TW201805094A - Method for manufacturing polarization plate and manufacturing device therefor - Google Patents

Abstract

The present invention pertains to providing: a method for manufacturing an irregularly shaped polarization plate having in particular a small-diameter recessed round part and/or hole part, wherein discoloration, or cracking or snapping, produced in the irregularly shaped polarization plate during machining, and the accumulation of scraping residue at the root section of a blade of an end mill, are inhibited; and a manufacturing method therefor. A method for manufacturing an irregularly shaped polarization plate having a recessed round part, wherein the method is characterized in including a step for forming the recessed round part using a cutting means in which a blade comes into contact from the lateral direction with a surface to be cut and performs cutting, the cutting means being an end mill, and the direction of rotation of the end mill being counterclockwise as viewed from the shank side if the blade of the end mill is a left hand cut right hand helix, and clockwise as viewed from the shank side if the blade of the end mill is a right hand cut left hand helix.

Description

Manufacturing method of polarizing plate and manufacturing device thereof

FIELD OF THE INVENTION The present invention relates to a method for manufacturing a special-shaped polarizing plate and a device for manufacturing the same. In more detail, it is related with the manufacturing method of the abnormal-shaped polarizing plate which has a concave R part and / or a hole part, and its manufacturing apparatus. The present invention also relates to an optical film using the special-shaped polarizing plate. More specifically, the present invention relates to an image display device such as a liquid crystal display device, an organic EL display device, and a PDP using the special-shaped polarizing plate and an optical film.

BACKGROUND OF THE INVENTION In recent years, the use of a polarizing plate is also expected in an instrument display portion of a car, a smart watch, and the like. In addition, from the viewpoint of design of a smart watch, a method of using a polarizer in a shape other than a rectangle, or forming a through-hole in the polarizer is also expected. In addition, in these forms of special-shaped machining, the pursuit of more delicate and delicate processing and more complicated processing processes not seen in the past is increasing, and small-diameter concave R processing or small-diameter drilling is being implemented. Processing situation.

In order to process the polarizing plate into a special shape, for example, a die cutting process in which a shaped die is formed to punch the polarizing plate, and a cutting process using laser irradiation are mentioned. However, in the former punching process, the following problems have been known: cracks and breaks in the polarizing plate are generated due to damage to the cutting of the polarizing plate. In the latter laser processing, the problem of discoloration of the polarizer due to heat has been known. Among them, it has been ascertained from discussions among patent applicants that cracks and breakage tend to occur particularly in concave processing portions such as small-diameter drilling and small-diameter concave R processing.

Prior to this, proposals have been made for a trimming process of the end face of a polarizing plate (see, for example, Patent Documents 1 and 2). However, any of the above-mentioned proposals is only a proposal concerning the trimming process of the end of the cutting processing port after cutting the polarizing plate into a rectangular shape, and is not a technique for performing concave processing on the polarizing plate itself. Further, in the above proposal, there is no disclosure of the problem of cracks and breaks that occur when the polarizing plate is micro-recessed.

In addition, according to the discussions of the applicants of this patent, the following matters have been ascertained this time: Although polarizing plates are generally a laminated body of an adhesive layer and a thin film, an adhesive is contained in the cutting chips, but when this kind of adhesive When the cutting debris of the agent accumulates at the root of the cutting edge, the resistance to rotation increases due to adhesion to the cutting edge, and there may be a problem that the cutting edge is stable without rotating. Prior Art Literature Patent Literature

Patent Document 1: Japanese Patent Laid-Open No. 2004-148461 Patent Document 2: Japanese Patent Laid-Open No. 2004-148419

SUMMARY OF THE INVENTION Problems to be Solved by the Invention The object of the present invention is to provide a method for manufacturing a special-shaped polarizing plate and a device for manufacturing the same, especially for a special-shaped polarizing plate having a concave R portion and / or a hole portion with a small diameter. A manufacturing method, a manufacturing method of the special-shaped polarizing plate, and a manufacturing device thereof suppress cracks, breaks, and discoloration generated on the special-shaped polarizing plate during processing, and accumulation of cutting chips on the edge of an end mill The condition of the roots. Means to solve the problem

As a result of intensive studies to solve the above-mentioned problems, the inventors of the present case discovered that the above-mentioned object can be achieved by a manufacturing method and the like shown below, and finally completed the present invention.

The manufacturing method of the special-shaped polarizing plate of the present invention is a method of manufacturing a special-shaped polarizing plate having a concave R portion, which is characterized in that it includes a step of forming the concave R portion by a cutting mechanism, the cutting mechanism is to make the blade edge The cutting surface abuts and performs cutting. The cutting mechanism is an end mill. When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side. Or when the edge of the end mill is a right-handed left spiral, the rotation direction of the end mill is clockwise when viewed from the shank side.

Since the manufacturing method of the special-shaped polarizing plate of the present invention is a technique for cutting the polarizing plate, and the polarizing plate is generally a laminated body of an adhesive layer and a thin film, the cutting chips during cutting contain an adhesive. As described above, according to the discussion of the applicants of this patent, the following was re-discovered this time: When the cutting chips containing such an adhesive are accumulated in the root of the blade, the resistance to rotation increases due to adhesion to the blade, However, there may be a problem that the blade is stabilized without rotating. On the other hand, the manufacturing method of the special-shaped polarizing plate of the present invention has the above-mentioned structure, and makes it possible to move the cutting chips toward the cutting edge side during the cutting of the laminated body having the adhesive layer. In the case where chips are accumulated in the root of the cutting edge of the end mill, manufacturing of a special-shaped polarizing plate becomes feasible. In addition, the above-mentioned root means the vicinity of the mounting portion on the shank side of the end mill with respect to the tip of the end mill.

