TW201811568A - Method for manufacturing optical member with separate film - Google Patents

Abstract

The present invention is to provide a method for manufacturing an optical member with separate film which is capable of maintaining good adhesion between an adhesive layer and its adjacent member, even if it undergoes bending caused by a flexible display. The method for manufacturing optical member with separate film of the present invention comprises the following steps: coating step that an active energy ray-curable type adhesive composition is coated on an elongated separate film to form a coating layer; exposure step that continuously transporting a separate film having a coating layer, while patterning exposure of the coating layer by irradiation with active energy ray to form a separate film having a coating layer comprises first exposed area and a second area having a smaller exposure amount than the first area; sticking step that while continuously conveying the film after the exposure step, a long optical member is laminated on the outer surface of the adhesive layer, and the laminate is being pressed from above and below.

Description

   Manufacturing method of optical module with release film   

The invention relates to a method for manufacturing an optical component with a release film, which comprises a release film, an adhesive layer, and an optical component in this order.

Various optical components typified by a polarizing plate and the like are used when they are bonded to other components such as an image display unit via an adhesive layer (for example, Patent Document 1). Therefore, the optical component circulates on the market in the form of an optical component with an adhesive layer attached to one side of the optical component in advance. Generally, a peelable release film (also called a "separation film") is temporarily provided on the outer surface of the adhesive layer to protect the surface.

    (Prior technical literature)         (Patent Literature)    

[Patent Document 1] Japanese Patent Laid-Open No. 2008-275722

As a display having both the optical component and the image display unit as described above, a flexible display having flexibility can be installed on a non-planar surface and a bent surface, and can be folded into a roll when carried. Can improve portability. Therefore, the portable device is expected to be used for assembly. For optical components with an adhesive layer used in flexible displays, even if the flexible display is bent (eg, bent, bent, etc.) or repeatedly bent, the adhesive layer is required to be adjacent to the component. Non-peeling adhesion.

An object of the present invention is to provide a method for manufacturing an optical component with a release film, wherein the optical component with the release film is a laminated body of the release film with an adhesive layer and the optical component, even for a flexible type The bending of the display can also maintain good adhesion between the adhesive layer and the adjacent components.

This invention provides the manufacturing method of the optical module with a peeling film shown below.

[1] A method for manufacturing an optical component with a release film, comprising the following steps: a coating step of applying an active energy ray-curable adhesive composition to a strip-shaped release film to form a coating layer Step; exposure step: while continuously transporting the above-mentioned release film with a coating layer, pattern exposure of the coating layer through irradiation of active energy rays to obtain a first area including the exposed area and an exposure amount less than the first area The step of peeling the adhesive layer of the second region of the first region; the laminating step: the film after the above exposure step is continuously transported, and a long optical component is laminated on the outer surface of the adhesive layer, and then A step of pressing the laminated body from above and below.

[2] The manufacturing method according to [1], in the above-mentioned exposure step, pattern exposure is performed through irradiation of the active energy ray through a mask.

[3] The manufacturing method according to [2], wherein the mask has a penetrating portion extending in a direction in which the release film having the coating layer is transported, and the penetrating portion is provided with coating along the penetrating portion. The release films of the layers are aligned in the width direction.

[4] The manufacturing method according to [2], wherein the mask is a gradation mask.

[5] The manufacturing method according to any one of [1] to [4], further including a curing step, which is a step of winding the optical module with a release film obtained by the above bonding step into a roll And then the step of curing the adhesive layer is performed in a rolled state.

[6] The manufacturing method according to any one of [1] to [5], in the exposing step, the active energy ray irradiates the coating layer a plurality of times.

[7] The manufacturing method according to any one of [1] to [6], further including a surface activation step, which is a step of bonding the adhesive layer to the optical component in the optical component before the bonding step. At least one of the bonding surface and the bonding surface of the adhesive layer and the optical component is subjected to a step of energy irradiation.

[8] The manufacturing method according to any one of [1] to [7], wherein the optical component is a polarizing plate.

According to the manufacturing method of the present invention, an optical component with a release film can be provided, and the optical component with the release film is adjacent to the adhesive layer for the bending in the flexible display used. Good adhesion can also be maintained between the components.

1‧‧‧ 1st feed roller

2‧‧‧ 2nd feed roller

3‧‧‧ Winding roller

10‧‧‧ peeling film

11‧‧‧ Coating

12‧‧‧ Adhesive layer

12a‧‧‧Region 1

12b‧‧‧Zone 2

15‧‧‧ release film with coating layer

20‧‧‧ Release film with adhesive layer

30‧‧‧Optical components

40‧‧‧ Optical unit with release film

50‧‧‧ coating device

60‧‧‧coating roller

70‧‧‧ drying means

80‧‧‧ exposure device (active energy ray irradiation device)

81‧‧‧Mask

81a‧‧‧ Hood

81b‧‧‧ Halftone Mask

82, 83‧‧‧ Halftone masked area

85‧‧‧ slit

90‧‧‧ Laminating roller

FIG. 1 is a schematic diagram showing an example of a method for manufacturing an optical module with a release film and a manufacturing apparatus used in the optical module of the present invention.

FIG. 2 is a schematic cross-sectional view showing an example of a release film having a coating layer.

FIG. 3 is a schematic cross-sectional view showing an example of a release film with an adhesive layer.

FIG. 4 is a schematic diagram showing an example of a bent state of the flexible display.

FIG. 5 is a schematic plan view showing a state where active energy rays are irradiated on the coating layer through a mask.

FIG. 6 is a schematic plan view showing an example of an arrangement pattern of the first region and the second region in the adhesive layer.

FIG. 7 is a schematic cross-sectional view showing an example of an irradiation method of active energy rays using a mask.

Fig. 8 is a schematic cross-sectional view showing another example of an irradiation method of active energy rays using a mask.

FIG. 9 is a schematic plan view showing another example of an arrangement pattern of the first region and the second region in the adhesive layer.

Fig. 10 is a schematic plan view showing another example of the arrangement pattern of the first region and the second region in the adhesive layer.

FIG. 11 is a schematic plan view showing another example of an arrangement pattern of the first region and the second region in the adhesive layer.

FIG. 12 is a schematic plan view showing another example of an arrangement pattern of the first region and the second region in the adhesive layer.

FIG. 13 is a schematic cross-sectional view showing an example of an optical module with a release film.

The method for producing an optical device with a release film of the present invention includes the following steps: a coating step: a step of applying an active energy ray-curable adhesive composition to a long release film to form a coating layer ; Exposure step: while continuously carrying a release film having a coating layer, while pattern-exposing the coating layer through irradiation of active energy rays, a first region including the exposed region and an exposure amount smaller than the first region are obtained The step of peeling off the adhesive layer in the second region; the laminating step: the film after the exposure step is continuously conveyed, and a long optical component is laminated on the outer surface of the adhesive layer, and then the laminate is laminated Press the body from above and below.

The method for manufacturing an optical module with a release film of the present invention may further include steps other than the above. Hereinafter, each step will be described with reference to the drawings. In addition, in the following, a release film having an adhesive layer bonded to a film intermediate of an optical component is also referred to as a "release film with an adhesive layer".

[Coating step]

This step is a step of applying an active energy ray-curable adhesive composition to the release film 10 to form a coating layer 11 to obtain a release film 15 having the coating layer 11 (see Figs. 1 and 2). . The application of the active energy ray-curable adhesive composition can be performed using a coating device 50.

