TW201928417A - Manufacturing method and manufacturing apparatus of optical member - Google Patents

Abstract

The present invention provides a manufacturing method and a manufacturing apparatus of optical member, by which adhesion of powder such as polishing swarf is less likely to adhere to the optical member. The manufacturing method of optical member according to the present invention including the steps of: preparing a laminate 100 having an optical film 50 and an adhesive layer 80 disposed on one surface of the optical film 50 and having powders f adhered to its end face E; and colliding dry ice particles d against the end face E of the laminate 100 to remove the powders f from the end face E.

Description

 Optical member manufacturing method and manufacturing device  

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

An optical member including an optical film such as a polarizer and an adhesive layer has been known.

A method of cutting a raw material laminate having an optical film and an adhesive layer by laser or a blade is known as a method of obtaining an optical member having a desired size (see Patent Documents 1 and 2).

 [Previous Technical Literature]    [Patent Literature]  

[Patent Document 1] WO2014/189078

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2009-86675

However, in recent years, the dimensional accuracy of optical members using optical films and adhesive layers has become stricter. Therefore, it is still difficult to obtain a desired dimensional accuracy by cutting only the original laminate. Among them, the end surface of the laminated body after cutting may be subjected to grinding, polishing, or the like.

However, when the end surface of the laminated body is subjected to polishing or the like, powder such as polishing dust may adhere to the end surface of the laminated body. If the powder remains in the laminate, contamination of the final product including the laminate is caused, which is not preferable.

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

The method for producing an optical member of the present invention comprises the steps of: preparing a layered body having an optical film and an adhesive layer provided on one surface of the optical film and adhering the powder to the end surface thereof (preparation step), and laminating the layer The step of colliding the above-mentioned end face with the dry ice particles and removing the powder from the end face (collision step).

According to the present invention, powders such as cutting chips, chips, and abrasive grains are appropriately removed from the end faces of the laminate (optical member) by dry ice particles.

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

Thereby, the powder such as the grinding chips can be appropriately removed, and the defect of the adhesive on the end surface can be suppressed.

Further, in the collision step, the end faces of the laminated structure in which the plurality of layers of the laminated body are laminated may collide with the dry ice particles.

Thereby, the laminate can be processed in a large amount.

Further, while a part of the end surface collides with the dry ice particles, at least one selected from the group consisting of cutting, cutting, and polishing may be applied to the other portion of the end surface of the laminated body.

Thereby, a plurality of steps can be performed in parallel at the same time to shorten the step time.

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

Thereby, since the environment (space) in which the powder is removed by the collision of the dry ice particles and the processing environment (space) in which the powder is generated can be distinguished, the powder generated by the end face processing can be suppressed from colliding with the dry ice. Part of the situation is contaminated.

The optical film may be at least one selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, and a touch sensor, or may be composed of two or more layers selected from the group described above. At least one laminated film may be a laminated film containing at least two selected from the group.

The relative humidity of the environment in the aforementioned collision step may be 30 to 75%.

The apparatus for producing an optical member according to the present invention includes: an end surface processed portion that cuts, cuts, or polishes an end surface of a laminate having an optical film and an adhesive layer provided on one surface of the optical film, and a layer processed portion of the laminated body The dry ice particle supply unit that collides with the dry ice particles in the processed portion of the end surface processing portion.

Further, the apparatus for manufacturing an optical member may further include: a conveying unit that moves the laminated body between the end surface processing unit and the dry ice particle supply unit.

According to the present invention, it is possible to provide a method and a manufacturing apparatus for an optical member having less adhesion of powder such as abrasive grains.

2‧‧‧Protective film

3‧‧‧ polarizer

50‧‧‧Optical film

70‧‧‧ protective film

80‧‧‧Adhesive layer

90‧‧‧Separator

100‧‧‧Layer

120‧‧‧Multilayer structure

200‧‧‧Face processing department

210‧‧‧Rotary axis

220‧‧‧ disc

230‧‧‧Cutter

240‧‧‧Cylinder

250‧‧‧ long blade

300‧‧‧ Dry Ice Particle Supply Department

310‧‧‧Liquid Carbon Dioxide Source

320‧‧‧Nozzles

330‧‧‧Transporting gas source

340, 360‧‧‧ valve

350‧‧ ‧ orifice

400‧‧‧Transportation Department

410‧‧‧Rotating mechanism

420‧‧‧Upper aids

420a‧‧‧ Dry ice particle supply port

422‧‧‧ lower aids

422b‧‧‧dry ice particle recovery port

430‧‧‧Cylinder

440‧‧‧Mobile agencies

1000‧‧‧Manufacture of optical components

D‧‧‧dry ice particles

E‧‧‧ end face

F‧‧‧ powder

L1, L2‧‧‧ pipeline

Fig. 1 (a) and Fig. 1 (b) are cross-sectional views showing a laminated body 100 according to an embodiment of the present invention.

Fig. 2 (a) and Fig. 2 (b) are cross-sectional views showing another example of the laminated body.

Fig. 3 is a schematic configuration diagram of a dry ice particle supply unit.

Fig. 4 is a conceptual diagram showing a state in which an end surface of a laminated structure 120 having a plurality of laminated bodies 100 collides with dry ice particles.

Fig. 5 is a perspective view showing an apparatus for manufacturing an optical member according to an embodiment of the present invention.

Fig. 6 is a perspective view showing another example of the end surface processed portion of Fig. 5.

Fig. 7 is a conceptual diagram showing a state in which the inner end surface of the laminated structure 120 having the through hole H' collides with the dry ice particles.

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

(Preparation of a laminate having a powder adhered to the end surface)

First, as shown in Fig. 1(a), a laminate 100 having an optical film 50 and an adhesive layer 80 provided on one surface of the optical film 50 and having a powder f adhered to the end surface E thereof is prepared. Further, the end surface E is not limited to the end surface of the outer side of the laminated body 100. For example, as shown in Fig. 1(b), when the laminated body 100 has the hole H penetrating in the lamination direction, the inner wall of the hole H, that is, the inner end surface E of the laminated body 100, also adheres to a powder such as open-cut swarf. f.

(optical film)

The so-called optical film 50 refers to a film that penetrates at least a portion of visible light.

Examples of the optical film 50 are a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, and a touch sensor. The optical film 50 may have a laminated structure having a plurality of such films. A laminated structure having a plurality of such thin films is provided.

(polarizer)

The so-called polarizer refers to a film in which the transmittance of linearly polarized light is different from each other in the vertical two directions in the surface. As the material of the polarizer, a known material used in the production of a conventional polarizer can be used, and examples thereof include a polyvinyl alcohol resin, a polyvinyl acetate resin, an ethylene/vinyl acetate (EVA) resin, a polyamide resin, and a poly Ester resin or the like. Among them, a polyvinyl alcohol-based resin is preferred. After the resin film is stretched, dyeing by iodine or a dichroic dye and boric acid treatment are carried out, whereby a film-shaped polarizer (thin film type polarizer) can be obtained.

