TW202136008A - Optical film punch device, and film product manufacturing method - Google Patents

Abstract

The present invention pertains to an optical film punch device that is not susceptible to cutting defects. The punch device manufactures a plurality of film products by using a cutting blade (61) to punch an optical film raw sheet (1). The device comprises: a conveyance part that conveys a blade support sheet (2) and the optical film raw sheet (1); and a punching processing part that presses the cutting blade (61) into the optical film raw sheet (1). The blade support sheet (2) has a seam (5) that abuts a first end surface and a second end surface of a sheet, and the seam (5) extends in a direction intersecting the direction of extension of the cutting blade (61).

Description

Punching device for optical film and manufacturing method of film product

The present invention relates to a punching device for an optical film and a method for manufacturing a thin film product by punching an optical film original sheet to produce a thin film product.

Previously, optical films have been used in image display devices such as liquid crystal display devices or organic EL (Electroluminescence) display devices. As said optical film, the polarizing film containing a polarizing element, a retardation film, a light-diffusion film, etc. are mentioned. In addition, polarizing films and the like are also used for purposes other than image display devices such as polarized sunglasses and dimming windows. Such an optical film is formed into a specific top-view shape matching the screen and the like so as to be assembled to the screen and the like of the above-mentioned image display device. In this specification, an optical film formed into a specific shape is referred to as a "film product". The film product is obtained, for example, by punching an original optical film (a long strip-shaped optical film or a large-size optical film) with a cutting knife.

For example, Patent Document 1 discloses a processing method in which a backing paper sheet and a cut sheet arranged on the backing paper are transported between a support table and a cutting blade, and the cut sheet is removed from the cut sheet. The upper part of the material presses against the cutting knife, thereby cutting the cut sheet material. In this press processing, by inserting the cutting blade into the cut sheet until the tip of the cutting blade reaches the backing paper, a plurality of products of a specific shape can be continuously obtained from the cut sheet. In the above processing method, the backing paper rolled into a roll on the upstream side is unrolled, transported to the press processing section and the cutting blade is pressed against the cut sheet, and then the backing paper is re-wound on the downstream side In a roll shape. Therefore, in order to continuously manufacture products, a splicing process is performed to connect a new backing paper to the remaining backing paper on the upstream side. [Prior Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open No. 2011-115890

However, in the case of punching a film product from an optical film original sheet, if the above-mentioned processing method is applied, the following problems will arise. That is, the backing paper (knife support sheet) after the splicing process has a seam formed by joining and joining the first end face and the second end face of the sheet. The seam is the gap between the sheets. Therefore, there is no backing paper that bears the pressing force of the cutting knife at the seam. When the cutting knife exactly matches the above-mentioned seam, since there is no backing paper that bears the pressing force of the cutting knife, there is a risk that the original optical film cannot be cut reliably. [The problem to be solved by the invention]

The purpose of the present invention is to provide a punching device for an optical film that is not prone to poor cutting and a method for manufacturing a film product. [Technical means to solve the problem]

As shown in FIG. 16, the knife support sheet 200 after butting the first end surface 210 and the second end surface 220 of the sheet to be spliced is provided with a gap (joint 500) between the first end surface 210 and the second end surface 220. ). Generally, a splicing tape 510 is attached to cover the seam 500 on one side while straddling the first end and the second end to join the sheets. When the extending direction of the cutting knife 610 is parallel to the seam 500, when the seam 500 and the cutting knife 610 overlap linearly (the seam 500 is parallel to the cutting knife 610, and the entire cutting knife 610 is parallel to it When the seams 500 overlap), as shown in FIG. 16, the cutting knife 610 enters the seam 500 as a whole. The splicing tape 510 generally does not have the strength to withstand the pressing force of a cutting knife. Therefore, there are cases where the lower portion of the original optical film sheet slightly expands as the cutting blade 610 enters, and the original optical film sheet 100 cannot be cut reliably. The inventors of the present invention found that by designing the shape of the joint of the knife support sheet, so that the entire cutting knife does not enter the joint, the cutting failure of the optical film original sheet can be suppressed.