(1) Release film

The release film 10 is generally a thermoplastic resin film, and a thermoplastic resin film having translucency (preferably optically transparent) is preferred. Specific examples of the thermoplastic resin include polyolefin resins such as chain polyolefin resins (polyethylene resin, polypropylene resin, etc.) and cyclic polyolefin resins (norbornene resin, etc.); Fluorinated polyolefin resins of fluoroethylene, polyvinylidene fluoride, polyfluorinated ethylene; such as polyester resins of polyethylene terephthalate resins, polyethylene naphthalate resins Resin; (meth) acrylic resin such as methyl methacrylate resin; cellulose resin such as cellulose triacetate [TAC], cellulose diacetate cellulose acetate resin; polycarbonate resin; Polyvinyl alcohol-based resins; polyvinyl acetate-based resins; polyarylate-based resins; polyfluorene-based resins; polystyrene-based resins; polyamine-based resins; polyether fluorene-based resins; polyfluorene-based resins; and These mixtures and copolymers. In this specification, "(meth) acrylic acid" means acrylic acid and / or methacrylic acid, and "(meth)" when it is called (meth) acrylate etc. also has the same meaning.

As for the peeling film 10, the surface of the side which has an adhesive layer laminated | stacked can be used, and the mold release process was performed. Examples of the release treatment are polysiloxane treatment, long-chain alkyl treatment, fluorine treatment, and the like. The thickness of the release film 10 is, for example, about 5 to 200 m, preferably 10 to 150 m, and more preferably 15 to 100 m.

(2) Active energy ray-curable adhesive composition

The active energy ray-curable adhesive composition is an adhesive composition that undergoes a hardening reaction by irradiation of active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. The active energy ray-curable adhesive composition is preferably an ultraviolet-curable adhesive composition. A preferable example of the ultraviolet curing adhesive composition is a (meth) acrylic ultraviolet curing adhesive composition containing a (meth) acrylic compound as a main component. In the present invention, any conventionally known active energy ray-curable adhesive composition can be used. The active energy ray-curable adhesive composition may be a solvent type, a solventless type, a water-dispersible type, or the like.

An example of the active-energy-ray-curable adhesive composition is a polymerizable monomer (hereinafter, also simply referred to as "polymerizable monomer") containing at least one active-energy-ray-curable site in one or two or more molecules. Adhesive composition. The active energy ray-hardening site is, for example, an ethylene double bond. A preferred active energy ray-curable adhesive composition is a (meth) acrylic adhesive composition containing a (meth) acrylic compound as a main component. In this case, a preferred polymerizable monomer is It is an active energy ray-curable (meth) acrylic monomer. One preferred example of the active energy ray-curable (meth) acrylic monomer is a (meth) acrylic monomer having a (meth) acrylfluorenyl group, and a specific example is represented by the following formula (I) (Meth) acrylate.

In the above formula (I), R ¹ represents a hydrogen atom or a methyl group, and R ² represents an alkyl group having 1 to 14 carbon atoms which may be substituted with an alkoxy group having 1 to 10 carbon atoms, or An alkoxy substituted aralkyl group having 7 to 21 carbon atoms. R ² is preferably an alkyl group having 1 to 14 carbon atoms which may be substituted with an alkoxy group having 1 to 10 carbon atoms. The (meth) acrylic acid esters represented by formula (I) may be used alone or in combination of two or more.

Specific examples of the (meth) acrylic acid ester represented by formula (I) include: the alkyl moiety of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, n-octyl acrylate, and lauryl acrylate is Linear alkyl acrylates; such as isobutyl acrylate, 2-ethylhexyl acrylate, and isooctyl acrylate with branched alkyl acrylates; such as methyl methacrylate and ethyl methacrylate Esters, propyl methacrylate, n-butyl methacrylate, n-octyl methacrylate, and lauryl methacrylate are linear alkyl methacrylates; such as isobutyl methacrylate, The alkyl part of 2-ethylhexyl methacrylate and isooctyl methacrylate is a branched alkyl methacrylate and the like.

When R ² is an alkoxy-substituted alkyl group, that is, when R ² is an alkoxy alkyl group, specific examples of the (meth) acrylic acid ester represented by the formula (I) include: 2-methoxy acrylate Ethyl ester, ethoxymethyl acrylate, 2-methoxyethyl methacrylate, ethoxymethyl methacrylate, and the like. Specific examples of the (meth) acrylate represented by the formula (I) when R ² is an aralkyl group having 7 to 21 carbon atoms include benzyl acrylate, benzyl methacrylate, and the like.

The (meth) acrylic monosystem having a (meth) acrylfluorenyl group may include a methacrylate having an alicyclic structure in the molecule. The carbon number of the alicyclic structure is generally 5 or more, preferably about 5 to 7. Specific examples of the (meth) acrylic acid ester having an alicyclic structure include isopropyl (meth) acrylate, cyclohexyl (meth) acrylate, dicyclopentyl (meth) acrylate, and (meth) Cyclododecyl acrylate, methyl cyclohexyl (meth) acrylate, trimethyl cyclohexyl (meth) acrylate, tertiary butyl cyclohexyl (meth) acrylate, cyclohexyl (meth) acrylate Phenyl ester, cyclohexyl α-ethoxyacrylate, and the like.

The polymerizable monomer system may include a polymerizable monomer having a polar functional group. The polymerizable monosystem having a polar functional group is preferably a (meth) acrylic monomer. Examples of the polar functional group include a heterocyclic group such as an ethoxy group, and the like, in addition to a free carboxyl group, a hydroxyl group, and an amine group.

Specific examples of the polymerizable monomer having a polar functional group include: a polymerizable monomer having a free carboxyl group such as (meth) acrylic acid and β-carboxyethyl (meth) acrylate; such as (meth) acrylic acid 2 -Hydroxyethyl ester, 3-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, 2- (2-hydroxyethoxy) ethyl (meth) acrylate, (meth) acrylic acid 2- or 3-chloro-2-hydroxypropyl, diethylene glycol mono (meth) acrylate polymerizable monomer having a hydroxyl group; such as acrylmorpholine, vinylcaprolactam, N- Vinyl-2-pyrrolidone, vinylpyridine, tetrahydrofuran methyl (meth) acrylate, tetrahydrofuran methyl acrylate modified, 3,4-epoxycyclohexyl meth (meth) acrylate Polymerizable monomers with heterocyclic groups, propylene oxide (meth) acrylate, 2,5-dihydrofuran; such as aminoethyl (meth) acrylate, N, N-di (meth) acrylate A polymerizable monomer having an amine group other than a heterocyclic ring, such as methylaminoethyl ethyl ester and dimethylaminopropyl (meth) acrylate. The polymerizable single system having a polar functional group may be used singly or in combination of two or more kinds.

Among the above, the polymerizable monosystem having a polar functional group is preferably a polymerizable monomer having a hydroxyl group and / or a polymerizable monomer having a free carboxyl group.

The polymerizable monomer may include, in addition to the polymerizable monomers exemplified above, for example, an aryloxyalkyl group having a phenoxyethyl group-containing (meth) acrylate represented by the following formula (II): (Meth) acrylates,

In the above (II), R ³ represents a hydrogen atom or a methyl group, n represents an integer of 1 to 8, and R ⁴ represents a hydrogen atom, an alkyl group, an aralkyl group, or an aryl group. When R ⁴ is an alkyl group, its carbon number may be about 1 to 9; if it is an aralkyl group, its carbon number may be about 7 to 11; if it is an aryl group, its carbon number may be about 6 to 10.

Examples of the alkyl group having 1 to 9 carbon atoms constituting R ⁴ in formula (II) include methyl, butyl, nonyl, and the like; examples of the aralkyl group having 7 to 11 carbon atoms include benzyl, Phenethyl, naphthylmethyl, and the like; aryl groups having 6 to 10 carbon atoms include phenyl, tolyl, naphthyl, and the like.

