adhesive layer; on an adhesive layer to protect the layer.

The laminating mechanism for use in the second laminating step may be a mechanism for laminating continuous optical ribbon laminates or optical ribbon laminates onto one surface of the optical display mechanism, or a mechanism for simultaneously laminating continuous optical ribbon laminates or optical ribbon laminates on both surfaces of the optical display mechanism.

The rollers for use in the first laminating step and the second laminating step are preferably formed by two rubber rollers for use in combination, or a rubber roller in combination with a metal roller.

The hardness of the rubber rollers is preferably from 60 to 80 ° based on the Shore C scale in accordance with JIS K 6301.

If the hardness of the rubber rollers is less than 60 °, pressure unevenness may occur.

If the hardness is higher than 80 °, the foil may be damaged.

As rubber materials for rolls, urethane rubber, butyl rubber, nitrile rubber, EPDM rubber, silicone rubber, and the like can be used, with EPDM rubber and silicone rubber being preferred for durability.

Examples of cutting means for use in a cutting step in a first manufacturing method or a second manufacturing method according to the present invention include a conventional optical belt cutting mechanism and an optical belt perforating mechanism.

The cutting means for use in the first manufacturing method may further be provided with a mechanism for cutting unwanted portions of the continuous optical film laminate from the optical display mechanism and for clearly smoothing the end faces of the optical display mechanism or truncated end faces of the laminated optical film laminate after the continuous optical film laminate imaging mechanism.

The cutting means for use in the second method of manufacture may further be provided with a mechanism for clearly smoothing the end faces of the cut optical sheet laminate prior to laminating the optical sheet laminate to the optical display mechanism.

The cutting means for use in the second method of manufacture may furthermore be provided with a mechanism for removing the optical sheet laminate cut in the cutting step to superimpose it on the optical display mechanism.

As the optical strip laminate removal mechanism, the commonly known strip laminating mechanism for the liquid crystal display mechanism used in a conventional liquid crystal panel manufacturing apparatus may be used.

The present invention will now be described in more detail by way of examples, but the present invention is not limited to these examples.

Example 1

According to the procedure shown in FIG. 1, the liquid crystal panel is manufactured using the first manufacturing method of the present invention.

Polarizing foil

A polyvinyl alcohol film having a thickness of 7 5 μιη, having an average degree of polymerization of 2400 and a saponification degree of 99.9 mole, kept under tension, is submerged and soaked in pure water at 30 ° C, the film being stretched in the longitudinal direction in pure water up to a stretching ratio of 1.3.

The polyvinyl alcohol sheet, maintained at the above-mentioned stretching stage, is immersed in an aqueous solution containing iodine and potassium iodide at 30 ° C (iodine: potassium iodide: water = 0.05: 2: 100 by weight) for drying, then immersed in an aqueous solution containing potassium iodide and boric acid at a temperature of ° C (potassium iodide: boric acid: water = 12: 5: 100 by weight) for crosslinking, the film being stretched up to an overall stretch ratio of 5 , 6 during these dyeing and crosslinking steps.

The film is then rinsed with clean water at 12 ° C.

After rinsing, the polyvinyl alcohol film is dried for three minutes in a drying oven maintained at 65 ° C.

In this way, a polarizing film is obtained in which iodine is adsorbed and oriented to the polyvinyl alcohol film.

Polarizing plate roll

Separately, an aqueous adhesive is prepared by dissolving in water (100 parts by weight) a carboxyl-modified polyvinyl alcohol (KURARAY SAIL KL318 from KURARAY CO., LTD.) (Three parts by weight) and a water soluble polyamide epoxy resin (Sumilez Resin 650 from Sumika Chemtex) Co., Ltd.) (an aqueous solution having a solid concentration of 30%) (1.5 parts by weight).

The biaxially stretched film, made of norbornene resin (ZEONOR 80 μπι film from OPTES), previously corona treated, is laminated to one surface of the polarizing film thus obtained using the adhesive described above.