In addition, the manufacturing method of the special-shaped polarizing plate of the present invention particularly uses a mechanism for abutting the blade edge on the cutting surface of the polarizing plate from the lateral direction, thereby suppressing the difficulty that has occurred before during the processing of the polarizing plate. The occurrence of cracks, breaks, and discoloration make it possible to manufacture a special-shaped polarizing plate having a concave R portion having a small diameter, in particular.

In addition, in the present invention, the concave R portion means a portion having a concave portion and a curved portion, and a corner portion including the concave portion is a curved portion such as a circle or an ellipse, a substantially circular shape, or the like. The convex R portion refers to a portion having a convex portion and a curved portion, and a corner portion including the convex portion is a curved portion such as a circle, an ellipse, or a substantially circular shape. Examples thereof include a concave R portion or a convex R portion shown in FIG. 1.

In addition, in the present invention, the edge of the end mill is a right edge. For example, as shown in FIG. 3, when viewed from the shank side, it is provided with an outer peripheral edge that can be used for clockwise rotation (clockwise, forward rotation). Blade. The left edge refers to a blade provided with an outer peripheral edge that can be used in a counterclockwise rotation (counterclockwise, reverse) when viewed from the handle side. In addition, if the edge of the end mill is a left spiral, for example, as shown in FIG. 3, when the shank side is regarded as the upper side, the end mill is viewed from the side, and it is inclined upward to the left relative to the center axis of the end mill. Attached blade. In addition, if the edge of the end mill is a right spiral, for example, in contrast to the case of FIG. 3, when the shank side is regarded as the upper side, the end mill is viewed from the side, and the end mill is oriented relative to the center axis of the end mill. An angled blade is attached to the top right. In addition, for the case of the right-edged left spiral, for example, the configuration shown in FIG. 3 can be cited.

Moreover, in the manufacturing method of the abnormal-shaped polarizing plate of this invention, it is preferable that the radius of the said recessed R part is 5 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the concave R portion is For example, the manufacture of a special-shaped polarizing plate with a concave R portion having a minute radius of 5 mm or less becomes feasible. In addition, the above-mentioned concave R portion is defined as a radius of the circle when the R portion is circular, and is a circular shape when the R portion is not circular, such as an ellipse or a substantially circular shape. Refers to its radius of curvature.

Further, in the method for manufacturing a special-shaped polarizing plate of the present invention, it is preferable that the cutting edge of the blade of the end mill is downward. By using the manufacturing method described above, it is possible to also avoid the situation where the cutting chips are present on the polarizing plate and cause contamination.

Further, in the present invention, when the cutting edge of the edge of the end mill is downward, it includes not only the case where the cutting edge is directed vertically downward, but also the case where it is substantially downward, and also includes the case where it is at a predetermined angle with respect to the vertical downward. . For example, it may be a case where the cutting edge side is lower than the shank side, and the cutting edge is moved to the cutting edge side to the extent that the effects of the present invention can be exerted.

Moreover, the manufacturing apparatus of the abnormal-shaped polarizing plate of this invention is a manufacturing apparatus of the abnormal-shaped polarizing plate which has a concave R part, It is provided with the cutting mechanism which makes a blade contact a cutting surface from a horizontal direction, and performs cutting, The said cutting mechanism It is an end mill. When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side, or when the edge of the end mill is a right edge and left spiral. When viewed from the shank side, the rotation direction of the above-mentioned end mill is clockwise.

By using the manufacturing apparatus described above, it is possible to suppress the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate, and it is possible to easily manufacture a special-shaped polarizing plate having a concave R portion having a small diameter. With the above-mentioned configuration, it becomes possible to move the cutting chips toward the cutting edge side during the cutting of the laminated body having the adhesive layer. As a result, the accumulation of cutting chips on the root of the edge of the end mill is particularly suppressed. The manufacturing of the irregularly shaped polarizing plate of the situation becomes feasible. Thereby, it is possible to bring about simplification and simplification of manufacturing steps, reduction of cleaning steps, reduction of occurrence of defective rate, reduction of manufacturing costs, and the like.

Moreover, in the manufacturing apparatus of the abnormal-shaped polarizing plate of this invention, it is preferable that the radius of the said recessed R part is 5 mm or less. By using the manufacturing apparatus described above, even when the radius of the recessed R portion is 5 mm or less, the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate is suppressed, and the recessed R portion can be easily performed. Manufacture of a special-shaped polarizing plate having a concave R portion having a minute radius of 5 mm or less.

Moreover, in the manufacturing apparatus of the special-shaped polarizing plate of this invention, it is preferable that the edge of the edge of the said edge milling cutter is downward. By using the manufacturing apparatus described above, it is possible to also avoid contamination caused by the presence of cutting chips on the polarizing plate.

In addition, the method for manufacturing a special-shaped polarizing plate of the present invention is a method for manufacturing a special-shaped polarizing plate having a hole portion, which is characterized by including a step of forming the hole portion by using an end mill, and the cutting mechanism is an end mill. When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side, or when the edge of the end mill is a right edge and left spiral, viewed from the shank side The direction of rotation of the end mill is clockwise.