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

Further, another example of the polarizer may be a liquid crystal coating type polarizer formed of a liquid crystal compound. The liquid crystal coating type polarizer can be produced, for example, by applying a liquid crystal polarizing composition to the substrate by using a suitable substrate. An alignment film can be formed before the liquid crystal polarizing composition is applied to the substrate. The liquid crystal polarizing composition may contain a liquid crystal compound and a dichroic dye compound. The liquid crystal compound may have a property of exhibiting a liquid crystal state, and particularly a nematic liquid crystal having a high liquid crystal state, and the obtained liquid crystal coating polarizer can exhibit high polarization performance, which is preferable. Further, it is also preferred that the liquid crystal compound has a polymerizable functional group. The dichroic dye compound exhibits a dichroic dye together with the liquid crystal compound, and the dichroic dye itself may have liquid crystallinity and may have a polymerizable functional group. Any of the compounds contained in the liquid crystal polarizing composition preferably has a polymerizable functional group. The liquid crystal polarizing composition may further contain a starter, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, a decane coupling agent, and the like.

Here, a typical example is shown in which a liquid crystal coating type polarizer is produced by applying an alignment film on a substrate and applying a liquid crystal polarizing composition to a substrate on which an alignment film is formed.

The thickness of the liquid crystal coated light-type polarizer produced by this method can be changed thinner than the above-mentioned thin film type polarizer. The liquid crystal coated light type polarizer has a thickness of 0.5 to 10 μm, preferably 1 to 5 μm.

For example, the alignment film can be applied to a coating film formed by coating an alignment film forming composition on a substrate, and imparting an alignment property by rubbing, polarized light irradiation or the like to form an alignment film on the substrate. The alignment film forming composition contains an alignment agent, and may contain a solvent, a crosslinking agent, a starter, a dispersant, a leveling agent, a decane coupling agent, and the like in addition to the alignment agent. Examples of the above-mentioned alignment agent include polyvinyl alcohols, polyacrylic acids, polyamic acids, and polyimines. When the photo-alignment is applied as a method for imparting the above-mentioned alignment property, an aligning agent containing a cinnamate group is preferred.

The aforementioned alignment agent may be a polymer. The polymer oriented agent has a weight average molecular weight of about 10,000 to 1,000,000. The thickness of the above-mentioned alignment film formed on the above-mentioned substrate is preferably from 5 nm to 10,000 nm, particularly from 10 to 500 nm, and exhibits sufficient alignment regulating force, which is preferable.

A liquid crystal polarizing film is applied onto a substrate on which an alignment film is formed, and if necessary, dried to form a coating film of a liquid crystal polarizing composition, and a liquid crystal coating type polarizing film is produced from the coating film of the liquid crystal polarizing composition.

The aforementioned liquid crystal polarizer produced in this manner can be peeled off from the substrate. In the method of peeling the liquid crystal coating type polarizer from the substrate, for example, the second substrate is bonded to the surface of the unlaminated substrate of the liquid crystal coating type polarizer, and then the substrate is peeled off to obtain a liquid crystal coating type polarizer. (2) The liquid crystal coating type polarizer can be transferred to the second substrate by using the method, and the liquid crystal coating type polarizer can be transferred to the second substrate without maintaining the laminate. The state of the substrate. The substrate or the second substrate is preferably a function of a transparent substrate that functions as a protective film, a retardation film, or a window film.

(protective film)

The protective film is a transparent film that prevents damage such as scratches of other optical films such as a polarizer, and/or scratches of the optical device (liquid crystal cell or the like) to be attached to the laminated body 100. The protective film may be various transparent resin films.

Here, a protective film for protecting the polarizer is described. Examples of the resin forming the protective film are a cellulose resin represented by cellulose triacetate, a polyolefin resin represented by a polypropylene resin, and a representative example of a decene-based resin. A cyclic olefin resin; an acrylic resin represented by a polymethyl methacrylate resin; and a polyester resin represented by a polybutylene terephthalate resin. Among these, cellulose-based resins are representative.

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

The protective film may optionally contain a plasticizer, an ultraviolet absorber, an infrared absorber, a pigment or dye coloring agent, a fluorescent whitening agent, a dispersing agent, a thermal stabilizer, a light stabilizer, an antistatic agent, an antioxidant, and a lubricating agent. Agent, solvent, etc.

In order to improve the scratch resistance of the surface of the protective film, a hard coat layer may be provided on at least one side of the protective film. The thickness of the hardened coating is usually in the range of 2 to 100 μm. When the thickness of the hard coat layer is less than 2 μm, it is difficult to ensure sufficient scratch resistance, and when it exceeds 100 μm, the buckling resistance is lowered, and when the protective film is bonded to a polarizer or the like, it may be caused by hardening and shrinkage. The problem of curling.

The hardened coating layer may be formed of a hardening coating composition containing a reactive material that forms a crosslinked structure by irradiation of an active energy ray or a heat ray. Among these, a hardened coating obtained by irradiation with an active energy ray is preferred. The so-called active energy line is defined as the energy line that can decompose a compound that produces an active species to produce an active species. Examples of the active energy rays include visible light, ultraviolet light, infrared light, X-rays, alpha rays, beta rays, gamma rays, and electron beams. Among these, ultraviolet light is particularly preferred. The hard coating composition preferably contains at least one of a radical polymerizable compound and a cationically polymerizable compound. The oligomer obtained by partially polymerizing the radically polymerizable compound and the cationically polymerizable compound may be contained in the hard coating composition.

First, a radical polymerizable compound will be described.

The radical polymerizable compound refers to a compound having a radical polymerizable group. The radical polymerizable group may be a functional group capable of generating a radical polymerization reaction, and examples thereof include a group containing a carbon-carbon unsaturated double bond, and a vinyl group or a (meth)acryl fluorenyl group. In addition, when the radically polymerizable compound has two or more radical polymerizable groups in one molecule, the radical polymerizable groups may be the same or different. When the radically polymerizable compound has two or more radical polymerizable groups in one molecule, the hardness of the obtained hard coat layer tends to increase. The radically polymerizable compound is preferably a compound having a (meth)acryl fluorenyl group from the viewpoint of high degree of reactivity, and for example, it has 2 to 6 (meth) acrylonitriles in one molecule. a compound called a multifunctional acrylate monomer, or an epoxy (meth) acrylate, a urethane (meth) acrylate, or a polyester (meth) acrylate. A plurality of (meth)acrylonitrile groups and oligomers having a molecular weight of several hundreds to several thousands. Among the compounds having a (meth)acryl fluorenyl group, one or more selected from the group consisting of epoxy (meth) acrylate, urethane (meth) acrylate, and polyester (meth) acrylate is Preferably.

Next, a cationically polymerizable compound will be described.

The cationically polymerizable compound refers to a compound having a cationically polymerizable group such as an epoxy group, an oxetane group or a vinyl ether group. The number of the cationically polymerizable groups of the cationically polymerizable compound in one molecule is preferably two or more, and more preferably three or more from the viewpoint of improving the hardness of the cured coating layer. Further, the cationically polymerizable compound is preferably a compound having at least one cationically polymerizable group of an epoxy group and an oxetanyl group. The cyclic ether group of an epoxy group or an oxetanyl group has an advantage that the shrinkage accompanying the polymerization reaction is small. Further, a compound having an epoxy group in a cyclic ether group is easy to obtain a compound having various structures from the market, and it is not easy to adversely affect the durability of the obtained hard coat layer. When a hard-coating composition is used together with a radically polymerizable compound and a cationically polymerizable compound, the compound having an epoxy group has an advantage of being easy to control compatibility with a radically polymerizable compound. Further, the oxetane group in the cyclic ether group has an advantage that the degree of polymerization is more likely to be higher than that of the epoxy group, and it is low in toxicity, and the network formed from the cationically polymerizable compound of the obtained hard coat layer is formed. In the region where the velocity and the radically polymerizable compound are mixed, the unreacted monomer remains in the film to form an independent network or the like.