The resulting stressed laminate is dried at 80 ° C for 5 minutes, then cut to a width equivalent to the panel width. Subsequently, the surface area of the norbornene resin film is subjected to a corona treatment, wherein an acrylic pressure-sensitive adhesive layer is formed on the corona treated surface of the film, and the release film is laminated to the surface of the pressure-sensitive adhesive layer.

Then, the resulting polarizing plate is wound onto a roll.

Thus, a roll of polarizing plate having a polarizing film, a norbornene resin film, and a pressure-sensitive adhesive layer (with release film) superimposed in this order is obtained.

Coil coated surface

The 83 μπι surface treated foil (i.e., Mat Hard Coat TAC DS-LR2 from DAI NIPPON PRINTING CO., LTD.) Is obtained by forming a glare-free layer on the surface of the triacetyl cellulose film with a width equivalent to the panel width .

Then, the acrylic pressure-sensitive adhesive layer is formed on the surface of the triacetyl cellulose surface-treated film, wherein the release film is superimposed on the surface of the pressure-sensitive adhesive layer.

The resulting surface-treated film with a pressure-sensitive layer is wound onto a roll to obtain a roll of the surface-treated film.

Roll of polyethylene terephthalate protective film

A uniaxially stretched polyethylene terephthalate film with a thickness of 45 μτη and a width equivalent to the width of the panel is subjected to a corona treatment on its surface, then an acrylic pressure sensitive adhesive layer is formed on its surface, and a release film superimposed on the acrylic pressure sensitive adhesive layer.

The resulting film is wound onto a roll to obtain a roll of protective film with a pressure-sensitive adhesive layer.

Liquid crystal panel

A polarizing plate roll, a surface-treated film with a pressure-sensitive adhesive layer, and a roll of protective film obtained as described above are used to produce a liquid-crystal panel according to the first manufacturing method of the present invention as shown in FIG. First

That is, the roll of the polarizing plate as the continuous optical web 1 and the roll of the surface-treated film with the pressure-sensitive adhesive layer as the continuous optical web 2 are pulled out and the release film is peeled from the surface of the pressure-sensitive adhesive layer.

Then, the surface of the pressure-sensitive adhesive layer of the coil of the surface-treated film is placed towards the side of the polarizing film from the coil of the polarizing plate, and is then superimposed and pressed therein while being held under tension using the clamping rollers.

Then, the release film is peeled from the surface of the pressure-sensitive adhesive layer on the side of the polarizing plate, then the pressure-sensitive adhesive layer side is positioned opposite the side of the liquid-crystal display mechanism and laminated to one side of the liquid-crystal display mechanism.

On the other hand, the roll of the polarizing plate as the continuous optical web 11 and the roll of the protective film with the pressure-sensitive adhesive layer as the continuous optical web 13 are respectively pulled out, and then the release film is peeled off the surface of the pressure-sensitive adhesive.

Then, the surface of the pressure-sensitive adhesive layer from the roll of the protective film is placed against the side of the polarizing film from the roll of the polarizing plate, then laminated and pressed therein while being held under tension using the clamping rollers.

Then, the release film is peeled away from the surface of the pressure-sensitive adhesive layer on the side of the polarizing plate, then the pressure-sensitive adhesive layer surface is positioned opposite the side of the liquid-crystal display mechanism and laminated to one side of the liquid-crystal display mechanism.

Then, for example, the rewinding cutting mechanism is used as cutting means to cut off an unwanted area of the foils that adheres to the liquid crystal display mechanism.

In this way, a liquid-crystal display having a liquid-crystal display mechanism on one side, a pressure-sensitive adhesive layer, a biaxially stretched film formed of norbornene resin, a polarizing film and a surface-treated film layered in this order, and having on the other hand, a liquid-crystal display mechanism, a pressure-sensitive adhesive layer, a biaxially stretched film formed of norbornene resin, a polarizing film, a pressure-sensitive adhesive layer, and a polyethylene terephthalate protective film layered respectively.