Specific examples of the phenoxyethyl-containing (meth) acrylate represented by the formula (II) include 2-phenoxyethyl (meth) acrylate and 2- (2-benzene) (meth) acrylate (Ethoxyethoxy) ethyl ester, (meth) acrylate of nonylphenol modified by ethylene oxide, 2- (o-phenylphenoxy) ethyl (meth) acrylate, and the like. The (meth) acrylic acid ester containing a phenoxyethyl group may be used individually by 1 type, and may use 2 or more types together. Among them, the phenoxyethyl-containing (meth) acrylates include 2-phenoxyethyl (meth) acrylate, 2- (o-phenylphenoxy) ethyl (meth) acrylate, and It is preferable to use 2- (2-phenoxyethoxy) ethyl (meth) acrylate.

Another example of the polymerizable monomer of a (meth) acrylic-type monomer is a (meth) acrylamide-type monomer. Specific examples of the (meth) acrylamide-based monomer include N-hydroxymethyl (meth) acrylamide, N- (2-hydroxyethyl) (meth) acrylamide, N- (3 -Hydroxypropyl) (meth) acrylamide, N- (4-hydroxybutyl) (meth) acrylamide, N- (5-hydroxypentyl) (meth) acrylamide, N- ( 6-hydroxyhexyl) (meth) acrylamide, N, N-dimethyl (meth) acrylamide, N, N-diethyl (meth) acrylamide, N-isopropyl (methyl) Propyl) acrylamide, N- (3-dimethylaminopropyl) (meth) acrylamide, N- (1,1-dimethyl-3-oxobutyl) (methyl) Acrylamide, N- [2- (2- pendant oxy-1-imidazolidinyl) ethyl] (meth) acrylamide, 2-propenylamino-2-methyl-1-propanesulfonate Acid, N- (methoxymethyl) acrylamide, N- (ethoxymethyl) (meth) acrylamide, N- (propoxymethyl) (meth) acrylamide, N -(1-methylethoxymethyl) (meth) acrylamide, N- (1-methylpropoxymethyl) (meth) acrylamide, N- (2-methylpropoxyl) Methyl) (meth) acrylamide [alias: N- (isobutoxymethyl) (meth) acrylamide], N- (butoxymethyl) (meth) acrylamide, N- (1,1-dimethylethoxy (Meth) (meth) acrylamide, N- (2-methoxyethyl) (meth) acrylamide, N- (2-ethoxyethyl) (meth) acrylamide, N -(2-propoxyethyl) (meth) acrylamide, N- [2- (1-methylethoxy) ethyl] (meth) acrylamide, N- [2- (1 -Methylpropoxy) ethyl] (meth) acrylamide, N- [2- (2-methylpropoxy) ethyl] (meth) acrylamide [alias: N- (2- Isobutoxyethyl) (meth) acrylamide], N- (2-butoxyethyl) (meth) acrylamide, N- [2- (1,1-dimethylethoxy) Group) ethyl] (meth) acrylamide and the like.

The (meth) acrylamide-based single system may be used alone or in combination of two or more.

The polymerizable monomer system may include other polymerizable monomers other than the (meth) acrylic monomer. Examples of other polymerizable monomers include styrene-based monomers and vinyl-based monomers. The polymerizable monomer system may contain one or more other polymerizable monomers.

Specific examples of the styrene-based monomer include: styrene; such as methylstyrene, dimethylstyrene, trimethylstyrene, ethylstyrene, diethylstyrene, triethylstyrene, and propylene Alkylstyrene, butylstyrene, hexylstyrene, heptylstyrene, octylstyrene; such as fluorostyrene, chlorostyrene, bromostyrene, dibromostyrene, iodostyrene Halostyrene; nitrostyrene, ethyl styrene, methoxystyrene, divinylbenzene, etc.

Specific examples of vinyl monomers include fatty acid vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, and vinyl laurate; such as vinyl chloride and vinyl bromide. Halogenated ethylene; such as vinylidene chloride; vinylidene halide; vinyl pyridine, vinyl pyrrolidone, and vinyl carbazole; nitrogen-containing aromatic ethylene; Co-working diene monomer; acrylonitrile, methacrylonitrile, etc.

The polymerizable single system may include a monomer having two or more ethylenic double bonds in the molecule, which are hardened by an active energy ray. An example of the polyfunctional monomer is a (meth) acrylic monomer having two or more (meth) acrylfluorenyl groups in a molecule.

Specific examples of the (meth) acrylic monomer having two or more (meth) acrylfluorene groups in the molecule include, for example, 1,4-butanediol di (meth) acrylate, 1,6-hexane Diethylene glycol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethyl Diethylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, tricyclodecanediyl dimethanol di (meth) acrylate, polyethylene Diethylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, two terminal (meth) acrylic acid adducts of bisphenol A diglycidyl ether, polyester di (meth) Acrylate, ethylene oxide or adduct of bisphenol A, diol di (meth) acrylate, hydrogenated bisphenol A, ethylene oxide or propylene oxide adduct Glycol di (meth) acrylate, tricyclodecanedimethanol di (meth) acrylate, cyclohexanedimethanol di (meth) acrylate have two (meth) acrylic acid in the molecule Monomers such as trimethylolpropane tri (methyl) propane Acid ester, trimethylolpropane trioxyethyl (meth) acrylate, neopentyl tetraol tri (meth) acrylate, tri (2-hydroxyethyl) trimeric isocyanate di (meth) acrylate 3. Tricyclodecane dimethanol di (meth) acrylate has three (meth) acrylfluorenyl monomers in the molecule; for example, neopentaerythritol tetra (meth) acrylate has four ( A monomer of meth) acrylfluorenyl; an epoxy (meth) acrylate obtained by adding a bisphenol A diglycidyl ether to a (meth) acrylate.

The active energy ray-curable adhesive composition of the (meth) acrylic-based active energy ray-curable adhesive composition may be composed of only the above-mentioned polymerizable monomer, but it is preferable that the active energy ray-curable adhesive composition contains one kind in addition to the polymerizable monomer Or two or more (meth) acrylic polymers and / or oligomers.

The (meth) acrylic polymer and / or oligomer may be a (co) polymer obtained by copolymerizing one or two or more of the polymerizable monomers. The (meth) acrylic polymer and / or oligomer are preferably those having one or two or more constituent units derived from the (meth) acrylic acid ester represented by the formula (I) as a main component. Out of 100 parts by weight of all the constituent units, it is more preferable to include 50 parts by weight or more of the constituent units, more preferably 60 parts by weight or more, and even more preferred to include 70 parts by weight or more. Among them, the (meth) acrylate represented by the formula (I) is preferably one containing n-butyl acrylate.

The (meth) acrylic polymer and / or oligomer is preferably one containing a structural unit derived from the polymerizable monomer having a polar functional group. The content of the constituent unit is generally from 0.1 to 20 parts by weight, and preferably from 0.4 to 10 parts by weight, based on 100 parts by weight of all the constituent units. The (meth) acrylic polymer and / or oligomer itself may have active energy ray-hardenable sites, such as an ethylenic double bond.

The weight average molecular weight Mw of the (meth) acrylic polymer by gel permeation chromatography (GPC) in terms of standard polystyrene may be, for example, 50,000 to 800,000. The active energy ray-curable adhesive composition system may include one or two or more (meth) acrylic polymers having Mw of 50,000 to 800,000. The active energy ray-curable adhesive composition may further include a (meth) acrylic polymer or oligomer having a Mw of less than 50,000.

When the active-energy-ray-curable adhesive composition includes the polymerizable monomer and the (meth) acrylic polymer and / or oligomer, these may be included as a part of the polymer of the polymerizable monomer.