Examples of the compound having an epoxy group include a polyglycidyl ether of a polyhydric alcohol having an alicyclic ring; and a ring containing a cyclohexene ring or a cyclopentene ring with a suitable oxidizing agent such as hydrogen peroxide or peroxy acid. An alicyclic epoxy resin obtained by oxidation; a polyglycidyl ether of an aliphatic polyol or an alkylene oxide adduct thereof; a polyglycidyl ester of an aliphatic long-chain polybasic acid; and a glycidyl (meth)acrylate An aliphatic epoxy resin such as a homopolymer or a copolymer; a bisphenol such as bisphenol A, bisphenol F or bisphenol A, or an alkylene oxide adduct or a caprolactone adduct or the like A glycidyl ether produced by a reaction between a derivative and epichlorohydrin; and a glycidyl ether type epoxy resin derived from a bisphenol or the like such as a novolak epoxy resin.

The hardening coating composition may further contain a polymerization initiator. The polymerization initiator may be selected from a suitable polymerization initiator (radical polymerization initiator, cationic polymerization initiator) depending on the kind of the polymerizable compound contained in the hard coating composition. These polymerization initiators are decomposed by at least one of active energy ray irradiation and heating to generate radicals or cations for radical polymerization or cationic polymerization.

The radical polymerization initiator may be one which can initiate radical polymerization by releasing at least one of active energy ray irradiation and heating. Examples of the thermal radical polymerization initiator include organic peroxides such as hydrogen peroxide and peroxybenzoic acid, and azo compounds such as azobisbutyronitrile.

The active energy ray radical polymerization initiator is a Type 1 type radical polymerization initiator which generates a radical due to decomposition of a molecule, and a Type 2 type radical polymerization which coexists with a tertiary amine and generates a radical in a hydrogen absorbing type reaction. Starting agents, these may also be used singly or in combination.

The cationic polymerization initiator may be one which can initiate the cationic polymerization by releasing at least one of the active energy ray irradiation and the heating. As the cationic polymerization initiator, an aromatic onium salt, an aromatic onium salt, a cyclopentadienyl iron (II) complex or the like can be used. Depending on the configuration, these may be initiated by any one or both of active energy ray irradiation or heating.

The content of the polymerization initiator may be from 0.1 to 10% by weight based on the total weight of the hard coating composition. When the content of the polymerization initiator is less than 0.1% by weight, the curing cannot be sufficiently performed, and the mechanical properties of the hardened coating layer finally obtained are likely to be lowered, or the adhesion between the cured coating layer and the protective film is likely to be difficult to be exhibited. When it exceeds 10% by weight, the adhesion failure, the cracking phenomenon, and the curling phenomenon may occur due to the hardening shrinkage at the time of formation of the hardened coating layer.

The hardening coating composition may further contain one or more selected from the group consisting of a solvent and an additive.

In the solvent, the polymerizable compound and the polymerization initiator may be dissolved or dispersed, and any solvent known as a hard coating composition of the technical region may be used without limitation.

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

Next, a method of bonding the protective film to the polarizer will be described.

The protective film of the polarizer is suitably attached to the polarizer via a binder. The water-based adhesive agent such as a polyvinyl alcohol-based resin aqueous solution or an aqueous two-liquid urethane-based emulsion adhesive; and a curable composition containing a polymerizable compound and a photopolymerization initiator; An active energy ray-curable adhesive such as a curable composition containing a photoreactive resin, a curable composition containing a binder resin and a photoreactive crosslinking agent, and the like.

The polyvinyl alcohol-based resin contained in the aqueous solution of the polyvinyl alcohol-based resin used as the adhesive agent is not the vinyl alcohol homopolymer obtained by saponifying the polyvinyl acetate which is a homopolymer of vinyl acetate. a vinyl alcohol-based copolymer obtained by saponifying a copolymer of vinyl acetate and another monomer copolymerizable with the vinyl acetate, or even a modified polyvinyl alcohol-based polymer modified by modifying the hydroxyl group Things and so on. A polyvalent aldehyde, a water-soluble epoxy compound, a melamine-based compound, a zirconia compound, a zinc compound or the like may be further added as an additive to such a water-based adhesive.

Moreover, the active energy ray-curable adhesive used as the adhesive agent may be the same as those listed as one of the above-mentioned hardening coating compositions, that is, a reactive material which forms a crosslinked structure by irradiating an active energy ray.

Although the above description has been made of a method of using a resin film as a protective film (or a protective film having a hard coat layer) and bonding it to a polarizer, a thinner protective layer may be directly laminated on the polarizer as a protective film. In place of the aforementioned resin film.

In the method of directly laminating a thinner protective layer on a polarizer, for example, a coating film containing an active energy ray-curable resin is formed on the surface of the polarizer, and the coating film is irradiated with an active energy ray (UV or the like). When hardened, a protective film thinner than the conventional protective film can be formed directly on the surface of the polarizer. The active energy ray-curable resin may be listed as one of the above-mentioned hardening coating compositions, that is, a reactive material that forms a crosslinked structure by irradiating an active energy ray.

(window film)

On the other hand, a transparent protective film that prevents the laminated body 100 from being damaged by scratches or the like of an optical device (liquid crystal cell or the like) to be attached later is also called a window film. For example, when the optical film 50 is provided with a laminated structure having a plurality of thin films, the window film is disposed on the outermost side of the plurality of thin films opposite to the surface on which the adhesive layer 80 is provided.

The window film system is disposed on the viewing side of the flexible image display device, and functions to protect other components from environmental changes such as flushing from outside or temperature and humidity. Although the conventional protective layer uses glass, the window film in the flexible image display device is not as rigid as glass, and has flexibility. The window film is composed of a flexible transparent substrate and may have a hard coat layer on at least one side.

(transparent substrate)

A transparent substrate that can be used as a window film is described.

The transmittance of visible light rays of the transparent substrate is 70% or more, preferably 80% or more. Any of the transparent substrates may be any polymer film having transparency. Specifically, the transparent substrate may be a film formed of the following polymer, or a film formed by using these polymers alone or in combination of two or more kinds thereof: having polyethylene, polypropylene, polymethyl group a polyolefin such as a cycloolefin derivative of a monomer of a pentene, a norbornene or a cycloolefin; a cellulose of diacetate, a cellulose triacetate, a cellulose propionate or the like (modified) cellulose; Acrylic acid such as methyl acrylate (co)polymer; polystyrene such as styrene (co)polymer; acrylonitrile-butadiene-styrene copolymer, acrylonitrile-styrene copolymer; ethylene-acetic acid Vinyl ester copolymers; polyvinyl chlorides, polydichloroethylenes; polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyarylate, etc. Polyesters; nylons and other polyamines; polyimines, polyamidiamines, polyetherimines; polyether oximes, polyfluorenes; polyvinyl alcohols, poly Ethylene acetals; polyurethanes; epoxy resins, etc.