According to the manufacturing method described above, it is possible to move the chips to the tip side during the cutting of the laminated body having the adhesive layer. As a result, the accumulation of the chips on the root of the edge of the end mill is particularly suppressed. Manufacturing of the irregularly shaped polarizing plate becomes feasible. In addition, a mechanism for abutting the blade edge on the cutting surface of the polarizing plate from the lateral direction is particularly used, thereby suppressing the cracks, breaks, and discoloration that were previously difficult to suppress during the processing of the polarizing plate, and This makes it possible to manufacture a special-shaped polarizing plate having a small-diameter hole portion.

In addition, in the present invention, the hole portion means a portion having holes such as a circular or oval shape, a substantially circular shape, an angular shape, and the like, and means a portion penetrating the polarizing plate. Examples thereof include a hole portion shown in FIG. 1.

Moreover, in the manufacturing method of the said abnormally polarizing plate, it is preferable that the radius of the said hole part is 5 mm or less. By using the above manufacturing method, even when the radius of the hole portion is 5 mm or less, the occurrence of cracks, breakage, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the hole portion is set to 5 mm, for example. The manufacture of the irregularly shaped polarizing plate with the following small radius holes becomes feasible. The radius of the hole is the radius of the circle when the hole is circular, and when the hole is not circular, such as an ellipse or a substantially circular shape. Is its radius of curvature.

Further, in the method for manufacturing a special-shaped polarizing plate of the present invention, it is preferable that the cutting edge of the blade of the end mill is downward. By using the manufacturing method described above, it is possible to also avoid the situation where the cutting chips are present on the polarizing plate and cause contamination.

Moreover, the manufacturing apparatus of the abnormally shaped polarizing plate of this invention is a manufacturing apparatus of the abnormally shaped polarizing plate which has a hole part, Comprising: It is equipped with the end mill, and when the edge of the said end mill is a left edge and a right spiral, from the shank side When the rotation direction of the end mill is viewed counterclockwise, or when the edge of the end mill is a right-handed left spiral, the rotation direction of the end mill viewed from the shank side is clockwise.

By using the manufacturing apparatus described above, it becomes possible to move the cutting chips toward the cutting edge side during cutting of a laminated body having an adhesive layer. As a result, the accumulation of cutting chips at the root of the cutting edge of the end mill is particularly suppressed. In this case, the manufacture of the shaped polarizing plate becomes feasible. In addition, it is possible to suppress the occurrence of cracks, breakage, and discoloration during the processing of the polarizing plate, and it is possible to easily manufacture a special-shaped polarizing plate having a small-diameter hole portion.

Moreover, in the manufacturing apparatus of the abnormally shaped polarizing plate of this invention, it is preferable that the radius of the said hole part is 5 mm or less. By using the above-mentioned manufacturing apparatus, even when the radius of the hole portion is 5 mm or less, the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the hole portion can be easily performed. Manufacture of a special-shaped polarizing plate with a hole portion with a small radius such as 5 mm or less.

Moreover, in the manufacturing apparatus of the special-shaped polarizing plate of this invention, it is preferable that the edge of the edge of the said edge milling cutter is downward. By using the manufacturing apparatus described above, it is possible to also avoid contamination caused by the presence of cutting chips on the polarizing plate.

Embodiments for Carrying Out the Invention Embodiments of the present invention will be described below.

The manufacturing method of the special-shaped polarizing plate of the present invention is a method of manufacturing a special-shaped polarizing plate having a concave R portion, which is characterized in that it includes a step of forming the concave R portion by a cutting mechanism, the cutting mechanism is to make the blade edge The cutting surface abuts and cuts. The cutting mechanism is an end mill. When the edge of the end mill is a left edge and a right helix, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side. When the edge of the end mill is a right-handed left spiral, the rotation direction of the end mill is clockwise when viewed from the shank side.

In addition, the method for manufacturing a special-shaped polarizing plate of the present invention is a method for manufacturing a special-shaped polarizing plate having a hole portion, which is characterized by including a step of forming the hole portion by using an end mill, and the cutting mechanism is an end mill. When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side, or when the edge of the end mill is a right edge and left spiral, viewed from the shank side The direction of rotation of the end mill is clockwise.

The manufacturing method of the special-shaped polarizing plate of the present invention includes a step of forming the concave R portion and / or the hole portion by using a cutting mechanism that causes a cutting edge to abut against a cutting surface from a lateral direction and performs cutting. In addition, it becomes possible to move the chips to the tip side during the cutting of the laminated body having the adhesive layer. As a result, the irregularly shaped polarizing plate in which the chips are accumulated in the root of the blade of the end mill is suppressed. Manufacturing becomes feasible. In addition, a mechanism for abutting the blade edge on the cutting surface of the polarizing plate from the lateral direction is particularly used, thereby suppressing the cracks, breaks, and discoloration that were previously difficult to suppress during the processing of the polarizing plate, and This makes it possible to manufacture a special-shaped polarizing plate having a concave R portion and / or a hole portion having a small diameter. Moreover, in the manufacturing method of the abnormal-shaped polarizing plate of this invention, an end mill (end mill processing) is used as a cutting mechanism which makes a cutting edge contact a cutting surface from a horizontal direction, and performs cutting.