Example 2

The liquid crystal display panel is manufactured by a second manufacturing method according to the present invention, i.e. by the method shown in FIG. 5 and FIG. 6th

Polarizing plate roll

The same polarizing plate roll is used as described in Example 1 in the section of the polarizing plate roll.

Coil coated surface

The 83 μπι surface-treated film (i.e., Mat Hard Coat TAC DS-LR2 from DAI NIPPON PRINTING CO., LTD.), Obtained by forming a glare-resistant cellulose layer, is cut on the triacetyl width of the film, equivalent panel width.

The cut surface treated film is wound directly onto the roll. This surface-treated film roll is equivalent to the surface-treated film roll as described in Example 1 of the Surface-treated film roll, but which has no pressure-sensitive adhesive layer.

Roll of polyethylene terephthalate protective film

The uniaxially stretched 45 µm polyethylene terephthalate film that has been wound onto the roll is cut to a width that is equivalent to the width of the panel, then the cut sheet is directly wound onto the roll.

This roll of polyethylene terephthalate protective film is equivalent to the roll of protective film described in Example 1 in the section of the roll of polyethylene terephthalate protective film but which has no pressure-sensitive adhesive layer.

Liquid crystal panel

As shown in FIG. 5, both the roll of the polarizing plate as the continuous optical web 1 and the roll of the surface-treated film as the continuous optical web 3 are respectively pulled out.

The side of the triacetylcellulose film from the surface of the coated film is placed opposite the side of the polarizing film from the side of the polarizing plate, wherein the ultraviolet light-curable resin adhesive containing the epoxy resin and the cationic polymerization initiator is interposed between the films so that the two films are stacked and stacked under tension when using clamping cylinders.

Then, the side of the polarizing plate of the resulting laminate is exposed to ultraviolet light on the λ / y hardening of the adhesive layer.

On the other hand, the polarizing plate roll as a continuous optical web 11 and the protective film roll as a continuous optical web 13 are respectively pulled out, then the protective film roll is placed against the polarizing film side of the polarizing plate blank and ultraviolet light curable resin adhesive containing epoxy resin. a cationic polymerization initiator is interposed between the two films so that the two films are superimposed on each other and are kept under tension using the clamping rollers.

Then, the side of the protective film of the resulting laminate is exposed to ultraviolet light to cure the adhesive layer.

Then, the polarizing plate and surface treated film laminate, and the polarizing plate and protective film laminate are respectively cut to a size corresponding to the size of the liquid-crystal display mechanism using the cutting means described in Example 1.

The optical web laminate 51, obtained by cutting off the polarizing plate laminate and the surface-treated film, is conveyed, wherein the release film is peeled off the side of the pressure-sensitive adhesive layer of the polarizing plate, as shown in FIG. 6th

Then, the pressure-sensitive adhesive layer is placed against the side of the liquid-crystal display mechanism, then layered on one side of the liquid-crystal display mechanism.

At the same time, the polarizing plate laminate and the protective film laminate are cut to obtain an optical sheet laminate 52, wherein the optical sheet laminate 52 is conveyed, and the release sheet is peeled off the side of the pressure-sensitive adhesive layer of the polarizing plate as shown in FIG. 6, and then the pressure-sensitive adhesive layer is placed against the side of the liquid-crystal display mechanism and is then superimposed on the other side of the liquid-crystal display mechanism.

In this way, the pressure-sensitive adhesive layer, the biaxial stretched norbornene resin film, the polarizing film and the surface-treated film are superimposed in this order on one side of the liquid crystal display mechanism, and the pressure-sensitive adhesive layer, and the biaxial stretched norbornene resin film. the polarizing film and the polyethylene terephthalate protective film are superimposed in this order on the other side of the liquid-crystal display mechanism.

A liquid crystal panel is thus obtained.