The punching device of the present invention is a device that uses a cutting knife to punch an optical film original sheet to produce a plurality of thin film products, and includes: a conveying section that supports a knife support sheet that supports the cutting edge of the cutting knife, and the optical film The original sheets are respectively conveyed in the longitudinal direction; and a press processing section which presses the cutting blade against the original optical film sheet from the side opposite to the blade support sheet; the blade support sheet has a The first end face and the second end face are joined to a seam, and the seam extends in a direction intersecting with the extending direction of the cutting blade.

In a preferable punching device of the present invention, the seam of the knife support sheet extends obliquely with respect to the short side direction orthogonal to the longitudinal direction of the knife support sheet. The preferred punching device of the present invention is to attach the splicing tape to the knife support sheet across the first end and the second end of the sheet, covering the seam, and the thickness of the splicing tape is 50 μm the following.

According to another aspect of the present invention, a method for manufacturing a film product is provided. The manufacturing method of the film product of the present invention is a method of punching an original optical film with a cutting knife to obtain a plurality of film products, and includes the following steps: a knife supporting sheet supporting the tip of the cutting knife, and the optical film The original film sheets are transported in the longitudinal direction respectively; the cutting knife is pressed against the original optical film sheet from the side opposite to the knife support sheet, thereby punching out a plurality of film products from the original optical film sheet; The knife support sheet has a seam formed by joining the first end face and the second end face of the sheet material, and the seam of the knife support sheet is along a direction crossing with respect to any edge of the punched film product extend.

In a preferred manufacturing method of the present invention, the seam of the knife support sheet extends obliquely with respect to the short side direction orthogonal to the longitudinal direction of the knife support sheet. The preferred manufacturing method of the present invention is that the film product is substantially quadrilateral in plan view, and the substantially quadrilateral in plan view has longitudinal sides that are substantially parallel to the long side direction of the optical film original sheet and that are substantially parallel to the short side direction of the optical film original sheet. Horizontal edge. The preferred manufacturing method of the present invention is to cover the seam with a splicing tape and affix it to the knife support sheet across the first and second ends of the sheet, and the thickness of the splicing tape is 50 μm the following. A preferable manufacturing method of the present invention is that the above-mentioned film product includes a surface protective film laminated through an adhesive layer. The preferred manufacturing method of the present invention is that the above-mentioned film product contains a polarizing element. [Effects of Invention]

According to the punching device and the manufacturing method of the present invention, it is difficult to produce cutting defects when punching the original optical film. Therefore, thin film products can be efficiently manufactured from the original optical film.

In this manual, "top view" refers to the shape of the object when viewed from the vertical direction relative to the surface of the object, and "top view shape" and "top view" refer to the shape and shape of the object when viewed from the vertical direction relative to the surface of the object figure. In addition, in this specification, the expression "approximately" refers to the range allowed in the technical field including the present invention. Furthermore, in this specification, the numerical range represented by "lower limit value X-upper limit value Y" means lower limit value X or more and upper limit value Y or less. In the case where a plurality of the above numerical ranges are individually described, an arbitrary lower limit value and an arbitrary upper limit value can be selected, and "arbitrary lower limit value-arbitrary upper limit value" can be set.

[First Embodiment] ＜Overview of optical film stamping equipment＞ Figure 1 shows the optical film punching device A1. 1, the press device A1 has a conveying unit B for conveying the optical film original sheet 1 and the knife support sheet 2, a press processing unit C, a punching residual edge removal unit D, and a product recovery unit E. The press processing part C has a cutting blade.