Furthermore, an end mill is a type of cutting tool, and unlike a drill that performs machining only in the axial direction (exclusive for drilling), it can also perform machining in a direction orthogonal to the rotation axis.

Hereinafter, an embodiment using an end mill machining will be described as an example with reference to FIGS. 2 and 3. For example, as shown in FIGS. 2 and 3, for the polarizing plate of the object to be formed with the concave R portion and / or the hole portion, the blade portion of the end milling cutter equivalent to the blade in this case is rotated, and the blade portion The direction abuts on the cutting surface of the polarizing plate and performs cutting. Then, it is moved in the machining direction together with the rotation of the blade portion of the end mill, and the polarizing plate is continuously cut to be processed into a predetermined shaped polarizing plate.

In the case of the above-mentioned end mill, for example, as shown in FIGS. 2 and 3, the rotation of the cutting edge portion is parallel to the cutting axis with respect to the cutting surface (for example, the rotation axis is relative to the workpiece being processed). The surface of the polarizing plate is rotated in a vertical direction), and the rotation of the polarizing plate by an end mill can be performed in the machining direction while the rotation is performed continuously, stepwise, or intermittently. At this time, the cutting edge portion of the end mill is cut in a state where the cutting surface is in contact with the cutting surface from the lateral direction. Moreover, in the conventional punching process such as punching with a die, the blade is formed from the upper part of the surface of the polarizing plate as the workpiece (and parallel to the cutting surface in FIG. 2), with respect to The surface of the polarizing plate is perpendicular to the surface), and the cutting process is performed.

In addition, for example, when drilling is performed, not only an end mill or the like is used for drilling directly, but also an end mill or the like may be additionally or additionally used for holes previously opened by other punching or the like. The end surface is cut to enlarge the hole or the like to form a hole having a desired shape.

Further, in the method for manufacturing a special-shaped polarizing plate of the present invention, for example, as shown in FIG. 3, when the blade of the end mill is a right-handed left spiral, it is viewed from the shank side (the orientation of the blade tip). ) The rotation direction of the above-mentioned end mill is clockwise (clockwise, forward). Also, it is characterized in that, unlike FIG. 3, when the cutting edge of the end mill is a left edge and a right spiral, the rotation direction of the end mill is viewed from the shank side (the orientation of the tool tip) is counterclockwise (counterclockwise). Direction, reverse). The manufacturing method of the abnormally shaped polarizing plate of the present invention has the above-mentioned structure, and makes it possible to move cutting chips toward the cutting edge side during cutting of a laminated body having an adhesive layer. As a result, cutting chips are particularly suppressed. It is possible to manufacture a special-shaped polarizing plate that is accumulated in the root of the blade of the end mill. In addition, even when the concave R portion has a small diameter or a small diameter, it is possible to appropriately perform manufacturing processing while suppressing occurrence of cracks, breakage, and discoloration during processing.

Therefore, in the manufacturing method of the irregularly shaped polarizing plate of this invention, even if the radius of the said recessed R part is 5 mm or less, it can manufacture easily. The radius may be, for example, 1 mm or more and 5 mm or less, or may be 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the concave R portion is For example, the manufacture of a special-shaped polarizing plate with a concave R portion having a minute radius of 5 mm or less becomes feasible.

Therefore, in the manufacturing method of the special-shaped polarizing plate of this invention, even if the radius of the said hole part is 5 mm or less, it can manufacture easily. The radius may be, for example, 1 mm or more and 5 mm or less, or may be 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the hole portion is 5 mm or less, the occurrence of cracks, breakage, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the hole portion is set to 5 mm, for example. The manufacture of the irregularly shaped polarizing plate with the following small radius holes becomes feasible.

Further, in the method for manufacturing a special-shaped polarizing plate of the present invention, the tip of the edge of the end mill may be used, for example, upward or laterally, but the tip of the edge of the end mill is directed downward. Is more ideal. With the above-mentioned configuration, it is possible to discharge the cutting chips downward, and also avoid the pollution caused by the chips adhering to the polarizing plate.

Moreover, the manufacturing apparatus of the abnormally shaped polarizing plate of this invention is a manufacturing apparatus of the abnormally shaped polarizing plate which has a concave R part, It is characterized by having the cutting mechanism structure which makes a blade contact a cutting surface from a horizontal direction, and performs cutting, The said cutting The mechanism is an end mill. When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side, or the edge of the end mill is a right edge and left spiral. At the time, when viewed from the shank side, the rotation direction of the end mill is clockwise.

In the manufacturing apparatus of the irregularly shaped polarizing plate having a concave R portion according to the present invention, a cutting mechanism including an end mill that causes a cutting edge to abut against the cutting surface in a lateral direction and performs cutting can be set to an appropriate device by a known method. on.

Moreover, in the manufacturing apparatus of the abnormal-shaped polarizing plate of this invention, even if the radius of the said recessed R part is 5 mm or less, it becomes easy to manufacture and process. The radius may be, for example, 1 mm or more and 5 mm or less, or may be 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the concave R portion is 5 mm or less, the occurrence of cracks, breaks, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the concave R portion is For example, the manufacture of a special-shaped polarizing plate with a concave R portion having a minute radius of 5 mm or less becomes feasible.

Moreover, in the manufacturing apparatus of the special-shaped polarizing plate of the present invention, although the cutting edge of the edge of the end mill may be used, for example, upward or laterally, the cutting edge of the edge of the end mill is directed downward. Is more ideal.