Further, the film may also use an unstretched, uniaxial or biaxial stretching film. Preferably, among the polymer transparent substrates listed, a polyimide film, a polyimide film, a polyimide film, a polyester film, or an olefin film which is excellent in transparency and heat resistance. An acrylic film or a cellulose film is preferred. Further, among the transparent base materials, inorganic particles such as cerium oxide, organic fine particles, rubber particles or the like are preferably dispersed. In addition, it may also contain a coloring agent such as a pigment or a dye, a fluorescent whitening agent, a dispersing agent, a plasticizer, a heat stabilizer, a light stabilizer, an infrared absorber, an ultraviolet absorber, an antistatic agent, an antioxidant, and a lubricant. Formulation, solvent and other formulating agents. The transparent substrate has a thickness of 5 to 200 μm, preferably 20 to 100 μm.

(hardened coating)

A hardened coating layer may be provided on at least one side of the transparent substrate as a window film. The hard coat layer may be the same as the hard coat layer of the above protective film.

(phase difference film)

The retardation film-based refractive index is a transparent film which is different from each other in the vertical two directions in the surface, and is a phase difference imparted to the transmitted light.

Examples of the material of the retardation film are a polycarbonate resin film, a polyfluorene resin film, a polyether fluorene resin film, a polyarylate resin film, and a norbornene resin film.

These resin films can impart a desired phase difference by stretching.

Further, a retardation film which is easily obtained from the market can be used.

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

(enhanced film)

The brightness enhancement film is a film that reflects polarized light parallel to the first direction in the surface and reflects the polarized light parallel to the second direction perpendicular to the first direction in the surface. When the optical film used in the present invention has a polarizer, it is preferred that the first direction coincides with the transmission axis of the polarizer.

The brightness enhancement film may be a multilayer laminate in which a layer having birefringence and a layer having substantially no birefringence are alternately laminated. Examples of the material of the layer having birefringence are naphthalene dicarboxylic acid polyester (for example, polyethylene naphthalate), polycarbonate, and acrylic resin (for example, polymethyl methacrylate), but substantially have no double An example of a refractive layer is a copolyester of naphthalene dicarboxylic acid and terephthalic acid.

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

Each of the films constituting the optical film listed above may have a plurality of functions. For example, the protective film may be a film having an optical function of a retardation film or a brightness enhancement film.

(continued in the optical film)

When the optical film 50 is provided with a laminated structure including a plurality of thin films, the films may be followed by an intermediate agent. The subsequent agent is not particularly limited, and may be any of the above-described water-based adhesive or active energy ray-curable adhesive.

Further, an adhesive may be used as the adhesive. This adhesive is described later.

The thickness of the subsequent agent can be set to 1 to 200 μm.

(thickness of optical film when laminated)

When the optical film 50 is provided with a laminated structure including a plurality of thin films, the thickness of the entire optical film 50 can be set to 10 to 1200 μm.

(adhesive layer)

As described above, the laminated system used in the present invention has an optical film and an adhesive layer provided on one side thereof. The adhesive layer refers to those formed by an adhesive. Here, the adhesive is described.

The term "adhesive" refers to a pressure-sensitive adhesive which exhibits a state of a soft solid (viscoelastomer) in a temperature range near room temperature (for example, 25 ° C), and has a tendency to simply follow the substrate due to pressure. Material of nature. The adhesive referred to herein is as defined in "CADahlquist, Adhesion: Fundamentaland Practice", McLaren & Sons, (1966), p. 143", and generally may have a complex tensile modulus E* (1 Hz). A material having a property of 10 ⁷ dyne/cm ² (typically a material having the above properties at 25 ° C). The adhesive in the technique disclosed herein can also be understood as a constituent of a solid (non-volatile component) or an adhesive layer of the adhesive composition.

In the case of the adhesive, an acrylic resin, a styrene resin, a polyoxymethylene resin or the like is used as a matrix polymer, and a crosslinking agent such as an isocyanate compound, an epoxy compound or an aziridine compound is added thereto. Things. In the present specification, the term "matrix polymer" of the adhesive means a main component of the rubbery polymer contained in the adhesive. The rubbery polymer described above means a polymer exhibiting rubber elasticity in a temperature range near room temperature. Further, in the present specification, the term "main component" means a component having a content of more than 50% by weight, unless otherwise noted.

The thickness of the adhesive can be set to 1 to 40 μm.

(thickness of optical film when laminated)

When the optical film 50 is provided with a laminated structure including a plurality of thin films, the thickness of the entire optical film 50 can be set to 10 to 1200 μm.

The adhesive layer 80 is provided on at least one side of the optical film (single layer structure or laminated structure) 50.

The foregoing can be used as the adhesive.

(isolation film)

The laminate 100 may have a separator 90 on a surface on the opposite side of the surface of the adhesive layer 80 that is in contact with the optical film 50.

The separator 90 is a film having a lower adhesion to the adhesive layer 80 than the optical film 50. Before the optical film 50 is attached to another member such as an optical device (liquid crystal cell) via the adhesive layer 80, the separator 90 protects the surface of the adhesive layer 80 during transportation or storage of the laminated body 100. When the adhesive layer 80 is attached to another member, the separator 90 is easily peeled off from the adhesive layer 80.

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

(protective film)

Further, the laminated body 100 may have a protective film 70 disposed on the outer surface of the optical film 50 opposite to the surface on which the adhesive layer 80 is provided.

The protective film 70 has a suppressing optical device when the laminated body 100 is processed, or when the laminated body 100 is attached to an optical device (such as a liquid crystal cell) or when an optical device to which the laminated body 100 is attached is transported. And/or the function of scratching the optical film 50.

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

The protective film 70 may also have a film that protects the optical film 50 before the article using the optical film 50 is used. At this time, after the optical film 50 is attached to the optical device (liquid crystal cell or the like) via the adhesive layer 80, the protective film 70 is not peeled off from the optical film 50.

The protective film 70 may be attached to the optical film 50 via an adhesive layer or self-adhesion by electrostatic attraction.

Specific examples of the laminated structure of the laminated body 100 are shown in Fig. 2 (a) and Fig. 2 (b).

In the laminated body 100 of Fig. 2(a), a protective film 70, a protective film 2, a polarizing plate 3, a protective film 2, an adhesive layer 80, and a separator 90 are laminated in this order. The protective film 2, the polarizer 3, and the protective film 2 constitute the optical film 50.

In the laminated body 100 of FIG. 2(b), the protective film 70, the protective film 2, the polarizer 3, the adhesive layer 80, and the separator 90 are laminated in this order. The protective film 2 and the polarizer 3 constitute the optical film 50. Further, although not shown, in all of the examples, the film in each of the optical films 50 may be followed by an adhesive or an adhesive.

(Laminated body for flexible image display device)

The optical film 50 used in the present invention may be a laminate for a flexible image display device used in a flexible image display device such as a bendable device.

In the flexible image display device, a typical example is an image display device including a laminate for a flexible image display device and an organic EL display panel. In the typical example, the flexible image display device is disposed on the viewing side with respect to the organic EL display panel, and the flexible image display device constitutes a bendable person. The laminated body for a flexible image display device may include a window film, a circular polarizing plate, and a touch sensor. The order of stacking is arbitrary, but the window film and the circular polarizing plate are sequentially arranged from the viewing side. The lamination sequence of the touch sensor or the sequential order of the window film, the touch sensor, and the circular polarizer is preferably formed. When a circular polarizing plate is present on the viewing side of the touch sensor, the pattern of the touch sensor is difficult to see, and the visibility of the displayed image becomes excellent, which is preferable. Each member may be laminated using an adhesive, an adhesive, or the like. Further, a light shielding pattern formed on at least one surface of any one of the window film, the circular polarizing plate, and the touch sensor may be provided.