The active energy ray-curable adhesive composition generally contains a photopolymerization initiator. Specific examples of the photopolymerization initiator include acetophenone, 2,2-diethoxyacetophenone, p-dimethylaminoacetophenone, methoxyacetophenone, and 2,2-diacetone. Acetophenones such as methoxy-2-phenylacetophenone, 2-hydroxy-2-cyclohexylacetophenone; diphenylketone, 2-chlorodiphenylketone, p, p'-dichloro Diphenyl ketone, p, p'-bis (diethylamino) diphenyl ketone, N, N'-tetramethyl-4,4'-diaminodiphenyl ketone, 4- (2- Ketones such as hydroxyethoxy) phenyl (2-hydroxy-2-propyl) ketone, 2-hydroxy-2-methyl-1-phenyl-propane-1-one; benzoin, benzoin Benzoin ethers such as methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether; thioxanthone, 2-chlorothioxanthone, 2- Thiothanone such as methyl thioxanthone; phosphine oxides such as bisfluorenylphosphine oxide, benzamidinephosphine oxide; ketals such as diphendione dimethyl ketal; pinane -2,3-dione, quinones such as phenanthrenequinone, etc. The photopolymerization initiators may be used alone or in combination of two or more.

The content of the photopolymerization initiator is generally 0.01 to 10 parts by weight, and preferably 0.05 to 5 parts by weight, with respect to 100 parts by weight of the active energy ray-curable component of the polymerizable monomer and the like.

The active energy ray-curable adhesive composition may further contain a crosslinking agent. Crosslinking agent is a compound having two or more polar functional groups in the molecule, such as a functional group capable of reacting with a reactive functional group possessed by an active energy ray-curable component, etc., to crosslink the active energy ray-curable component. Compound. Specific examples include isocyanate-based compounds, epoxy-based compounds, aziridine-based compounds, and metal chelate-based compounds. Among these, the isocyanate-based compound, the epoxy-based compound, and the aziridine-based compound have two or more functional groups in the molecule that can react with the polar functional group in the active energy ray-curable component. The crosslinking agent may be used singly or in combination of two or more kinds.

Isocyanate-based compounds are compounds having at least two isocyanate groups (-NCO) in the molecule. Specific examples of the isocyanate-based compound include toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, diphenylmethane diisocyanate, and hydrogenated diisocyanate. Phenylmethane diisocyanate, naphthalene diisocyanate, triphenylmethane triisocyanate, hydrogenated diphenylmethane diisocyanate; biuret form and trimer isocyanate form of these isocyanate compounds; such as ethyl isocyanate compounds Adducts obtained by the reaction of diols, propylene glycol, neopentyl glycol, trimethylolpropane, castor oil, glycerol and trimethylolpropane; these isocyanate compounds become dimers and trimers Wait.

An epoxy-based compound is a compound having at least two epoxy groups in the molecule. Specific examples of the epoxy-based compound include: bisphenol A epoxy resin, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerol diglycidyl ether, and triglyceride Glycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, N, N-glycidylaniline, N, N, N ', N'-tetraglycidyl-m-xylylenediamine, 1,3-bis (N, N'-glycidylaminomethyl) cyclohexane, and the like.

An aziridine-based compound is also referred to as ethyleneimine, and is a compound having at least two three-membered skeletons composed of one nitrogen atom and two carbon atoms in the molecule. Specific examples of the aziridine-based compound include diphenylmethane-4,4'-bis (1-aziridinecarboxamide) and toluene-2,4-bis (1-aziridinecarboxamide). , Triethylenemelamine, m-xylylenedi-bis-1- (2-methylaziridine), tri-1-aziridinylphosphine oxide, hexamethylene-1,6-bis (1-aziridinecarboxamide), trimethylolpropane-tri-β-aziridinylpropionate, tetramethylolmethane-tri-β-aziridinylpropionate, and the like.

Specific examples of metal chelate compounds include polyvalent metals such as aluminum, iron, copper, zinc, tin, titanium, nickel, antimony, magnesium, vanadium, chromium and zirconium, etc. Position of compounds, etc.

The content ratio of the crosslinking agent is generally 0.05 to 10 parts by weight, and preferably 0.1 to 5 parts by weight with respect to 100 parts by weight of the active energy ray-curable component.

The active energy ray-curable adhesive composition may further contain an ionic compound as an antistatic agent. The ionic compound is, for example, a compound having an inorganic cation or an organic cation, and an inorganic anion or an organic anion. The ionic compound may be used alone or in combination of two or more.

In terms of inorganic cations, for example, alkali metal ions such as lithium cation [Li ⁺ ], sodium cation [Na ⁺ ], potassium cation [K ⁺ ], and beryllium cation [Be ²⁺ ], magnesium cation [Mg ²⁺ ], Alkaline earth metal ions of calcium cations [Ca ²⁺ ], and the like.

Examples of the organic cation include an imidazolium cation, a pyridinium cation, a pyrrolidium cation, an ammonium cation, a sulfonium cation, and a sulfonium cation.

Among the above-mentioned cationic components, the organic cationic component has excellent compatibility in the adhesive composition. Among the organic cationic components, a pyrrolidinium cation and an imidazolium cation are advantageous from the viewpoint of antistatic properties.

Inorganic anions aspect, for example, include: chlorine anions [Cl ^-], bromine anion [Br ^-], iodide anion [I ^-], tetrachloroaluminate anion [AlCl ₄ ^-], heptachlor aluminum anions [Al ₂ Cl ^_7--], tetrafluoroborate anion [BF ₄ ^-], hexafluorophosphate anions [PF ₆ ^-], perchlorate anion [ClO ₄ ^-], nitrate anions [NO ₃ ^-], hexafluoroarsenate anion [AsF ₆ ^-], hexafluoroantimonate anion [SbF ₆ ^-], niobium hexafluorophosphate anion [NbF ₆ ^-], six tantalum fluoride anion [TaF ₆ ^-], dicyanimide ion [(CN) ₂ N ^- ] Etc.

Organic anion regard include, for example: acetate anion [CH ₃ COO ^-], trifluoroacetate anion [CF ₃ COO ^-], methanesulfonate anion [CH ₃ SO ₃ ^-], triflate anion [CF ₃ SO ₃ ^-], - toluenesulfonic acid anion _{[p-CH 3 C 6 H} 4 SO 3 -], bis (sulfo-fluoro-acyl) imide anion ^{_{[(FSO 2) 2 N -}} ], bis (trifluoromethyl methanesulfonamide acyl) imide anion _{[(CF 3 SO 2) 2} N -], tris (trifluoromethanesulfonyl acyl) methide anion _{[(CF 3 SO 2) 3} C -], dimethylphosphinic anion ^{_{[(CH 3) 2 POO -}} ], ( poly) hydrogen fluoride anion ^{_{[F (HF) n -]}} (n is about 1 to 3), thiocyanate anion [SCN ^-], perfluoro butane sulfonate anion ^{_{[C 4 F 9 SO 3 -}} ], bis (pentafluoroethane sulfonyl acyl) imide anion _{[(C 2 F 5 SO 2} ) 2 N -], perfluoro butyrate anion [C ₃ F ₇ COO ^-], (trifluoromethanesulfonyl acyl) (carbonyl trifluoromethanesulfonyl) imide anion _{[(CF 3 SO 2) (} CF 3 CO) N -], -1,3- perfluoropropane disulfonate anion ^[- _{O 3 S (CF 2) 3} SO 3 -], carbonate anion [CO ₃ ^2-] and the like. Among the above-mentioned anionic components, an anionic component containing a fluorine atom is advantageous from the viewpoint of antistatic properties.

Specific examples of the ionic compound may be appropriately selected from a combination of the above-mentioned cationic component and anionic component. Examples of the ionic compound having an organic cation by the structure of the organic cation are listed below.