Moreover, the manufacturing apparatus of the abnormally shaped polarizing plate of this invention is a manufacturing apparatus of the abnormally shaped polarizing plate which has a hole part, Comprising: It is equipped with the end mill, and when the edge of the said end mill is a left edge and a right spiral, from the shank side When the rotation direction of the end mill is viewed counterclockwise, or when the edge of the end mill is a right-handed left spiral, the rotation direction of the end mill viewed from the shank side is clockwise.

Moreover, in the manufacturing apparatus of the special-shaped polarizing plate which has a hole part of this invention, the said end mill can be set to an appropriate apparatus by a well-known method.

Moreover, in the manufacturing apparatus of the abnormally shaped polarizing plate of this invention, even if the radius of the said hole part is 5 mm or less, it becomes easy to manufacture and process. The radius may be, for example, 1 mm or more and 5 mm or less, or may be 1 mm or more and 4 mm or less, or 2 mm or more and 3 mm or less. By using the above manufacturing method, even when the radius of the hole portion is 5 mm or less, the occurrence of cracks, breakage, and discoloration during the processing of the polarizing plate is suppressed, and the radius of the hole portion is set to 5 mm, for example. The manufacture of the irregularly shaped polarizing plate with the following small radius holes becomes feasible.

Moreover, in the manufacturing apparatus of the abnormally shaped polarizing plate of the present invention, although the edge of the edge of the end mill may be used, for example, upward or laterally, the edge of the edge of the end mill is downward. Is more ideal.

In addition, as the above-mentioned end mill, for example, the end mill described in FIG. 3 can be suitably used.

As the shape of the end mill, the number of blades should be set to 1 to 6, and the number of blades can be set to 1-4.

The bevel angle of the blade portion of the end mill is preferably 0 to less than 15 °, and may be set to 3 to 12 °. When the above-mentioned oblique angle is 15 ° or more, it is easy for the blade to form a notch.

The clearance angle of the blade portion of the end mill is preferably larger than 0 ° and smaller than 20 °, and may be set to 3 to 15 °. When the clearance angle is 0 °, it will cause friction with the film, and when it is 20 ° or more, the blade will easily form a notch.

The helix angle of the blade portion of the end mill is preferably -75 ° to 75 °, and may be set to -65 to 65 °. When the said helix angle exceeds the said range, it becomes easy to form a chip discharge defect.

The tool diameter (outer diameter) φ of the blade portion of the end mill is preferably 3 to 30 mm, and may also be 5 to 25 mm. When the above-mentioned tool diameter φ is less than 3 mm, it becomes easy to break, and when it is more than 30 mm, it becomes difficult to perform fine profile processing.

Moreover, as a manufacturing condition at the time of manufacture using an end mill, it is suitable to set the feed rate of the blade part of an end mill to 100-10000 mm / min, and it is also possible to set it to 200-8000 mm / min.

Moreover, in the manufacturing apparatus of the abnormally shaped polarizing plate of the present invention, as described above, when the edge of the end mill is a left edge and a right spiral, the end mill is viewed from the shank side (the orientation of the tip). The direction of rotation is counterclockwise (counterclockwise, reverse). It is also characterized in that when the cutting edge of the end mill is a right-handed left spiral, viewed from the shank side (orientation of the tool tip), the rotation direction of the end mill is clockwise (clockwise, forward) .

In addition, FIG. 4 is a schematic diagram showing a case where the right blade right spiral, the right blade left spiral, the left blade right spiral, and the left blade left spiral. Each solid line portion indicates the cutting edge of the outer peripheral edge, and the dotted line portion indicates the back surface of the outer peripheral edge. In the present invention, the right-handed left spiral is rotated clockwise, or the left-handed right spiral is rotated counterclockwise and moved in the machining direction together with the rotation of the blade portion of the end mill. , And continue the cutting process of the polarizing plate, and move the cutting chips to the direction of the tool tip and discharge. In addition, when the cutting edge of the end mill is set to perform cutting, it becomes possible to discharge the cutting chips downward, and contamination caused by the chips attached to the polarizing plate can be prevented. , Processed into a predetermined shaped polarizer.

In addition, the rotation speed of the blade portion of the end mill is preferably 1,000 to 120,000 rpm, and may be set to 2,000 to 60,000 rpm, or 3,000 to 50,000 rpm. When the rotation speed becomes slower than 1000 rpm, it may cause cracks. On the other hand, when the rotation speed becomes faster than 60,000 rpm, heat may be generated, which may cause damage to the polarizing plate and the like.

The polarizing plate used in the present invention is not particularly limited, and a known polarizing plate can be appropriately used. Examples of the above-mentioned polarizing plate include a polarizing plate manufactured by stretch molding, a polarizing plate manufactured by coating molding, and the like.

The polarizer is not particularly limited, and various polarizers can be used. Examples of the polarizer include adsorbing iodine on a hydrophilic polymer film such as a polyvinyl alcohol-based film, a partially formalized polyvinyl alcohol-based film, and an ethylene / vinyl acetate copolymer-based partially saponified film. A film obtained by uniaxially stretching a dichroic material such as a dichroic dye, or a polyolefin-based alignment film such as a dehydrated product of polyvinyl alcohol or a dehydrochlorinated product of polyvinyl chloride. Among these, a polarizer made of a polyvinyl alcohol-based film and a dichroic substance such as iodine is particularly preferable.