Example 3

The liquid crystal display panel is manufactured by the first manufacturing method of the present invention, by the process illustrated in FIG. Third

Polarizing plate roll

The polyethylene release film is superimposed on both sides of the polarizing film obtained by the process described in Example 1 in the Polarizing Film section, then the resulting laminate is cut to width corresponding to the width of the liquid crystal display mechanism, and the cut laminate is wound onto a roll.

Coil coated surface

The roll of the same surface-treated film as described in Example 2 in the Roll of the Surface-Treated Film is used.

Roll of Norbornene resin foil

The coil of a biaxially stretched film formed from a norenenen j resin (ZENOR 80 µm thick film from OPTES) is pulled out and cut to a width equivalent to the panel width, then the cut film is directly wound onto a roll to obtain a roll of norborne protective film.

Roll of polyethylene terephthalate protective film

The same polyethylene terephthalate protective film is used as described in Example 2 in the section of the roll of polyethylene terephthalate protective film.

Liquid crystal panel

As shown in FIG. 3, the continuous optical film 21 obtained by peeling the release film from the above-described coil of the polarizing film, a continuous optical strip 3 that is on the roll of the surface-treated film described above, a continuous optical film 23 that is on the coil of the above-described norbornene film and a continuous optical film 25, obtained by superimposing the release film on the surface of a pressure-sensitive film formed of an acrylic pressure-sensitive adhesive.

During this extraction operation, the side of the tryacetyl cellulose film of the surface-treated film is placed against the polarizing film, and ultraviolet light-curable resin adhesives each containing an epoxy resin and a cationic polymerization initiator are sandwiched between the surface-treated film and the polarizing film and between the polarizing film and then the surface-treated film, the adhesive layer, the polarizing film, the adhesive layer, the protective film, the pressure-sensitive film, and the release film are stored in this order.

In this state, all the films are stacked on top of each other and are kept under tension using the clamping rollers.

Thereafter, the side of the release film is exposed to ultraviolet light such that the adhesive layer between the surface-treated film and the polarizing film, as well as the adhesive layer between the polarizing film and the protective film are cured.

Subsequently, the release film is peeled away from the pressure-sensitive film, and this pressure-sensitive film side is positioned against the side of the liquid-crystal display mechanism, then is superimposed on one side of the liquid-crystal display mechanism.

On the other hand, the continuous optical film 31 obtained by peeling the release film from the above polarizing film roll, the continuous optical film 13 on the roll of the polyethylene terephthalate protective film described above, and the continuous optical film 33 obtained by laminating the release film on one side a pressure-sensitive film formed of an acrylic pressure-sensitive adhesive.

During this pulling operation, the ultraviolet light-curable resin adhesive comprising the epoxy resin and the cationic polymerization initiator is sandwiched between the polarizing film and the polyethylene terephthalate protective film such that the protective film, adhesive layer, polarizing film and the pressure-sensitive film are placed in this order.

In this state, the films are laminated to each other and are kept under tension using clamping rollers.

Then, the side of the protective film of the resulting laminate is exposed to ultraviolet light to cure the adhesive layer between the polarizing film and the protective film.

Subsequently, the release film is peeled away from the pressure-sensitive film, and this pressure-sensitive film side is positioned opposite the side of the liquid-crystal display mechanism, and is then superimposed on the other side of the liquid-crystal display mechanism.

In this way, the respective optical film laminates are laminated on both sides of the liquid-crystal display mechanism.

Then, the cutting means described in Example 1 are used to cut off an undesirable region of the foils adhered to the liquid crystal display mechanism.

In this way, the pressure-sensitive film, biaxially stretched norbornene resin film, polarizing film and surface-treated film are superimposed in this order on one side of the liquid crystal display mechanism, and the pressure sensitive film, polarizing film and polyethylene terephthalate protective film are superimposed on the other side of the liquid crystal display mechanism.

A liquid crystal panel is thus obtained.

Example 4

The liquid crystal display panel is manufactured by the first manufacturing method of the present invention, by the process illustrated in FIG. 4th

Coil of polarizing foil

The same roll of polarizing film is used as described in Example 3 in the section Roll of polarizing film.