(circular polarizer)

The circularly polarizing plate is a functional film having a function of penetrating only the right or left circularly polarized light component by a λ/4 phase difference plate in which a linear polarizing plate is laminated as a retardation film. When the external light that has entered the display device passes through the circularly polarizing plate disposed on the viewing side, it is converted into right circularly polarized light and emitted to the organic EL panel side. When the right circularly polarized light is reflected (reflected light) by the metal electrode of the organic EL panel, the reflected light becomes left circularly polarized light. Since the left circular polarized light cannot penetrate the circular polarizing plate, as a result, the reflected light is not emitted outside the display device. With such a function, only the light-emitting component of the organic EL that is observed in the display panel of the display device can be easily viewed by preventing the influence of the reflected light by penetrating only the light-emitting component.

In order to achieve the circular polarization function, the absorption axis of the linear polarizing plate and the slow axis of the λ/4 phase difference plate must theoretically be 45°, but practically 45 ± 10°. The linear polarizing plate and the λ/4 phase difference plate are not necessarily adjacent to each other and laminated, as long as the relationship between the absorption axis and the slow axis satisfies the aforementioned range. Although it is preferable to achieve complete circularly polarized light in the entire wavelength range, there is no such need in practical use. Therefore, the circularly polarizing plate of the present invention also includes a circularly polarizing plate. It is also preferable to further laminate the λ/4 retardation plate on the viewing side of the linear polarizing plate to make the emitted light into circularly polarized light, thereby improving the visibility in the state in which the polarized sunglasses are worn.

The term "linear polarizing plate" refers to a functional layer having a function of passing light that vibrates in the direction of the transmission axis, but blocking the polarization of the vibration component perpendicular thereto. The linear polarizing plate is generally configured to include a polarizing plate and a protective film attached to at least one surface thereof. The polarizer may be either the film type polarizer or the liquid crystal coating type polarizer. The protective film can be used as described. The thickness of the linear polarizing plate constituting the circular polarizing plate is preferably 200 μm or less, more preferably 0.5 μm to 100 μm. When the thickness exceeds 200 μm, the flexibility (flexibility) applicable to the laminate for a flexible image display device may be lowered. By adjusting the thickness of the polarizer and the protective film, the appropriate thickness of the linear polarizer can be adjusted.

The λ/4 phase difference plate as the retardation film is also referred to as a quarter-wave plate, and is a phase difference of π/2 (=λ/4) to the polarizing surface of the incident light. A retardation film having such a property may be selected from the retardation film to prepare a λ/4 phase difference plate, but as another example, a liquid crystal coating type retardation film formed by coating a liquid crystal composition may be used as λ/4 phase difference plate. The liquid crystal coating type retardation film formed by applying the liquid crystal composition can obtain a λ/4 phase difference plate having an extremely small thickness as will be described later. Therefore, the liquid crystal coating type retardation film is particularly preferably a λ/4 phase difference plate which is a circularly polarizing plate constituting a laminate for a flexible image display device.

Here, a liquid crystal composition in which the aforementioned λ/4 phase difference plate is formed will be described.

The liquid crystal composition includes a liquid crystal compound having a property of exhibiting a liquid crystal state such as a nematic type, a cholesteric type, or a smectic type. The liquid crystal compound has a polymerizable functional group. The liquid crystal composition may contain a plurality of liquid crystal compounds, and when a plurality of liquid crystal compounds are contained, at least one of the liquid crystal compounds has a polymerizable functional group. The liquid crystal composition may further contain a starter, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a crosslinking agent, a decane coupling agent, and the like. In the same manner as described in the method for producing a liquid crystal polarizer, the liquid crystal coating type retardation film can be coated and cured by applying a liquid crystal composition to an alignment film of a substrate on which an alignment film is formed in advance. It is produced by forming a liquid crystal phase difference layer on the film. The thickness of the liquid crystal coating type phase difference plate can be made thinner than the extended phase difference plate. The liquid crystal polarizing layer has a thickness of 0.5 to 10 μm, preferably 1 to 5 μm. The liquid crystal coating type retardation film may be peeled off from the substrate and transferred to laminate, or the substrate may be directly laminated. The substrate is also preferably used as a transparent substrate as a protective film or a retardation film.

In a general material constituting the retardation film, generally, the birefringence becomes large as the wavelength becomes shorter, and the birefringence becomes smaller as the wavelength becomes longer. At this time, since the phase difference of λ/4 cannot be achieved in the all-visible light region, the in-plane phase difference of λ/4 is usually designed to be 100 to 180 nm, preferably 130 to 150 nm, in the vicinity of 560 nm where the visibility is high. In general, it is preferable to use an inversely dispersed λ/4 phase difference plate having a material having an inverse birefringence wavelength dispersion property to improve visibility. In the case of the above-mentioned material, it is preferable to use the Japanese Patent Publication No. 2007-232873, etc., and the liquid crystal coating type retardation plate is preferably used in the Japanese Patent Publication No. 2010-30979. The person stated in the communique.

Further, another method of forming a circularly polarizing plate and forming a preferable retardation film is known as a technique of obtaining a broadband λ/4 phase difference plate by combining with a λ/2 phase difference plate (Japanese Patent Laid-Open No. 10-90521) Bulletin). The λ/2 phase difference plate is also manufactured by the same material method as the λ/4 phase difference plate. The combination of the extended retardation film and the liquid crystal coating type retardation film is arbitrary, but both of them are preferably formed by using a liquid crystal coating type retardation film to reduce the thickness of the film.

In order to improve the visibility of the circular polarizing plate in the oblique direction, a method of laminating a positive C-plate is known (JP-A-2014-224837). The positive C plate may also be a liquid crystal coated phase difference plate or an extended phase difference plate. The positive C plate has a phase difference in the thickness direction of -200 to -20 nm, preferably -140 to -40 nm.

(touch sensor)

The touch sensor is used as an input means. As a touch sensor, various types such as a resistive film type, a surface elastic wave type, an infrared type, an electromagnetic induction type, and a capacitance type have been proposed, and any type can be used. Among these, a capacitor type is preferable.

Viewed from the surface of the display panel, the capacitive touch sensor is divided into an active area and an inactive area located in an outer contour portion of the active area. The active area is an area corresponding to the area (display portion) of the display panel display screen, and is an area for sensing the touch of the user, and the inactive area is an area corresponding to the area (non-display portion) on which the display device displays the screen.

The touch sensor may include: a substrate having a flexible property; a sensing pattern formed on the active region of the substrate; and each sensing line formed in an inactive region of the substrate and configured to transmit the sensing pattern The pad portion is connected to an external drive circuit. As the substrate having flexibility characteristics, a substrate formed of the same material as the transparent substrate of the above-described window film can be used. The substrate of the touch sensor has a mobility of 2,000 MPa% or more, and is preferable from the viewpoint of suppressing cracking of the touch sensor. More preferably, it is from 2,000 MPa% to 30,000 MPa%.