As a material of a polyvinyl alcohol-based film suitable for a polarizer, polyvinyl alcohol or a derivative thereof can be used. Examples of polyvinyl alcohol derivatives include polyvinyl formaldehyde, polyvinyl acetal, and the like, as well as unsaturated carboxylic acids such as olefins such as ethylene and propylene, acrylic acid, methacrylic acid, and crotonic acid, and Modified substances such as alkyl esters and acrylamide. The degree of polymerization of polyvinyl alcohol is preferably about 1000 to 10,000, and generally, polyvinyl alcohol having a degree of saponification of about 80 to 100 mol% is used.

The polyvinyl alcohol-based film (unstretched film) is subjected to uniaxial stretching treatment and iodine dyeing treatment according to at least a conventional method. In addition, a boric acid treatment and an iodine ion treatment can be further performed. The polyvinyl alcohol-based film (stretched film) subjected to the above-mentioned treatment is dried in accordance with a conventional method to obtain a polarizer.

The polarizing plate used in the present invention may be a polarizing plate in which a protective film is bonded to at least one side of a polarizer through an adhesive. The protective film may be laminated on one or both sides of the polarizer. The protective film may have other optical functions at the same time, and may be formed by further laminating other layers.

In the case where the polarizing plate has protective films on both sides of the polarizer, the protective film on one side and the protective film on the other side may be the same protective film or different protective films. In addition, at least one protective film may be used on each side, or a laminate of two or more layers may be used.

Although the thickness of the protective film can be appropriately determined, it is generally about 1 to 500 μm in terms of workability such as strength, workability, and thinness. It is particularly preferably 1 to 300 μm, and more preferably 5 to 200 μm.

Examples of the material constituting the protective film include thermoplastic resins having excellent transparency, mechanical strength, thermal stability, and moisture barrier properties. When optical isotropy is required for the protective film, it is preferable to select a resin having a small intrinsic birefringence. Specific examples of such thermoplastic resins include polyester resins, polyether fluorene resins, polyfluorene resins, polycarbonate resins, polyamine resins, polyimide resins, and polymer resins. An olefin resin, a (meth) acrylic resin, a norbornene resin, a polyarylate resin, and a mixture of these resins. Further, a thermosetting resin such as a (meth) acrylic-based resin or an ultraviolet curing resin may be used. Among the above, (meth) acrylic resins, polyimide-based resins, and norbornene-based resins are preferably used from the viewpoint of moisture permeability and optical characteristics.

As the protective film, the protective film on the cell side may also have a phase difference function for viewing angle compensation, and the opposite side of the protective film on the cell side may or may not have a phase difference.

On the surface adhering to the polarizer of the protective film, an easy adhesion treatment can be performed. Examples of the easy-adhesion treatment include dry treatment such as plasma treatment and corona treatment, chemical treatment such as alkali treatment (saponification treatment), and coating treatment for forming an easy-adhesion layer. Among these processes, a coating process or an alkali process for forming an adhesive layer is preferred. For the formation of the easy-adhesion layer, various easy-adhesion materials such as a polyol resin, a polycarboxylic acid resin, and a polyester resin can be used. In addition, the thickness of the easy-adhesion layer is usually set to about 0.001 to 10 μm, preferably about 0.001 to 5 μm, and more preferably about 0.001 to 1 μm.

A hard coating layer or an anti-reflective treatment, anti-sticking, diffusion, or even anti-glare treatment may be performed on the surface of the protective film that does not adhere to the polarizer.

The adhesive constituting the polarizing plate is not particularly limited as long as it is optically transparent. Although various types of adhesives, such as water-based, solvent-based, hot-melt, and radical curing types, can be used, but water-based adhesives or A radical hardening type adhesive is suitable.

Although the water-based adhesive for forming the adhesive layer is not particularly limited, examples thereof include vinyl polymer, gelatin, vinyl latex, polyurethane, isocyanate, and polyester. System, epoxy system, etc.

As the radical-curing adhesive, various adhesives such as an electron beam curing type, an ultraviolet curing type, and an active energy ray curing type and a heat curing type can be listed, but the active energy ray curing type can be cured in a short time. Type adhesives are preferred.

The manufacturing method of the special-shaped polarizing plate of the present invention is a method for manufacturing a special-shaped polarizing plate having a concave R portion and / or a hole portion, which is characterized by including a step of forming the concave R portion by a cutting mechanism such as an end mill. In the cutting mechanism, the cutting edge is brought into contact with the cutting surface in a lateral direction and performs cutting.

In the manufacturing of the polarizing plate itself at the previous stage of forming the concave R portion and / or the hole portion used in the present invention, a known method can be appropriately used. Furthermore, in the manufacturing method of the present invention, the step of forming the concave R portion by using a cutting mechanism such as an end mill that causes the cutting edge to abut against the cutting surface from the lateral direction and perform cutting is performed after the polarizing plate itself is manufactured. It may be carried out in the manufacturing steps of the polarizing plate itself as appropriate.

In the manufacturing process of the polarizing plate itself before forming the concave R portion and / or the hole portion, a known method can be appropriately used for cutting or the like. For example, in the stage of making it into a certain size before microfabrication, a conventional laser or the like is used to form a rectangular shape in advance, and fine concave R portions and / or holes are formed. It may be appropriately used as a production method or the like of the present invention at the stage of the process. In the former stage, although the shape of the polarizing plate at the time of this cutting is not particularly limited, it is generally only required to be a quadrangle and the cutting can be performed in the absorption axis direction and the transmission axis direction of the polarizing plate. In the former stage, for example, cutting by a laser may be performed on at least one end, but it is preferably performed in the absorption axis direction, the penetration axis direction, or both.