＜Transportation Department＞ The conveyance part B of the press apparatus A1 has the guide roller 31 which conveys the optical film original sheet 1 and the knife support sheet 2, etc., and a drive device (not shown). The conveying unit B unwinds the original optical film 1 from the unwinding unit 321 and conveys the original optical film 1 in the longitudinal direction. Moreover, the said conveyance part B unwinds the knife support sheet 2 from the unwinding part 322, and conveys this knife support sheet 2 in the longitudinal direction. Furthermore, the long side direction of the optical film original sheet 1 and the long side direction of the knife support sheet 2 are the same direction, and the short side direction of the optical film original sheet 1 and the short side direction of the knife support sheet 2 are the same direction. The optical film original sheet 1 and the knife support sheet 2 independently conveyed by the conveying unit B are superimposed on the way, and are conveyed to the press processing unit C in their superimposed state. For example, the optical film original sheet 1 is overlapped on the front surface of the knife support sheet 2. The overlapped optical film original sheet 1 and the knife support sheet 2 are simultaneously conveyed to the press processing section C. The conveying section B is provided with a belt conveyor 34 for conveying the overlapped optical film original sheet 1 and the knife support sheet 2 as necessary.

The optical film original sheet 1 that has been transported to the above-mentioned press processing section C is punched by the cutting blade 61 and then divided into punching residual edges and film products. The knife support sheet 2 that has been transported to the above-mentioned press processing unit C receives the cutting edge of the cutting knife 61, and is then transported toward the downstream side and wound to the winding unit 332.

＜Original optical film＞ The punching device A1 of the present invention is one that punches the optical film original sheet 1 to obtain a thin film product. The original optical film used to obtain thin film products is generally a long strip-shaped film or a large-size film. In the example shown in the figure, it shows a case where a long strip-shaped optical film original sheet 1 is used to stamp a film product. However, in FIG. 2, one side in the longitudinal direction of the long strip-shaped optical film original sheet 1 is omitted. The long strip-shaped optical film original sheet 1 is disposed in the roll-out portion 321 of the punching device A1 in a state of being rolled into a roll shape. Here, in this specification, the long strip shape refers to a substantially rectangular shape in plan view whose length in the long side direction is sufficiently longer than in the short side direction. The length in the longitudinal direction of the optical film original sheet 1 is, for example, 5 m or more, and preferably, the length in the longitudinal direction is 10 m or more. In addition, the short-side direction is a direction orthogonal to the long-side direction.

The optical film original sheet 1 contains an optical film. The optical film original sheet 1 may consist of only an optical film, and may have components other than an optical film and an optical film. 3 and 4 illustrate the layer structure of the original optical film 1. The optical film original sheet 1 has an optical film 11, an isolating film 13, and an adhesive layer 12 interposed between the optical film 11 and the isolating film 13 and bonding the two films 11 and 13 together. The adhesive layer 12 is firmly adhered to the optical film 11 and releasably adhered to the isolation film 13. The isolation film 13 can be peeled off at the interface with the adhesive layer 12. Furthermore, an optical film original sheet (not shown) that does not have the above-mentioned adhesive layer 12 and isolation film 13 can also be used.

The optical film 11 includes an optical functional film. As said optical function film, a polarizing element, a retardation film, a light diffusion film, a brightness enhancement film, an anti-glare film, a light reflection film, etc. are mentioned. The polarizing element is a film having the property of transmitting light (polarized light) vibrating in a specific direction and blocking light vibrating in other directions. The retardation film is a film that exhibits optical anisotropy, and representative examples include stretched films such as acrylic resin, cycloolefin resin, and cellulose resin. In addition, the optical film 11 may include a protective film. The protective film is laminated in order to protect the above-mentioned optical function film. Typically, a colorless transparent film can be used as the protective film.