Pyridinium salts: N-hexylpyridinium hexafluorophosphate, N-octylpyridinium hexafluorophosphate, N-octyl-4-methylpyridinium hexafluorophosphate, N-butyl-4-methyl Pyridinium hexafluorophosphate, N-decylpyridinium bis (fluorosulfonyl) imine, N-dodecylpyridinium bis (fluorosulfonyl) imine, N-tetradecylpyridinium bis (Fluorosulfonyl) imine, N-hexadecylpyridinium bis (fluorosulfonyl) imine, N-dodecyl-4-methylpyridinium bis (fluorosulfonyl) imine, N-tetradecyl-4-methylpyridinium bis (fluorosulfonyl) imine, N-hexadecyl-4-methylpyridinium bis (fluorosulfonyl) imine, N-benzyl 2-methylpyridinium bis (fluorosulfonyl) imine, N-benzyl-4-methylpyridinium bis (fluorosulfonyl) imine, N-hexylpyridinium bis (trifluoromethyl) Sulfofluorenyl) imine, N-octylpyridinium bis (trifluoromethanesulfonyl) imine, N-octyl-4-methylpyridinium bis (trifluoromethanesulfonyl) imine, N- Butyl-4-methylpyridinium bis (trifluoromethanesulfonyl) imine.

Imidazolium salts: 1-ethyl-3-methylimidazolium hexafluorophosphate, 1-ethyl-3-methylimidazolium p-toluenesulfonate, 1-ethyl-3-methylimidazolium bis (Fluorosulfonyl) imine, 1-ethyl-3-methylimidazolium bis (trifluoromethanesulfonyl) imine, 1-butyl-3-methylimidazolium methanesulfonate, 1- Butyl-3-methylimidazolium bis (fluorosulfonyl) imine.

Pyrrolidinium salts: N-butyl-N-methylpyrrolidinium hexafluorophosphate, N-butyl-N-methylpyrrolidinium bis (fluorosulfonyl) imine, N-butyl-N -Methylpyrrolidinium bis (trifluoromethanesulfonyl) imine.

Quaternary ammonium salts: tetrabutylammonium hexafluorophosphate, tetrabutylammonium p-toluenesulfonate, (2-hydroxyethyl) trimethylammonium bis (trifluoromethanesulfonyl) imine, (2 -Hydroxyethyl) trimethylammonium dimethyl phosphinate.

Examples of the ionic compound having an inorganic cation are as follows.

Lithium bromide, lithium iodide, lithium tetrafluoroborate, lithium hexafluorophosphate, lithium thiocyanate, lithium perchlorate, lithium trifluoromethanesulfonate, lithium bis (fluorosulfonyl) imide, bis (trifluoromethanesulfonyl) Lithium imine, lithium bis (pentafluoroethanesulfonyl) imide, lithium tris (trifluoromethanesulfonyl) methylate, lithium p-toluenesulfonate, sodium hexafluorophosphate, bis (fluorosulfonyl) Sodium imine, sodium bis (trifluoromethanesulfonyl) imine, sodium p-toluenesulfonate, potassium hexafluorophosphate, potassium bis (fluorosulfonyl) imide, bis (trifluoromethanesulfonyl) imide Potassium amine, potassium p-toluenesulfonate.

From the viewpoint of persistence of antistatic properties, it is preferable that the ionic compound has a melting point of 30 ° C or higher, or even 35 ° C or higher. On the other hand, from the viewpoint of compatibility with the active energy ray-curable component, the ionic compound preferably has a melting point of 90 ° C or lower, more preferably 70 ° C or lower, and even more preferably 50 ° C or lower.

The blending ratio of the ionic compound is preferably 0.2 to 8 parts by weight, and more preferably 0.2 to 5 parts by weight with respect to 100 parts by weight of the active energy ray-curable component. A content of the ionic compound of 0.2 parts by weight or more is advantageous for improving antistatic properties, and a content of 8 parts by weight or less is advantageous for improving the durability of the adhesive layer.

When the adhesive layer 12 of the release film 20 with the adhesive layer is attached to the optical component 30 made of glass, in order to improve the adhesiveness between the adhesive layer 12 and the glass, the active energy ray-curable adhesive composition can be further Contains silane compounds. Silane compounds can be used alone or in combination of two or more.

Examples of the silane compound include vinyltrimethoxysilane, vinyltriethoxysilane, methacryloxypropyltrimethoxysilane, and vinyltri (2-methoxyethoxy) silane. , N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane, N- (2-aminoethyl) -3-aminopropyltrimethoxysilane, 3- Aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 2- (3,4-epoxy Cyclohexyl) ethyltrimethoxysilane, 3-chloropropylmethyldimethoxysilane, 3-chloropropyltrimethoxysilane, 3-methacrylmethyloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethyl Oxymethylsilane, 3-glycidoxypropylethoxydimethylsilane, etc.

The silane compound may be a polysiloxane oligomer type. Examples of the polysiloxane oligomer include the following.

3-mercaptopropyltrimethoxysilane-tetramethoxysilane copolymer, 3-mercaptopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-mercaptopropyltriethoxysilane-tetramethoxyoxide Mercaptopropyl-containing copolymers, such as methylmercaptosilane copolymers, 3-mercaptopropyltriethoxysilane-tetraethoxysilane copolymers; mercaptomethyltrimethoxysilane-tetramethoxysilane copolymers, mercapto groups Methyltrimethoxysilane-tetraethoxysilane copolymer, mercaptomethyltriethoxysilane-tetramethoxysilane copolymer, mercaptomethyltriethoxysilane-tetraethoxysilane copolymer, etc. Copolymer containing mercaptomethyl; 3-glycidoxypropyltrimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltrimethoxysilane-tetraethoxysilane copolymer Polymer, 3-glycidoxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltriethoxysilane-tetraethoxysilane copolymer, 3- Glycidoxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldimethoxysilane-tetraethoxysilane copolymer Copolymer, 3-glycidoxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldiethoxysilane-tetraethoxysilane copolymer Copolymers containing 3-glycidyloxypropyl groups; 3-methacrylfluorenyloxypropyltrimethoxysilane-tetramethoxysilane copolymers, 3-methacrylfluorenyloxy Propyltrimethoxysilane-tetraethoxysilane copolymer, 3-methacrylfluorenyloxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-methacrylmethyloxypropyl Triethoxysilane-tetraethoxysilane copolymer, 3-methacrylfluorenyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-methacrylfluorenyloxy Propylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-methacrylmethyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-methyl Copolymers containing methacrylfluorenyloxypropyl, such as allylacryloxypropylmethyldiethoxysilane-tetraethoxysilane copolymer; 3-propenyloxypropyltrimethoxy Silane-tetramethoxysilane copolymer Polymer, 3-propenyloxypropyltrimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-propene Fluorenyloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-propenylsiloxane Oxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-propenylsiloxane Propylene methyloxypropyl-containing copolymers such as oxypropylmethyldiethoxysilane-tetraethoxysilane copolymer; vinyltrimethoxysilane-tetramethoxysilane copolymer, vinyl Trimethoxysilane-tetraethoxysilane copolymer, vinyltriethoxysilane-tetramethoxysilane copolymer, vinyltriethoxysilane-tetraethoxysilane copolymer, vinylmethyldi Methoxysilane-tetramethoxysilane copolymer, vinylmethyldimethoxysilane-tetraethoxysilane copolymer, vinylmethyldiethoxysilane-tetramethoxysilane Vinyl-containing copolymers such as oxysilane copolymers, vinylmethyldiethoxysilane-tetraethoxysilane copolymers; 3-aminopropyltrimethoxysilane-tetramethoxysilane copolymers , 3-aminopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-aminopropyltriethoxysilane-tetramethoxysilane copolymer, 3-aminopropyltriethoxy Silane-tetraethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetraethoxy Silane copolymer, 3-aminopropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldiethoxysilane-tetraethoxysilane copolymer, etc. Amine-based copolymers and the like.