The production of the polarizing plate itself can be performed by, for example, a step of manufacturing by bonding the polarizer and the protective film using the adhesive. In the obtained polarizing plate, a protective film can be provided on one or both sides of the polarizer through an adhesive layer formed by the polarizing plate adhesive.

In addition, the above-mentioned polarizing plate can be used as an optical film laminated with other optical layers in practical applications. The special-shaped polarizing plate in the manufacturing method of the special-shaped polarizing plate of the present invention also includes, together with the special-shaped polarizing plate, a special-shaped optical film in which at least one layer of the polarizing plate is laminated. In the manufacturing method of the present invention, it may be set to make an optical film after undergoing a processing step of making the polarizing plate itself into a special shape, or may be set to first make an optical film and then go through a processing step of forming a special shape. You may use both together suitably.

Although the optical layer is not particularly limited, one or two or more optical layers for forming a liquid crystal display device or the like can be used, such as a reflective plate, a semi-transmissive plate, and a retardation plate (including 1/2 or 1/4 wavelength plate), viewing angle compensation film, etc. Particularly, a reflective polarizing plate or a transflective polarizing plate in which a reflective plate or a transflective reflecting plate is further laminated on the polarizing plate, and an elliptical polarizing plate in which a retardation plate is further laminated on the polarizing plate are particularly desirable. Or a circular polarizer, a wide-view polarizer made by laminating a viewing angle compensation film on the polarizer, or a polarizer made by laminating a brighter film on the polarizer.

An adhesive layer may be provided on the above-mentioned polarizing plate or an optical film in which at least one polarizing plate is laminated, to be adhered to other members such as a liquid crystal cell. Although the adhesive for forming the adhesive layer is not particularly limited, for example, an acrylic polymer, a silicone polymer, a polyester, a polyurethane, a polyamide, a polyether, and a fluorine-based polymer can be appropriately selected and used. A polymer such as rubber or the like is used as an adhesive for the base polymer. In particular, an adhesive that is excellent in optical transparency, such as an acrylic adhesive, can exhibit suitable wettability, cohesiveness, and adhesive properties, and is excellent in weather resistance and heat resistance.

Attaching an adhesive layer to one or both sides of a polarizing plate or an optical film can be performed in an appropriate manner. As this example, for example, a method can be mentioned in which a base polymer or a composition thereof is prepared by dissolving or dispersing a base polymer or a composition thereof in a solvent composed of a single kind or a mixture of appropriate solvents such as toluene or ethyl acetate, and the like. 40% by weight of an adhesive solution, and the solution is directly attached to a polarizing plate or an optical film by a suitable spreading method such as a casting method or a coating method, or formed on a separator according to the above. Adhesive layer, and transfer it to a polarizing plate or an optical film.

The adhesive layer can also be made as an overlapping layer of adhesive layers of different compositions or types, and is provided on one or both sides of the polarizing plate or optical film. In addition, when provided on both sides, an adhesive layer having a different composition, type, and thickness may be formed on the front and back surfaces of the polarizing plate or optical film. The thickness of the adhesive layer can be appropriately determined according to the purpose of use or adhesive force, and is generally 1 to 500 μm, preferably 5 to 200 μm, and particularly preferably 10 to 100 μm.

The exposed surface of the adhesive layer is for the purpose of preventing contamination, etc., and is temporarily installed and covered with a separation film before being supplied to the actual application. Thereby, it is possible to prevent contact with the adhesive layer in a normal operation state. As the separator, in addition to the above-mentioned thickness conditions, a suitable separator can be used, such as a plastic film, rubber sheet, paper, cloth, non-woven fabric, net, foam sheet, or metal foil, or the like. A suitable sheet is a separator or the like obtained by applying a suitable release agent such as a silicone-based or long-chain alkyl-based, fluorine-based, or molybdenum sulfide-based coating.

The above-mentioned polarizing plate or optical film can be preferably used for formation of various devices such as a liquid crystal display device. [Example]

Hereinafter, examples and the like which specifically show the configuration and effects of the present invention will be described.

[Examples and Comparative Examples] The processing in the examples and comparative examples was performed under the conditions shown in Table 1 below and processed into the processed shapes shown in FIG. 5. In addition, a laminated body in which a surface protection film (PPF-100T) manufactured by Nitto Denko Corporation was laminated on a polarizing plate (NPF-CWQ1463VDUAG380-ACJ) manufactured by Nitto Denko Corporation was used as a workpiece. The unit in FIG. 5 is mm. In addition, in Examples 1, 2, and Comparative Examples 1, 2, cutting was performed by setting the cutting edge of the end mill downward. [Table 1]

(Measurement and Evaluation of Degree of Freedom of Shape) The degree of freedom of shape of each of the irregularly shaped polarizing plates processed and manufactured in the examples and comparative examples was measured and evaluated as follows. In each of the examples and comparative examples, processing was performed on the polarizing plate to produce the irregularly shaped portions of the convex R portion, the concave R portion, and the hole portion as shown in FIG. It is "○", and when it is impossible, it is evaluated as "×". When the formation of the processed portion is possible, the minimum value that can be formed is measured using a three-dimensional measuring device (QV-Apex606) manufactured by Mitutoyo.