In the original optical film 1 illustrated in FIG. 3, the optical film 11 has a first protective film 111, a polarizing element 112, and a second protective film 113 in order from the bottom of the drawing to the top. One laminated film (optical film 11) is formed by adhering the respective films 111 to 113 to each other. Furthermore, in the example shown in the figure, the first protective film 111 and the polarizing element 112, and the polarizing element 112 and the second protective film 113 are directly bonded respectively, but an adhesive layer (or Adhesive layer) and each film is adhered via the adhesive layer (or adhesive layer) (not shown). In addition, a surface protective film 14 is laminated on the surface of the optical film 11 (the surface of the second protective film 113) via the adhesive layer 15. The surface protection film 14 can be peeled from the surface of the optical film 11 along with the adhesive layer 15, for example. Furthermore, the surface protection film 14 and the adhesive layer 15 are provided as needed, and therefore, the optical film original sheet 1 without the surface protection film 14 and the adhesive layer 15 can also be used.

In the optical film original sheet 1 illustrated in FIG. 4, the optical film 11 has a retardation film 115. In addition, a surface protective film 16 is laminated on the surface of the above-mentioned optical film 11 (the surface of the retardation film 115) via the adhesive layer 17. The surface protection film 16 can be peeled from the surface of the optical film 11 (retardation film 115) along with the adhesive layer 17, for example. Furthermore, the surface protection film 16 and the adhesive layer 17 are provided as needed, and therefore, the optical film original sheet 1 without the surface protection film 16 and the adhesive layer 17 can also be used. In addition, the optical film 11 is not limited to the layer structure of FIG. 3 and FIG. 4, and can be variously changed. For example, the optical film may include two or more optical functional films, or may be composed of only one optical functional film.

The adhesive layers 12, 15, and 17 provided on the optical film 11 have adhesiveness at room temperature, and the adhesiveness continues after peeling and can be attached again. The adhesive layers 12, 15, and 17 are made of well-known adhesives. Examples of the above-mentioned adhesives include colorless and transparent acrylic adhesives, rubber-based adhesives, silicone-based adhesives, urethane-based adhesives, vinyl alkyl ether-based adhesives, and polyvinylpyrrolidone-based adhesives. Adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, etc. The thickness of the adhesive layer 12, 15, 17 is not particularly limited, and is, for example, 0.1 μm to 50 μm, preferably 1 μm to 30 μm.

The isolation film 13 is not particularly limited, and usually a film that does not include an optical function film can be used. The isolation film 13 has a release surface which is excellent in releasability with respect to the adhesive layer 12 described above. Examples of the separator film 13 include resin films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films; paper; porous films such as woven fabrics, nonwoven fabrics, and mesh fabrics; and foamed resin films. Since the surface smoothness is excellent, the isolation film 13 is suitable as a resin film. As the above-mentioned resin film, for example, polyethylene terephthalate film, polybutylene terephthalate film, polyethylene film, polypropylene film, polybutene film, polybutadiene film, polymethyl Pentene film, polyvinyl chloride film, vinyl chloride copolymer film, polyurethane film, ethylene-vinyl acetate copolymer film, etc. The thickness of the isolation film 13 is not particularly limited, and is, for example, 5 μm to 200 μm, preferably 10 μm to 100 μm.