Coil coated surface

The flattened roll of the surface-treated film as described in Example 2 in the Roll of the surface-treated film is used.

Roll of protective film of triacetylcellulose

A roll of stretched 43 gm film (KC4FR-1 from KONICA MINOLTA) made of tryacetylcellulose is pulled out and is then cut to a width equivalent to the width of the panel, the cut film being directly wound onto a roll to obtain a roll of protective film. film.

Roll of polyethylene terephthalate protective film

A roll of polyethylene terephthalate protective film, as described in Example 2 in the section Roll of polyethylene terephthalate protective film, is used.

Liquid crystal panel

As shown in FIG. 4, the continuous optical film 21 obtained by peeling the release film from the above-described polarizing film roll, the continuous optical web 2 / which is the above-described roll of the surface-treated film, the continuous optical web 23 which is the above described roll of tryacetlycellulose protective film; a continuous optical film 25, obtained by superimposing the release film on one surface of a pressure sensitive film formed of an acrylic pressure sensitive adhesive.

During this pulling operation, the side of the triacetylcellulose film of the surface-treated film is placed against the polarizing film, and ultraviolet light-curable resin adhesives, each containing an epoxy resin and a cationic polymerization initiator, are sandwiched between the surface-treated film and the polarizing film, and the protective film of triacetylcellulose, then the surface-treated film, the adhesive layer, the polarizing film, the adhesive layer, the protective film, the pressure-sensitive film and the release film are placed in this order.

In this state, all the films are stacked on top of each other and are kept under tension using the clamping rollers.

Then, the side of the release film is exposed to ultraviolet light such that the adhesive layer between the surface-treated film and the polarizing film, and the adhesive layer between the polarizing film and the protective film are cured.

Subsequently, the release film is peeled away from the pressure-sensitive film, the pressure-sensitive film side facing the side of the liquid-crystal display mechanism, and then superimposed on one side of the liquid-crystal display mechanism.

On the other hand, the continuous optical film 31, obtained by peeling the release film from the above-described coil of the polarizing film, is drawn, a continuous optical film

13, which is the above-described roll of polyethylene terephthalate protective film, a continuous optical film 41 that is a roll of protective film of triacetylcellulose, and a continuous optical film 33, obtained by laminating a release film on one side of a pressure sensitive film formed of an acrylic pressure sensitive adhesive.

During this pulling operation, the ultraviolet light-curable resin adhesives, each containing an epoxy resin and a cationic polymerization initiator, sandwiched between a polyethylene terephthalate protective film and a polarizing film, and between the polarizing film and the protective film of triacetyl cellulose, a polarizing film, an adhesive layer, a triacetyl cellulose protective film, a pressure-sensitive film, and a release film disposed in this order.

In this state, all the films are stacked on top of each other and are kept under tension using the clamping rollers.

Then, the side of the polyethylene terephthalate protective film of the resulting laminate is exposed to ultraviolet light to cure the adhesive layers between the polyethylene terephthalate protective film and the polarizing film, and between the polarizing film and the triacetylcellulose protective film.

Subsequently, the release film is peeled away from the pressure-sensitive film, the pressure-sensitive film side facing the side of the liquid-crystal display mechanism, and then superimposed on one side of the liquid-crystal display mechanism.

Then, the cutting means described in Example 1 are used to cut off an unwanted region of the foils adhered to the liquid crystal display mechanism.

In this way, the pressure-sensitive film, the triacetylcellulose protective film, the polarizing film and the surface-treated film are stacked in this order on one side of the liquid-crystal display mechanism, and the pressure-sensitive film, triacetylcellulose protective film, polarizing film and polyethylene terephthalate protective film. superimposed in this order on the other side of the liquid crystal display mechanisms.

A liquid crystal panel is thus obtained.