The content ratio of the silane compound is generally 0.01 to 10 parts by weight, and preferably 0.05 to 5 parts by weight with respect to 100 parts by weight of the active energy ray-curable component. When the content of the silane compound is 0.01 parts by weight or more, the effect of improving the adhesion between the adhesive layer 12 and glass can be easily obtained. When the content is 10 parts by weight or less, bleeding of the silane compound from the adhesive layer 12 can be suppressed.

The active energy ray-curable adhesive composition system may contain one or two or more solvents (aromatic hydrocarbons, aliphatic hydrocarbons, ketones, esters, etc.), cross-linking catalysts, weathering stabilizers, and tackifiers. Additives, plasticizers, softeners, dyes, pigments, inorganic fillers, light-scattering particles, and tackifiers.

(3) Coating of active energy ray-curable adhesive composition

The method for applying the active energy ray-curable adhesive composition to the release film 10 using the coating device 50 is not particularly limited, and examples thereof include a slit die method, a reverse gravure coating method, a microgravure method, a dipping method, Roller coating method, flexographic printing method, etc. The thickness of the coating layer 11 composed of the active energy ray-curable adhesive composition is adjusted so that the thickness of the adhesive layer 12 of the release film 20 with the adhesive layer is within the following range.

As shown in FIG. 1, the coating step may be, more specifically, continuously coating an active energy ray-curable adhesive composition on one side of the long release film 10 continuously rolled from the first feed roll 1. The steps. At this time, as shown in FIG. 1, the release film 10 can be wound around the coating roller 60 while coating the active energy ray-curable adhesive composition at the same time.

[Exposure steps]

In this step, the peeling film 15 having the coating layer 11 is continuously transported, and at the same time, the coating layer 11 is irradiated with active energy rays, thereby performing pattern exposure, and obtaining the peeling of the adhesive layer with the adhesive layer 12 with the adhesive layer. Process of the film 20 (refer to FIG. 1 and FIG. 3). Through this step, the release film 20 with the adhesive layer 12 having the adhesive layer 12 is continuously manufactured as an intermediate of the optical module with the release film. The active energy ray is preferably ultraviolet.

On the adhesive layer 12 irradiated with active energy rays and exposed through a pattern, an exposed first region 12a and a second region 12b with an exposure amount smaller than the first region 12a are formed (FIG. 3). The second region 12b may be an unexposed region. However, it is preferable that the second region 12b is a region where the exposure amount is smaller than the first region 12a to a certain degree of exposure, and the hardening reaction proceeds to a certain extent through irradiation of active energy rays.

The arrangement pattern of the first region 12a and the second region 12b in the adhesive layer 12 can be selected according to the bending state of the flexible display used. An example of the bending state of the flexible display is shown in FIG. 4. Figure 4 (a) is a flexible display that can be rolled, and Figure 4 (b) is a foldable flexible display.

As shown in FIG. 1, the adhesive layer 12 including the first region 12 a and the second region 12 b can be irradiated with an active energy ray from an exposure device (active energy ray irradiation device) 80 through a mask 81. Layer 11 is formed by the method. The coating layer 11 may be irradiated with an active energy ray several times. By appropriately selecting the shape and characteristics of the slits of the mask 81 to be used, and the method of irradiating the active energy rays through the mask 81, the arrangement patterns of the first region 12a and the second region 12b can be obtained as desired. picture of. Specific examples of the arrangement pattern of the first region 12a and the second region 12b and the irradiation method of the active energy ray through the mask 81 are as follows.

a) FIG. 5 is a schematic plan view showing a state in which an active energy ray is irradiated on the coating layer 11 through a light shield 81 a. The arrows indicate the transport direction of the release film 15 having the coating layer 11. The light hood 81a has a plurality of slits (through portions) 85 extending along the lengthwise direction (conveying direction) of the release film 15 with the coating layer 11, and the plurality of slits 85 are along the film width direction. arrangement. The exposure device (active energy ray irradiation device) 80 is fixed to the hood 81a. For example, when the active energy ray from the exposure device 80 is irradiated onto the release film 15 having the coating layer 11 through the hood 81a, the first region 12a and the second region 12b can be obtained as shown in FIG. 6 (a).胶 胶剂 层 12。 Adhesive layer 12. This arrangement pattern is beneficial to the flexible display that can be rolled up as shown in FIG. 4 (a), and the first area 12a and the direction extending slightly perpendicular to the winding direction as shown in FIG. 6 (a) and The alternate arrangement of the second regions 12b can alleviate the stress during winding, and thereby can maintain the adhesion between the adhesive layer 12 and its adjacent components well.

b) If the mask 81 with the center portion in the width direction and the other portion as the penetration portion (slit) is used, the first region 12a and the second region 12b can be obtained, for example, as shown in FIG. 6 (b). Of the adhesive agent layer 12. This arrangement pattern is beneficial to the foldable flexible display shown in FIG. 4 (b). By setting the second region 12b at the position corresponding to the folded portion, the stress during folding can be reduced, and thus, adhesion can be achieved. The adhesive layer 12 maintains good adhesion with the adjacent components.

c) When the active energy ray is irradiated once with the slit mask of the mask 81a shown in FIG. 5, the light-shielded area becomes the second area 12b that is not exposed (the exposure amount is 0). On the other hand, as shown in FIG. 7, after the active energy ray is irradiated through the hood 81 a having the slit 85 (FIG. 7 (a)), the active energy is irradiated on the coating layer 11 without the hood. The multiple irradiation method of the ray (Fig. 7 (b)) can be used to create an exposed area of the second area 12b. The order of the steps of FIG. 7 (b) and the steps of FIG. 7 (a) may be reversed.

d) As shown in Fig. 8, when the active energy ray is irradiated through the half-tone mask 81b, the exposed second region 12b can be formed in a single irradiation. The half-tone mask 81b refers to a mask having a region 82 with a large amount of transmission of active energy rays and a region 83 with a smaller (non-zero) area.

e) FIGS. 9 to 12 show other examples of the arrangement pattern of the first region 12a and the second region 12b. The extension direction of the first region 12a and the second region 12b may be the transport direction of the film (or when the optical module 40 with a release film is formed into a sheet, for example, the short side direction) is parallel (Figure 9) ).

The width of the first region 12a and the second region 12b is not particularly limited, and when there are a plurality of these, they may be the same as each other (Fig. 10 (a)) or different (Fig. 10 (b)). The ratio of the first region 12a occupied by the surface of the adhesive layer 12 is not particularly limited, and the distance between adjacent first regions 12a can be shortened (Figure 11 (a)) or increased (Figure 11 (b) )). As shown in FIG. 12, the first area 12 a and / or the second area 12 b can gradually change the exposure amount along a certain direction. With such a gradation, the change (difference) of the storage modulus of the adhesive layer 12 at the boundary between the first region 12a and the second region 12b can be reduced, and thus the pair of adhesive layers 12 can be obtained. Bend durability. The first region 12a and / or the second region 12b whose exposure amount changes successively can be formed by irradiating active energy rays through a gradient mask. Gradient masks are masks that change the transmittance of active energy rays one after another along a certain direction.

The light source of the active energy ray irradiated on the coating layer 11 is not particularly limited. It is preferably ultraviolet rays having a light emission distribution below a wavelength of 400 nm. Specifically, low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, and chemical Lamps, black light lamps, microwave-excited mercury lamps, metal halide lamps, LED-type ultraviolet lamps, etc.

The irradiation intensity of the active energy ray on the coating layer 11 is, for example, 1 to 1000 mW / cm ² . The cumulative light amount expressed as the product of the light irradiation intensity and the light irradiation time is, for example, 10 to 5000 mJ / cm ² .