(Measurement and Evaluation of End Part Quality) The end part quality of each of the irregularly shaped polarizing plates processed and manufactured in the examples and comparative examples was measured and evaluated as follows. In each of the examples and comparative examples, when no cracks, breaks, or discoloration occurred at each end portion after processing and manufacturing, the evaluation was "○", and when cracks, breaks, or discoloration occurred. It was evaluated as "×". When cracks, breaks, or discoloration occur, the magnitude of these problems and the like are measured using a microscope. In addition, the evaluation of the accumulation of chippings is based on the case where the root of the cutting edge is visually observed and no chippings are accumulated, and "circumferential" is set to be visually observed even if a small amount of chips is still accumulated. Is "×". In addition, the evaluation of the contamination was "○" when the polarizing plate was seen visually without chipping, and when it was visually seen with a small amount of chipping, "Í".

The obtained results are shown in Table 2 below. [Table 2]

In Examples 1 and 2, the minimum value of R in the concave R is 3 mm. On the other hand, in Comparative Examples 1 and 2, the chips were accumulated at the root of the blade, and the chips also adhered to the polarizing plate and contaminated. In Comparative Examples 3 and 4, cracks of 100 μm at the maximum occurred. Further, in Comparative Examples 3 and 4, a breakage of a maximum of 1,000 μm occurred. In Comparative Example 5, discoloration of 50 μm at the maximum occurred.

As described above, when the manufacturing method in the embodiment of the present invention is used, it is possible to suppress the occurrence of chip accumulation, cracks, breakage, discoloration, and contamination, and to easily obtain especially the concave R portion and / or the hole portion having a small diameter. Shaped polarizing plate. On the other hand, when the manufacturing method in the comparative example was used, in addition to the accumulation of chips, cracks, breaks, discoloration, or contamination also occurred.

FIG. 1 shows an example of a deformed polarizing plate obtained by the method for producing a deformed polarizing plate of the present invention. FIG. 2 shows an example of an embodiment of a method for manufacturing a special-shaped polarizing plate of the present invention. FIG. 3 shows an example of an embodiment of a method for manufacturing a special-shaped polarizing plate of the present invention. FIG. 4 is a schematic diagram showing a method for manufacturing a special-shaped polarizing plate including the present invention. FIG. 5 is a diagram showing a processed shape performed in the embodiment of the present invention.

(no)

Claims (12)

A method for manufacturing a special-shaped polarizing plate, which is a method for manufacturing a special-shaped polarizing plate having a concave R portion, comprising: a step of forming the concave R portion by using a cutting mechanism, wherein the cutting mechanism allows a cutting edge to cut in a lateral direction; The cutting mechanism is an end mill. When the cutting edge of the end mill is a left edge and a right helix, the rotation direction of the end mill viewed from the shank side is counterclockwise or at the end. When the cutting edge of the milling cutter is a right spiral and a left spiral, the rotation direction of the end milling cutter viewed from the shank side is clockwise. The manufacturing method of the deformed polarizing plate according to claim 1, wherein a radius of the concave R portion is 5 mm or less. According to the method for manufacturing a special-shaped polarizing plate according to claim 1 or 2, wherein the edge of the blade of the end mill is downward. A manufacturing apparatus for a special-shaped polarizing plate, which is a manufacturing apparatus for a special-shaped polarizing plate having a concave R portion, comprising: a cutting mechanism that allows a blade edge to abut against a cutting surface from a lateral direction and perform cutting; the cutting mechanism is an end mill When the edge of the end mill is a left edge and right spiral, the rotation direction of the end mill is viewed counterclockwise when viewed from the shank side, or when the edge of the end mill is a right edge and left spiral, When viewed from the side, the rotation direction of the end mill is clockwise. The manufacturing apparatus of the abnormally shaped polarizing plate of Claim 4 whose radius of the said recessed R part is 5 mm or less. The manufacturing apparatus of the special-shaped polarizing plate according to claim 4 or 5, wherein the tip of the blade of the end mill is downward. A manufacturing method of a special-shaped polarizing plate is a method of manufacturing a special-shaped polarizing plate having a hole portion, which is characterized in that it includes a step of forming the hole portion by using an end mill, the cutting mechanism is an end mill, and the end mill When the cutting edge of the left end is right spiral, the rotation direction of the end mill viewed from the shank side is counterclockwise, or when the cutting edge of the end milling cutter is right side left spiral, the end milling cutter is viewed from the shank side. The rotation direction is clockwise. According to the method of claim 7, the radius of the hole is 5 mm or less. The manufacturing method of the special-shaped polarizing plate of claim 7 or 8, wherein the edge of the blade of the end mill is downward. A manufacturing device for a special-shaped polarizing plate having a hole portion is provided. The device includes an end mill. When the blade of the end-milling knife is a left-handed right spiral, the end is viewed from the shank side. The rotation direction of the milling cutter is counterclockwise, or when the cutting edge of the end mill is a right-handed left spiral, the rotation direction of the end mill is clockwise when viewed from the shank side. The manufacturing apparatus of the abnormal-shaped polarizing plate as described in claim 10, wherein a radius of the hole is 5 mm or less. The manufacturing apparatus of the abnormally shaped polarizing plate as claimed in claim 10 or 11, wherein the tip of the blade of the end mill is downward.