The sensing pattern may include a first pattern formed in the first direction and a second pattern formed in the second direction. The first pattern and the second pattern are arranged in directions different from each other. The first pattern and the second pattern are formed on the same layer, and in order to sense the location of the touch, each pattern must be electrically connected. The first pattern is formed by connecting the unit patterns to each other through the joint. However, since the second pattern is formed such that each unit pattern is separated into an island form, an additional bridge electrode is required in order to electrically connect the second pattern. The sensing pattern is formed from a well-known transparent electrode material. Examples of the transparent electrode material include indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium zinc zinc oxide (IZTO), cadmium tin oxide (CTO), and poly(3,4-ethylene two). Oxythiophene) (PEDOT), carbon nanotubes (CNT), graphene, and metal wires (metals used for the metal wires are not particularly limited, and examples thereof include silver, gold, aluminum, copper, iron, nickel, titanium, and antimony. Chromium, etc. These may be used alone or in combination of two or more kinds, and the like may be used alone or in combination of two or more. It is preferably ITO. A bridge electrode may be formed on the upper portion of the insulating layer via an insulating layer on the upper portion of the sensing pattern, or a bridge electrode may be formed on the substrate, and an insulating layer and a sensing pattern may be formed thereon. The bridge electrode may be formed of the same material as the sensing pattern, or may be formed of a metal such as molybdenum, silver, aluminum, copper, palladium, gold, platinum, zinc, tin, titanium or two or more of these. The first pattern and the second pattern must be electrically insulated, so that an insulating layer is formed between the sensing pattern and the bridge electrode. The insulating layer may be formed only between the junction of the first pattern and the bridge electrode, or may be formed as a layer covering the sensing pattern. In the latter case, the bridge electrode can be connected to the second pattern through a contact hole formed in the insulating layer. The touch sensor may further include an optical adjustment layer between the substrate and the electrode to appropriately compensate for a difference in transmittance between the patterned pattern region and the unpatterned non-pattern region, specifically It is the difference in light transmittance caused by the difference in refractive index in the regions. The aforementioned optical adjustment layer may contain an inorganic insulating material or an organic insulating material. The optical adjustment layer can be formed by applying a photocurable composition containing a photocurable organic binder and a solvent onto a substrate. The photohardenable composition may further contain inorganic particles. The refractive index of the optical adjustment layer can be increased by the aforementioned inorganic particles.

The photocurable organic binder may include, for example, a copolymer of each monomer such as an acrylate monomer, a styrene monomer, or a carboxylic acid monomer. The photocurable organic binder may be, for example, a copolymer comprising repeating units containing an epoxy group, an acrylate repeating unit, a carboxylic acid repeating unit, and the like, which are different from each other.

The inorganic particles may include, for example, zirconia particles, titanium oxide particles, alumina particles, or the like.

The photocurable composition may further contain each additive such as a photopolymerization initiator, a polymerizable monomer, and a curing agent.

The respective layers (the window film, the circularly polarizing plate, and the touch sensor) for forming the laminated body for the flexible image display device can be formed by an adhesive. The subsequent agent is usually a water-based adhesive or an active energy ray-hardening adhesive or an adhesive as described.

(shading pattern)

The light shielding pattern can be applied as at least one of a frame or a casing of the aforementioned flexible image display device. By hiding the wiring disposed at the edge portion of the flexible image display device in a light-shielding pattern, it is difficult to view the image, and the visibility of the image can be improved. The light shielding pattern may be in the form of a single layer or a plurality of layers. The color of the light-shielding pattern is not particularly limited, and may be various colors such as black, white, and metallic. The light-shielding pattern can be formed of a pigment for expressing a color, and a polymer such as an acrylic resin, an ester resin, an epoxy resin, a polyurethane, or a polyoxyn resin. These may be used alone or in a mixture of two or more types. The light-shielding pattern can be formed by various methods such as printing, lithography, and inkjet. The thickness of the light shielding pattern may be from 1 μm to 100 μm, preferably from 2 μm to 50 μm. Further, a shape such as a slope can be imparted to the thickness direction of the light shielding pattern.

The optical film and the adhesive contained in the laminate used in the production method of the present invention have been described above. Next, the manufacturing method of the present invention will be described.

(powder)

The manufacturing method of the present invention will be described with reference to Figs. 1(a) and 1(b) again.

The powder f adhering to the end surface E of the optical film 50 is adhered to the end surface by the processing of the end surface of the laminated body 100. Usually, in order to obtain the laminated body 100 of a desired size from the raw material of the laminated body 100, the end surface of the laminated body 100 is processed. Examples of processing are cutting, cutting, and grinding. Here, the so-called cutting is a concept including an opening. Therefore, as described above, the end surface of the laminated body 100 includes not only the end surface E of the outer side of the laminated body 100 shown in Fig. 1(a) but also the inner wall of the hole (opening) H in which the laminated body 100 is formed. The inner end face E.

The term "cutting" refers to a step of forming a slit from the surface to the back surface of the laminated body by inserting a blade, removing by a laser, or the like, whereby the structure of the laminated body can be established.

The so-called cutting refers to a step of cutting a part of the end portion by bringing a relatively moving cutting blade (blade) into contact with the end portion of the laminated body to form a new end surface. Further, the cutting includes the drilling process as described above. For example, as shown in FIG. 1( b ), the hole forming process is performed by using a drill or the like on the laminated body 100 and providing the hole H at a desired position. In such a drilling process, the powder f (opening processing chips) may be attached to the end surface E on the inner side of the inner wall forming the hole H.

By grinding is meant the step of contacting relatively moving abrasive particles (which may be fixed abrasive particles or free abrasive particles) with the end faces of the laminate to cut a portion of the end faces. Grinding also includes a step called grinding.

For example, after the original material of the laminated body 100 is cut into a planar shape slightly larger than a desired size by a blade or a laser, the end surface of the cut laminated body is ground and/or polished, and the planar shape of the laminated body can be set in advance. The dimensions are set and the straight angle or planarity of the end faces can be increased.

The planar shape of the laminate (the shape viewed from the thickness direction) is not particularly limited. For example, it can be set as a square, a rectangle, a circle, or the like

A powder of a material constituting the layered body 100 is generated by the processing of the end faces of the laminate, and a part thereof adheres to the end surface E of the layered body 100. Therefore, the processing of the above-mentioned laminated body is an embodiment of the production steps in the production method of the present invention. The end face E may be a surface that connects the two main faces of the laminated body 100.

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

(collision step (step of removing powder by collision of dry ice particles))

Next, the dry ice particles collide with the end surface E of the laminated body 100 to remove the powder f on the end surface from the end surface.

Specifically, the dry ice particles are transported by gas, and it is suitable to collide with the end surface E of the laminated body 100.

The average particle diameter of the dry ice particles to be collided is not particularly limited, and is preferably 100 μm or more from the viewpoint of efficiently removing the powder. Moreover, from the viewpoint of suppressing the adhesion of the adhesive layer by dry ice, it is preferably 1000 μm or less.

The average particle size of the dry ice particles can be determined by a laser Doppler Velocimeter.

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

The transport gas of the dry ice is not particularly limited, and may be, for example, nitrogen, air, or carbonic acid gas.

Specifically, a dry ice particle supply unit (apparatus) 300 as shown in Fig. 3 can be used.

This apparatus includes a liquid carbon dioxide source 310, a nozzle 320, a transport gas source 330, a line L1 that connects the liquid carbon dioxide source 310 and the nozzle 320, and a line L2 that connects the transport gas source 330 and the nozzle 320.

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

The valve 340 is opened to cause the liquid of the liquid carbon dioxide source 310 to adiabatic expansion at the orifice 350 to generate dry ice particles (dry ice) and to the nozzle 320. The valve 360 is opened, gas is supplied from the carrier gas source 330 to the nozzle 320, and the dry ice particles d are ejected from the nozzle 320 by the gas and supplied to the end face E of the laminated body 100.