The thickness of the adhesive layer 12 included in the adhesive film-attached release film 20 obtained through the exposure step is, for example, 1 to 200 μm, and preferably 5 to 35 μm. A thickness of the adhesive layer 20 of 200 μm or less is advantageous from the viewpoint of thinning of the display and irradiation efficiency of active energy rays. In addition, if the thickness is 5 μm or more, it is advantageous that the stress is relaxed when the flexible display is bent, and the adhesiveness with adjacent optical components is improved.

[Laminating step]

This step is a step of laminating the optical component 30 on the outer surface of the adhesive layer 12 of the release film 20 with an adhesive layer to obtain an optical component 40 with a release film (see FIGS. 1 and 13). As shown in FIG. 13, the optical module 40 with a release film is a layer in which the release film 20 with an adhesive layer is laminated on the surface of the optical module 30 via the adhesive layer 12. According to the optical module 40 with a release film obtained according to the present invention, the flexible display formed by peeling and removing the release film 10 and laminating it to other optical components such as an image display unit through the exposed adhesive layer 20, even if it is bent, Good adhesion can also be maintained between the adhesive layer and its adjacent components (the optical component 30 and other optical components such as the image display unit). Therefore, a flexible display using the optical module 40 with a release film obtained by the present invention can be excellent in durability and reliability.

The bonding step can be specifically performed as follows. The long strip of adhesive film 20 with an adhesive layer obtained after the exposure step is continuously conveyed, and the long optical module 30 is unwound from the second feed roller 2 and continuously conveyed. The optical components are laminated on the A laminated body is formed on the outer surface of the adhesive layer 12 of the release film 20 with an adhesive layer. The laminated body is continuously manufactured by pressing the laminated body from above and below using a pair of bonding rollers 90 and the like to produce an optical module 40 with a release film. From the standpoint of the adhesiveness between the adhesive layer 12 and the optical component 30, the release film 20 with the adhesive layer obtained through the exposure step is supplied to the sticker with the optical component 30 without being rolled into a roll at one time. The combination step is preferably performed, and it may also be supplied to the bonding step with the optical module 30 after performing a surface activation treatment or the like as required.

FIG. 1 shows an example of a release film 20 having an adhesive layer attached to one side of the optical component 30. However, a release film 20 having an adhesive layer attached to both sides of the optical component 30 may be attached.

When the release film 20 with an adhesive layer is attached to both sides of the optical component 30, the release film 20 with an adhesive layer at both sides may be attached simultaneously or in stages.

The optical component 30 is an optical component that can be incorporated into a flexible display, and can be, for example, an optical film having a single-layer or multi-layer structure. Specific examples of optical films include: polarizing films; optical compensation films (such as retardation films), anti-reflection films (sheets), light diffusion films (sheets), reflective films (sheets), and other optical functional films; polarizing films Protective film; polarizing plate; glass film (including glass sheet and glass substrate), etc. The optical component 30 is preferably a polarizing plate.

The polarizing plate may be one in which a protective film is bonded to at least one side of the polarizing film through an adhesive layer. The protective film can also function as an optical compensation film such as a retardation film. The polarizing plate may be a layer having a curable resin layer made of a curable resin on at least one area of the polarizing film. In addition, other optical functional films such as a retardation film and a brightness enhancement film may be laminated on a polarizing film, a protective film, or a hardened resin layer through an adhesive layer or an adhesive layer.

A protective film may be laminated on a polarizing film, a protective film, or a hardened resin layer. A protective film is a peelable film temporarily attached to an optical component for the purpose of protecting the optical component from scratches and dust on the surface. Generally, the protective film is composed of a substrate film containing a thermoplastic resin and an adhesive layer laminated thereon. .

The polarizing film is a film having a function of taking out linearly polarized light from incident natural light. A preferred example is a film in which a uniaxially stretched polyvinyl alcohol resin film adsorbs dichroic dyes such as directional iodine and dichroic dye. The thickness of the polarizing film is not particularly limited, but is generally 2 to 35 μm.

The protective film may be a thermoplastic resin film having translucency (preferably optically transparent). Specific examples of the thermoplastic resin include polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.); polyester resins (polyesters) Ethylene phthalate resins, etc.); (meth) acrylic resins (methyl methacrylate resins, etc.); cellulose resins (such as cellulose triacetate, cellulose diacetate cellulose acetate resins) Etc.); Polycarbonate resin; Polyvinyl alcohol resin; Polyvinyl acetate resin; Polyarylate resin; Polystyrene resin; Polyether fluorene resin; Polyfluorene resin; Polyamine resin ; Polyimide resins; and mixtures and copolymers of these. The thickness of the protective film is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The curable resin layer is formed of a curable resin such as a thermosetting resin or an active energy ray-curable resin. The curable resin may include a thermally polymerizable compound, a cationically polymerizable compound, a radically polymerizable compound, or a plurality of these types. The thickness of the cured resin layer is, for example, about 0.1 to 10 μm, and preferably 1 to 5 μm.

When a protective film is bonded to both sides of the polarizing film, the protective films may be composed of the same type of thermoplastic resin, or may be composed of different types of thermoplastic resins. Moreover, the thicknesses may be the same or different. When two areas of the polarizing film have a hardened resin layer, the hardened resin layers may be composed of the same kind of hardenable resin layer, or may be made of different kinds of hardenable resin layers. Moreover, the thicknesses may be the same or different. The protective film or hardened resin layer may have a surface treatment layer (coating layer) such as a hard coat layer, an anti-glare layer, an anti-reflection layer, a light diffusion layer, an antistatic layer, an antifouling layer, and a conductive layer. When a protective film is laminated on one side of the polarizing film or a hardening resin layer is laminated, the adhesive layer 12 of the release film 20 with an adhesive layer can be directly adhered to the surface of the polarizing film.

The retardation film is an optical film showing optical anisotropy, and may be a uniaxially or biaxially stretched film of a thermoplastic resin film composed of a resin or the like that can be used in the above-mentioned protective film, and a liquid crystal coated with a thermoplastic resin film A film that exhibits optical anisotropy in a parallel orientation, a film that exhibits optical anisotropy by coating an inorganic layered compound on a thermoplastic resin film, and the like.

A protective film (or a retardation film, etc.) can be bonded to a polarizing film via an adhesive layer. As the adhesive for forming the adhesive layer, a water-based adhesive, an active energy ray-curable adhesive, or a heat-curable adhesive can be used. A water-based adhesive and an active energy ray-curable adhesive are preferred.

Examples of the water-based adhesive include adhesives containing a polyvinyl alcohol-based resin aqueous solution, and water-based two-liquid polyurethane-based emulsion adhesives. Among them, an aqueous adhesive containing an aqueous solution of a polyvinyl alcohol resin is suitable. For polyvinyl alcohol resins, in addition to vinyl alcohol homopolymers obtained by saponifying polyvinyl acetate, which is a homopolymer of vinyl acetate, copolymers of vinyl acetate and other monomers copolymerizable therewith may also be used. A polyvinyl alcohol-based copolymer obtained by saponification, or a modified polyvinyl alcohol-based polymer in which the hydroxyl group is partially modified. The water-based adhesive may include a crosslinking agent such as an aldehyde compound (such as glyoxal), an epoxy compound, a melamine-based compound, a methylol compound, an isocyanate compound, an amine compound, or a polyvalent metal salt.

When using a water-based adhesive, it is preferable to perform a drying step to remove water contained in the water-based adhesive after laminating the polarizing film and the protective film. After the drying step, an aging step may be performed, for example, at a temperature of about 20 to 45 ° C.