Example 5

The liquid crystal display panel is manufactured by the first manufacturing method of the present invention, by the process illustrated in FIG. First

Polarizing plate roll

A biaxially stretched film, made of norbornene resin (ZEONOR 80 μπι thick film from OPTES), previously corona treated, is laminated to one side of the polarizing film obtained by the process described in Example 1 of the Polarizing film, by ultraviolet curable. a resin adhesive comprising an epoxy resin and a cationic polymerization initiator such that the corona treated surface of the biaxially stretched film may be an outer surface (non-adhesive surface).

The 8 µm thick protective film, containing a glare-protected layer on the surface of the methacrylic resin film, is laminated to the other side of the polarizing film by an ultraviolet curing resin adhesive comprising an epoxy resin and a cationic polymerization initiator so that the anti-glare layer can be treated. (non-adhesive area).

Then, the side of the biaxially stretched norbornene resin film is exposed to ultraviolet light to cure the adhesive.

The resulting foil laminate is wound onto a roll to obtain a coil of the polarizing plate.

Liquid crystal panel

As shown in FIG. 1, a continuous optical strip 3, which is the above described roll of a polarizing plate, and a continuous optical film 1 having a release film laminated on one side to a pressure-sensitive film formed of an acrylic pressure-sensitive adhesive are drawn.

During this pulling operation, the corona treated surface of the biaxially stretched film formed of norbornene resin, the coil of the polarizing plate, is placed against the pressure-sensitive film so that the release film on the pressure-sensitive film can be deposited as an outer layer.

In this state, the web and the foils are pressed and stacked on top of each other and are kept under tension using the clamping rollers.

Further, the release film is peeled from the outer surface of the pressure-sensitive film, and this pressure-sensitive film side is positioned opposite the liquid-crystal display mechanism and is then superimposed on one surface of the liquid-crystal display mechanism.

Thus, the stretched polarizing pressure film, film, and polyethylene terephthalate sensitive adhesive layer, biaxially formed of a norbornene resin, the pressure sensitive adhesive layer of the protective film are superimposed in this order on the other side of the liquid crystal display mechanism.

In this manner, the pressure-sensitive film, the biaxial film formed of norbornene resin, the polarizing film and the methacrylic resin film, provided with the anti-glare coating, are superimposed in this order on one side of the liquid crystal display mechanism, and the pressure-sensitive adhesive layer. a biaxially stretched film formed of norbornene resin, a polarizing film, a pressure-sensitive adhesive layer, and a polyethylene terephthalate protective film are laminated in turn to the other side of the liquid-crystal display mechanism.

A liquid crystal panel is thus obtained.

Industrial usability

According to the manufacturing method of the present invention, the manufacturer of the optical elements may be exempted from work on the laminating step, the cutting step and the packaging step for the films and the supply (or transport) of the films to the panel manufacturer.

Therefore, the optical films laminated to the optical display panel are much cleaner and the number of errors is reduced. In addition, the yield of optical films or optical strips as their laminates is improved so that product availability is improved.

In the case where the optical display mechanism is a liquid crystal display mechanism, different films are usually used between the surface and the back of the liquid crystal display mechanism (i.e., the visible side and the back side).

However, preferably some of such films, for example polarizing films, may be used together between the surface and the back.

In a number of cases, the polarizing plate on the visible side of the liquid crystal display mechanism is subjected to a surface treatment, such as anti-glare treatment or anti-reflection treatment, while the polarizing plate on the rear side of the liquid crystal display mechanism is assigned a specific function such as light scattering. or lighting enhancement function.

The optical element manufacturer has so far laminated optical films or optical strips according to these requirements and has supplied such laminates to the panel manufacturer.

However, different manufacturing methods become possible, that is, one type of polarizing film is used to form the surface of the polarizing plate and the reverse of the polarizing plate, and different and desired types of optical films or optical strips are superimposed on the surface of the polarizing plate and the reverse of the polarizing plate. wherein the resulting laminates are superimposed on both sides of the liquid-crystal display mechanism to obtain the liquid-crystal mechanism.