The particle diameter of the dry ice particles d can be adjusted by the distance (adiabatic expansion distance) after the adiabatic expansion of the orifice 350 until it is ejected by the nozzle 320, or the distance (injection distance) between the nozzle 320 and the supply target of the dry ice particles. Further, an appropriate preliminary experiment using the dry ice particle supply unit (device) may be performed, and the degree of removal of the powder f may be confirmed to adjust the adiabatic expansion distance or the ejection distance.

The distance (ejection distance) between the nozzle 320 and the end surface E of the laminated body 100 is preferably set to less than 20 mm. Further, the adiabatic expansion distance can be, for example, 10 to 500 mm.

By moving the position of the laminated body 100 and the nozzle 320 by the conveying unit 400, it is preferable that the portion where the dry ice particles d collide is swept on the end surface E. For example, in the third embodiment, the layered body 100 can be swept in a surface perpendicular to the discharge direction (lateral direction) of the dry ice particles d by the conveyance unit 400 to move the collision portion of the dry ice particles d of the end surface E.

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

(action)

According to the present embodiment, since the dry ice particles d are blown to the end surface E of the laminated body 100, powders such as cutting chips, chips, drilling chips, and grinding dust are appropriately removed from the end faces. Thereby, it is preferable to reduce the contamination by the powder in the subsequent step. Moreover, the time taken for the removal of the powder is also shorter than the method of attaching and peeling off the tape.

In addition, when the particle size of the dry ice particles to be collided is 100 to 1000 μm, the removal rate of the powder can be improved and the defect of the adhesive layer on the end surface can be suppressed. Therefore, it is more preferably 200 to 700 μm.

(The powder of the laminated structure having a plurality of laminated layers is removed)

In the above, the layered body 100 collides with the dry ice particles. However, as shown in Fig. 4, it is also preferable that the end face E of the laminated structure body 120 in which the plurality of laminated bodies 100 are laminated in the thickness direction collide with the dry ice. Thereby, the laminated body 100 can be processed in a large amount.

(Order processing and removal order of powder)

After the processing (cutting, cutting, and polishing) of a part of the end surface of the laminated body 100 is completed, while the other portion of the end surface of the laminated body 100 is being processed, the dry ice particles may be simultaneously blown to the end portion of the end surface to remove the powder. body. Thereby, the step time can be shortened.

On the other hand, after the end surface of the laminated body is cut, cut, polished, and the like, the end faces of the laminated body 100 are collided with the dry ice particles to clean the powder of the end face, and when the dry ice particles are collided with the end faces, the laminated body may not be laminated. Processing of other parts of the end face. In this case, it is possible to distinguish between an environment (space) in which the powder is removed by collision of dry ice particles, and an environment (space) in which the end surface is processed, so that end surface contamination due to powder generated by the processing can be prevented.

(the environment at the time of the collision step (the removal step of the powder))

In the step of removing the powder of the layered body and the end face of the laminated structure by the dry ice particles, the surrounding environment of the laminated body and the laminated structure may be an air environment, but may be an environment such as nitrogen or carbonic acid gas if necessary. Further, the temperature of the environment is usually 20 to 30 ° C, preferably 20 to 27 ° C. The relative humidity of the environment is usually less than 80%, preferably from 30 to 75%, more preferably from 40 to 70%. When the relative humidity of the environment is 80% or more, dew condensation occurs due to cooling of the laminate or the laminated structure, and a film (for example, a polarizer) having a high water absorbability in the laminate is swelled and the like. Adverse conditions are caused to the appearance or optical characteristics of the laminated body or the laminated structure.

(Manufacturer of optical member)

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

The manufacturing apparatus 1000 includes an end surface processing unit 200 that cuts, cuts, or grinds the end surface of the laminated body 100 or the laminated structure 120, and partially collides dry ice particles processed by the end surface processing unit 200 in the laminated body 100. The dry ice particle supply unit 300 and the transfer unit 400 that transports the laminated body 100.

In Fig. 5, a cutting device is drawn as the end surface processing portion 200. The cutting device includes a rotating shaft 210 that extends in the horizontal direction, a disk 220 that is attached to the rotating shaft, and a cutting blade 230 that is attached to the disk 220. The end surface of the laminated body or the like can be cut by the rotation of the cutter 230.

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

The conveying unit 400 has an upper auxiliary member 420 and a lower auxiliary member 422 that sandwich the laminated body 100 or the laminated structure 120 in the thickness direction and supports the pair of upper auxiliary members 420 in the thickness direction (downward direction). The pressing cylinder 430 is coupled to the lower auxiliary 422 to rotate the upper auxiliary 420 and the lower auxiliary 422 around the vertical axis (Z axis), and the upper auxiliary 420 and the lower auxiliary 422 are horizontal A moving mechanism 440 that moves in the direction (X direction).

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

Next, the end surface processing unit 200 is activated. Specifically, the disk 220 is rotated. Then, the moving body 440 moves the laminated body 100 and the laminated structure 120 in the X direction, and the cutting blade 230 of the end surface processing part 200 comes into contact with the end surface E. Thereby, the laminated body 100 and the laminated structure body 120 are cut by the cutting blade 230 with respect to the pair of end faces E. At this time, chips are attached to the end surface E.

Then, the layered body 100 and the laminated structure 120 are moved in the -X direction by the conveying unit 400, and dry ice particles are supplied from the nozzle 320 of the dry ice particle supply unit 300. Thereby, the cut end faces E of the laminated body 100 and the laminated structure 120 collide with the dry ice particles to remove the powder of the end face E.

Then, the laminated body 100 and the laminated structure 120 are further moved in one direction by the conveying unit 400, and the laminated body 100 and the laminated structure 120 are rotated by the rotating mechanism 410 so that the remaining two end faces are parallel to the X direction. . Then, in the same manner as before, the processing of the remaining two end faces and the subsequent powder removal by the dry ice particles can be carried out in sequence.

The end surface processing unit 200 can be formed in various forms depending on the aspect of processing. For example, as shown in Fig. 6, the rotary blade of the planing type has a cylindrical body 240 that rotates around the vertical axis and a length that extends in the axial direction on the outer circumferential surface of the cylindrical body 240. Blade 250.

Further, instead of the cutting blade 230, a polishing plate provided with a large amount of abrasive grains on the surface of the disk may be used for polishing.

Moreover, it can also be used as a cutting device when it is not necessary to perform cutting and polishing.

Finally, an example of a method of removing the powder f (opening processing chips) attached to the end surface E of the hole H provided in the laminated body 100 will be described with reference to FIG.

First, the laminated body 100 is subjected to a drilling process, and a plurality of laminated bodies 100 in which powder (opening processing chips) f are adhered to the end surface E on the inner side of the hole H are prepared. As shown in Fig. 1(b), each of the laminated bodies 100 has a hole H provided at a predetermined position by the drilling process. Then, the laminated body 100 is laminated such that the positions of the holes H of the respective laminated bodies 100 are aligned on one axis (the axis extending in the thickness direction) to obtain the laminated structure 120. In this way, the respective holes H of the laminated layers 100 are connected to each other, and the laminated structure 120 forms a through hole H' penetrating in the thickness direction of the laminated structure 120.