The active energy ray-curable adhesive refers to an adhesive that is cured by irradiating active energy rays such as ultraviolet rays, visible light, X-rays, and electron beams, and examples thereof include curable compositions containing a polymerizable compound and a photopolymerization initiator. , A curable composition containing a photoreactive resin, a curable composition containing a binder resin and a photoreactive crosslinker, and the like. A UV-curable adhesive is preferred. Examples of the polymerizable compound include photopolymerizable monomers such as a photocurable epoxy-based monomer, a photocurable (meth) acrylic monomer, and a photocurable polyurethane-based monomer. Monomer oligomer. The photopolymerization initiator includes, for example, a substance containing an active species such as a neutral radical, an anionic radical, and a cationic radical upon irradiation with active energy rays. As the active energy ray-curable adhesive containing a polymerizable compound and a photopolymerization initiator, a hardenable composition containing a photocurable epoxy-based monomer and a photocationic polymerization initiator can be preferably used; and photocurable (Meth) acrylic monomer and photoradical polymerization initiator hardening composition; containing photocurable epoxy monomer, photocurable (meth) acrylic monomer, photocationic polymerization initiation A hardening composition of an agent and a photoradical polymerization initiator.

When using an active-energy-ray-curable adhesive, the polarizing film and the protective film may be bonded together, and then a drying step may be performed as required. Agent), and then performing a hardening step of hardening the active energy ray-curable adhesive by irradiating the active energy ray. The source of the active energy ray is not particularly limited. It is preferably ultraviolet rays with a light emission distribution below a wavelength of 400 nm. Specifically, low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, chemical lamps, black light lamps, and microwave excitation can be used Mercury lamps, metal halide lamps, etc.

Prior to the bonding of the protective film, in order to improve the adhesion, the bonding surface of at least one of the polarizing film and the protective film may be subjected to, for example, corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, saponification treatment, primer Surface activation treatment for lacquer formation.

When a protective film is attached to both sides of the polarizing film, the adhesive used to attach the protective films may be the same type of adhesive or different types of adhesives.

[Other steps]

(1) drying step

The manufacturing method of the present invention may include a drying step of drying (solvent volatilization) the coating layer 11 of the release film 15 with the coating layer 11 between the coating step and the exposure step. This drying step is generally performed when the coating layer 11 (active energy ray-curable adhesive composition) contains a solvent. Referring to FIG. 1, the drying step can be carried out continuously by continuously introducing the long release film 15 having the coating layer 11 obtained through the coating step, and (introducing) the drying means 70.

The drying means 70 is not particularly limited as long as it is a means for volatilizing the solvent, and is, for example, a drying furnace (heating furnace). The drying furnace may further include a means for reducing pressure in addition to a means for heating. The drying conditions such as the amount of hot air supplied to the drying furnace, the temperature and pressure in the drying furnace, and the like are appropriately set in consideration of the surface state after drying, such as the type of solvent, smoothness, and dew condensation contained in the coating layer 11. The drying temperature (for example, the temperature in a drying furnace) is generally 50 to 120 ° C, and preferably 60 to 110 ° C.

(2) Surface activation step

The manufacturing method of the present invention may further include a surface activation step before the bonding step, more specifically, between the exposure step and the bonding step, on the bonding surface and adhesion of the optical component 30 and the adhesive layer 12 At least one side of the bonding surface between the agent layer 12 and the optical component 30 is irradiated with energy. The surface activation treatment in the surface activation step may be a corona treatment, a plasma treatment, an ultraviolet irradiation treatment, a flame treatment, a saponification treatment, or the like.

When surface activation treatment is performed on both the bonding surface of the optical component 30 and the adhesive layer 12 and the bonding surface of the adhesive layer 12 and the optical component 30, such surface activation treatment is performed by the adhesive layer 12 and the optical component From the viewpoint of the adhesion of 30, it is preferable that the time until the release film 20 with the adhesive layer reaches the bonding step after the exposure step is the same as the time until the optical component 30 after the surface activation treatment reaches the bonding step. Or at roughly the same time. In addition, from the viewpoint of the adhesiveness between the adhesive layer 12 and the optical component 30, the time period from the energy irradiation in the surface activation step to the pressing of the laminated body using a pair of bonding rollers 90 or the like in the bonding step, It is preferably 5 seconds or less. The surface activation treatment may be performed a plurality of times on the bonding surface.

(3) Winding step and curing step

The manufacturing method of the present invention may include a winding step of forming a film roll by winding a long strip of optical module 40 with a release film obtained through a laminating step around a winding roll 3 to form a roll (refer to (Figure 1). Furthermore, the manufacturing method of the present invention may include a curing step of curing (aging) the adhesive layer 12 in a rolled state after the winding step. By implementing the curing step to promote the hardening reaction of the adhesive layer 12, the adhesive force of the adhesive layer 12 can be improved. In addition, by curing the adhesive layer 12 in a state of being in close contact with the optical component 30 (hardening reaction of the adhesive), the interaction with the optical component 30 (including chemical reaction) and the wetting of the optical component 30 by the adhesive are improved. Therefore, the adhesion between the adhesive layer 12 and the optical component 30 can be further improved. The aging temperature is, for example, 20 to 45 ° C.

(4) Bonding steps with other optical components

The manufacturing method of the present invention may include a peeling step of peeling and removing the peeling film 10 from the optical element 40 with a peeling film, and bonding an optical element other than the optical element on the surface of the adhesive layer 12 exposed through the peeling step. Bonding step (second bonding step). After the peeling step and before the second bonding step, corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, saponification treatment, etc. may be performed on at least one of the adhesion layers of the adhesive layer 12 and the other optical components described above. Surface treatment such as primer layer forming treatment.

The other optical components mentioned above can be incorporated into the optical components of a flexible display, such as an image display unit. The image display unit is, for example, a flexible liquid crystal cell, an organic EL display element, or the like. The optical laminated system obtained through the laminating step (the second laminating step), when the other optical components are image display units, they have an image display unit / adhesive layer 12 / optical component 30 (such as polarized light) in this order. Board). In the flexible display including the optical laminated body having the structure, the stress generated in the adhesive layer 12 in a bent state can be alleviated. Therefore, even if the display is bent, the adhesive layer is adjacent to the adhesive layer. The components (the optical component 30 and the other optical components described above) can also maintain good adhesion.

Claims (8)

    A method for manufacturing an optical component with a release film includes the following steps: a coating step: a step of applying an active energy ray-curable adhesive composition to a strip-shaped release film to form a coating layer; Exposure step: while continuously carrying the release film having the coating layer, pattern exposure of the coating layer through irradiation with active energy rays, to obtain a first area including the exposed area, and an exposure amount less than the first area The step of peeling off the adhesive layer in the second region; the laminating step: while continuously transporting the film after the above exposure step, a long optical component is laminated on the outer surface of the adhesive layer, and then the The laminated body is extruded from above and below.         According to the manufacturing method described in item 1 of the scope of patent application, in the above-mentioned exposure step, pattern exposure is performed through irradiation of active energy rays through a mask.         The manufacturing method according to item 2 of the scope of patent application, wherein the mask has a penetrating portion extending in a direction in which the release film having the coating layer is transported, and the penetrating portion is provided along the coated portion. The release films of the cloth layer are aligned in the width direction.         The manufacturing method according to item 2 of the scope of patent application, wherein the mask is a gradation mask.         The manufacturing method according to any one of claims 1 to 4, further comprising a curing step of winding the optical module with a release film obtained by the above-mentioned bonding step into a roll. And then the step of curing the adhesive layer is performed in a rolled state.         According to the manufacturing method described in any one of the claims 1 to 5, in the above-mentioned exposure step, the active energy ray is irradiated to the coating layer a plurality of times.         The manufacturing method according to any one of claims 1 to 6, further comprising a surface activation step, which is performed prior to the above-mentioned laminating step, applying the optical component to the adhesive layer in the optical component. At least one of the bonding surface and the bonding surface of the adhesive layer and the optical component is subjected to a step of energy irradiation.         The manufacturing method according to any one of claims 1 to 7, wherein the optical component is a polarizing plate.