Claims (14)

A method of manufacturing an optical display panel by laminating optical web laminates with optical functions onto an optical display mechanism, the method comprising the pulling step of pulling continuous optical webs with optical functions or continuous optical webs as their laminates from a plurality of rollers on which the continuous optical webs or continuous optical webs wound, a first layering step of laminating the drawn continuous optical films or continuous optical tapes to each other to obtain continuous optical film laminates, a second direct layer laminating step of the continuous optical film laminates to the optical display mechanism, and a cutting step of cutting the optical film laminate from of continuous optical ribbon laminates in a laminate of a continuous optical ribbon laminate and an optical display mechanism along the an area that is not smaller than the display areas of the optical display panel, and no larger than the total area of the optical display panel. A method of manufacturing an optical display panel by laminating optical web laminates with optical functions onto an optical display mechanism, the method comprising the pulling step of pulling continuous optical webs with optical functions or continuous optical strips as their laminates from a plurality of rollers on which the continuous optical films are or a continuous optical tape laminate wound, a first layering step of laminating the stretched continuous optical films or continuous optical tapes to each other to obtain continuous optical tape laminates, a cutting step of cutting the optical tape laminates from the continuous optical tape laminates, and a second layering step optical display mechanism. Method according to claim 1 or 2, characterized in that one of the continuous optical films or continuous optical strips for exposing the drawing step comprises a polarizing film comprising a polyvinyl alcohol resin film. The method of claim 1 or 2, wherein one of the continuous optical strips for exposing the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film and a protective film formed of a thermo92 plastic resin, and superimposed on at least one surface of the polarizing film. A method according to claim 1 or 2, wherein one of the continuous optical strips for exposing the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a pressure-sensitive adhesive layer formed on at least one and a release film to protect the pressure-sensitive adhesive layer, wherein in the first or second lamination step, the release film is peeled off, and the exposed pressure-sensitive layer is laminated to another optical film or optical strip or optical display mechanism. A method according to claim 1 or 2, characterized in that one of the continuous optical strips for subjecting the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a protective film formed of a thermoplastic resin, and superimposed on one surface of the polarizing film, a pressure-sensitive adhesive layer formed on the other surface of the polarizing film, and a release film for protecting the pressure-sensitive adhesive layer, wherein in the first layering step or the second layering step the release film is peeled and exposed to the pressure-sensitive adhesive the layer is laminated to a second optical film or optical tape or optical display mechanism. The method of claim 1 or 2, wherein one of the continuous optical strips for subjecting the pulling step is a polarizing plate comprising a polarizing film comprising a polyvinyl alcohol resin film, a thermoplastic polarizing film resin, for a protective film. a film formed and stacked on one surface with a pressure-sensitive adhesive layer formed on the outer surface of the protective film, and a release film to protect the pressure-sensitive adhesive layer, wherein in the first lamination step or the second lamination step the release film is peeled and exposed to the pressure-sensitive adhesive the layer is laminated to a second optical film or optical tape or optical display mechanism. A method according to claim 1 or 2, characterized in that one of the continuous optical films or continuous optical strips for subjecting to the extraction step comprises a film of cycloolefin resin. The method of claim 1 or 2, wherein one of the continuous optical films or continuous optical strips for subjecting to the pulling step comprises a cellulose ester resin film. The method according to claim 1 or 2, wherein one of the continuous optical films or continuous optical strips for subjecting to the pulling step comprises a polyethylene terephthalate resin film. The method of claim 1 or 2, wherein one of the continuous optical films or continuous optical strips for subjecting to the pulling step comprises a (meth) acrylic resin film. The method of claim 1 or 2, wherein one of the continuous optical films or continuous optical strips for subjecting to the pulling step comprises a polypropylene resin film. The method of claim 1 or 2, wherein the optical display mechanism is a liquid crystal display mechanism, wherein the optical display panel is a liquid crystal panel. Method according to claim 1 or 2, characterized in that the UV-curable resin adhesive is used for the lamination in the first laminating step.