The laminated structure 120 is pressed in one of the upper auxiliary 420 and the lower auxiliary 422 in the thickness direction, and one of the auxiliary members is provided with the dry ice particle supply port 420a in advance, and the other auxiliary device is provided with the dry ice particle recovery port 422b. . The upper auxiliary member 420 and the lower auxiliary member 422 are disposed such that the through hole H' communicates with the dry ice particle supply port 420a and the dry ice particle recovery port 422b, and the laminated structure body 120 is pressed in the thickness direction. Thereby, the preparation step before the dry ice collision step is completed.

Next, dry ice particles are supplied from the nozzle 320 to the through hole H' through the dry ice particle supply port 420a (collision step). The dry ice particles ejected from the nozzle 320 are diffused in the width direction as they advance, and collide with the end surface E of the through hole H' of the laminated structure 120, and are discharged together with the powder f from the dry ice particle collecting port 422b. According to such a device, the powder f can be efficiently removed from the layered body 100 to which the powder f is adhered to the end surface E of the inner wall of the hole H by the drilling process.

 (Example)  

(layered body material)

A raw material laminate having the following layer constitution was obtained: a protective film (made of PET (polyethylene terephthalate): 53 μm) / a protective film (made of TAC (cellulose triacetate): 32 μm) / polarizer (PVA ( Iodine absorbing polyvinyl alcohol): 12 μm) / protective film (manufactured by COP (cyclic olefin resin): 23 μm) / adhesive layer (acrylic adhesive: 20 μm) / separator (PET: 38 μm).

The protective film and the polarizer are followed by a water-based adhesive. The thickness of the laminate was 178 μm.

(Processing of the end face of the laminated body)

The laminate was obtained by cutting a raw material laminate into a rectangular shape of a size of 140 × 65 mm by a Thomson blade.

Next, 50 laminated bodies were stacked to obtain a laminated structure. Each end surface of the laminated structure is cut by a cutting device. Then, the respective end faces of the laminated structure are ground by a polishing device.

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

In each of the examples and the comparative examples, the powder of the end face of the laminate was removed under the following conditions.

(Example 1)

Dry ice particle supply device: carbon dioxide gas dry ice blasting

CO ₂ pressure: 5 MPa (in addition, CO ₂ pressure refers to the supply pressure of the orifice)

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end surface: about 50mm

Sweep speed of the nozzle: 50mm/5 seconds

The center position of the nozzle and the nozzle sweeping direction: the nozzle is directed toward the center in the thickness direction of the end surface of the laminated structure, and the nozzle is swept in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle size of dry ice particles: 1 to 100 μm

Ambient temperature: 24 ° C to 26 ° C, relative humidity of the environment: 45% to 65%

(Example 2)

Dry ice particle supply device: carbon dioxide gas dry ice blasting

CO ₂ pressure: 7MPa

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end surface: about 50mm

Sweep speed of the nozzle: 50mm/5 seconds

The center position of the nozzle and the nozzle sweeping direction: the nozzle is directed toward the center in the thickness direction of the end surface of the laminated structure, and the nozzle is swept in a direction perpendicular to the thickness of the end surface of the laminated structure.

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

Ambient temperature: 24 ° C to 26 ° C, relative humidity of the environment: 45% to 65%

(Example 3)

Dry ice particle supply device: granular dry ice blasting

Particle diameter: 3mm

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end surface: about 50mm

Sweep speed of the nozzle: 50mm/5 seconds

The center position of the nozzle and the nozzle sweeping direction: the nozzle is directed toward the center in the thickness direction of the end surface of the laminated structure, and the nozzle is swept in a direction perpendicular to the thickness of the end surface of the laminated structure.

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

Ambient temperature: 24 ° C to 26 ° C, relative humidity of the environment: 45% to 65%

(Example 4)

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

Further, since the laminate is cooled by contact with the dry ice particles at the time of removal, dew condensation occurs in the laminate. When the condensation-producing portion was confirmed, no abrasive grains or defects were generated, but swelling occurred at the end portion of the laminate.

(Comparative Example 1)

The end surface of the laminated structure was wiped with a wiping cloth (manufactured by KURARAY KURAFLEX) impregnated with ethanol.

(Comparative Example 2)

The OLFA cutting blade is moved along the end surface of the laminated structure.

(Comparative Example 3)

After attaching an adhesive tape (Cellotape (registered trademark) manufactured by Nichiban Co., Ltd.) to the end surface of the laminated structure, the adhesive tape was peeled off from the end surface.

(Comparative Example 4)

The air flow was blown to the end surface of the laminated structure in the same manner as in Example 1 except that liquid carbon dioxide was not supplied.

(Evaluation)

The end face was observed with a microscope, and the residual state of the powder on the end face and the adhesive layer on the end face were investigated for defects.

The results are shown in Table 1.

In addition, the ○ series of "the powder residue of the end surface" indicates that no powder was observed in the field of view of a length of 30 mm (hereinafter simply referred to as length) in the direction perpendicular to the thickness, and Δ means that 1 to 10 was observed in the field of view of a length of 30 mm. Two powders, × indicates that three or more powders were observed in a field of view of a length of 30 mm.

In addition, the ○ of the "adhesive layer defect of the end surface" indicates that no defect was observed in the field of view of a length of 30 mm (hereinafter simply referred to as length) in the direction perpendicular to the thickness, and Δ indicates that 1 to 1 was observed in the field of view of 30 mm length. Two defects, × indicates that defects of three or more positions were observed in a field of view of a length of 30 mm.

Claims (9)

 A method for producing an optical member, comprising the steps of: preparing a laminate having an optical film and an adhesive layer provided on one surface of the optical film and having a powder adhered to an end surface thereof; and the aforementioned end face of the laminate The step of removing the powder from the aforementioned end face by colliding with dry ice particles.    The production method according to claim 1, wherein the dry ice particles have an average particle diameter of 100 to 1000 μm.    The manufacturing method according to the first or second aspect of the invention, wherein in the step of performing the collision, the end faces of the laminated structure in which the plurality of layers of the laminated body are laminated are collided with the dry ice particles.    The manufacturing method according to claim 1 or 2, wherein a part of the end surface collides with the dry ice particles, and the other portion of the end surface of the laminated body is selected from the group consisting of cutting, cutting, and grinding. At least one of the groups formed.    The manufacturing method according to claim 1 or 2, wherein in the step of performing the preparation, the end surface is at least one selected from the group consisting of cutting, cutting, and grinding, and the end surface is When a part collides with the dry ice particles, the end surface is not selected from any one of the above groups.    The manufacturing method according to any one of claims 1 to 5, wherein the optical film is selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film, and a touch sensor. At least one of the group consisting of a laminated film including at least one selected from the group consisting of two or more layers, or a laminated film containing at least two selected from the group.    The manufacturing method according to any one of claims 1 to 6, wherein the relative humidity of the environment in the step of colliding the end face with the dry ice particles is 30 to 75%.    An apparatus for manufacturing an optical member, comprising: an end surface processed portion that cuts, cuts, or polishes an end surface of a laminate having an optical film and an adhesive layer provided on one surface of the optical film; and the laminated body The dry ice particle supply unit that collides with the dry ice particles after the processed portion of the end surface processing portion.    The apparatus for manufacturing an optical member according to the eighth aspect of the invention, further comprising: a conveying unit that moves the laminated body between the end surface processing unit and the dry ice particle supply unit.