＜Knife support sheet＞ The knife support sheet 2 is a sheet that supports the cutting edge of the cutting knife 61. The cutting edge of the cutting knife 61 that penetrates the optical film original sheet 1 and is exposed to the back side of the optical film original sheet 1 bites into the knife support sheet 2 to reliably cut the optical film original sheet and prevent the above The tip of the cutting knife 61 is deteriorated. As the knife support sheet 2, a sheet having flexibility to accept the cutting edge of the cutting blade 61, and strength and thickness to the extent that the cutting edge does not break even if the cutting edge enters can be used. For example, as the knife support sheet 2, a synthetic resin sheet, a rubber sheet, a non-woven fabric, etc. can be used, and a synthetic resin sheet is particularly preferred. Examples of the above-mentioned synthetic resin sheets include styrene resin sheets such as polystyrene; polyolefin resin sheets such as polyethylene or polypropylene; polyester resin sheets such as polyethylene terephthalate; 66 Polyamide resin sheets such as nylon; polyvinyl chloride resin sheets such as polyvinyl chloride. In addition, a laminated sheet formed by laminating two or more kinds of resin sheets can also be used. The thickness of the knife support sheet 2 is not particularly limited. If the thickness of the knife support sheet 2 is too small, it may be easily broken by the cutting knife 61. Therefore, the thickness of the knife support sheet 2 is preferably greater than the penetration amount of the cutting edge of the cutting knife 61. From the above viewpoint, the thickness of the knife support sheet 2 is, for example, 0.4 mm or more, preferably 0.5 mm or more. In addition, if the thickness of the knife support sheet 2 is too large, it is difficult to handle, and the material cost also increases. From the above viewpoint, the thickness of the knife support sheet 2 is, for example, 2 mm or less, preferably 1 mm or less, and more preferably 0.8 mm or less.

The knife support sheet 2 of the present embodiment is in the shape of a long strip as shown in FIG. 5. However, in FIG. 5, both sides of the longitudinal direction of the long strip-shaped knife support sheet 2 are omitted (it is the same in FIG. 7). The knife support sheet 2 is installed in the unwinding part 322 of the press device A1 in a state of being wound into a roll shape. The knife support sheet 2 has a seam 5 formed by butting the first end face 21 and the second end face 22 of the sheet. The present invention is characterized in that the seam 5 of the knife support sheet 2 extends in a direction intersecting with the extending direction of the cutting knife 61. As described below, when the optical film original sheet 1 is punched with the cutting blade 61, a thin film product having an edge of the same shape as that of the cutting blade 61 in plan view is formed. Therefore, in terms of the relationship with the film product, it can also be considered that the seam 5 of the knife support sheet 2 extends in a direction intersecting with any edge of the film product. The joint 5 of the knife support sheet 2 is a gap between the first end face 21 and the second end face 22 facing each other. The above-mentioned seam 5 extends from the edge on the short side direction of the knife support sheet 2 in a direction intersecting with the extending direction of the cutting knife 61, and extends to the edge on the opposite side to the short side direction of the knife support sheet 2 .

Specifically, in this embodiment, the knife support sheet 2 is obtained by butting the end surfaces 21 and 22 of at least two sheets with each other and joining the two sheets with the splicing tape 51. This type of splicing is called splicing. FIG. 7 is a plan view showing the knife support sheet 2 before the splicing tape 51 is attached. The first end surface 21 of the first sheet is formed in a linear shape inclined with respect to the short-side direction (the direction orthogonal to the long-side direction) in a plan view. Therefore, the first end surface 21 of the first sheet material is inclined at a specific angle with respect to the short-side direction in a plan view and extends in the short-side direction. The second end surface 22 of the second sheet material is formed in a linear shape inclined with respect to the short-side direction in a plan view so as to be substantially parallel to the first end surface 21 described above. Therefore, the joint 5 between the first end surface 21 and the second end surface 22 extends in a straight line inclined with respect to the short-side direction in a plan view. The angle α of the seam 5 with respect to the short side direction is not particularly limited. For example, the angle α of the seam 5 is 5 degrees to 30 degrees with respect to the short side direction, preferably 10 degrees to 20 degrees. The width 5W of the seam 5 (the interval between the first end face 21 and the second end face 22) is not particularly limited, and is, for example, 0.5 mm to 3 mm, preferably 0.7 mm to 2 mm. Furthermore, the width of the seam 5 may be uniform in the short-side direction, or may not be uniform. When the seam 5 is uneven, the width 5W of the seam 5 is the maximum value.

As shown in FIG. 7, after the first end face 21 and the second end face 22 of the sheet are butted, the splicing tape is applied while covering the seam 5 and straddling the first end 21a and the second end 22a of the sheet 51. By this, a long strip-shaped knife support sheet 2 as shown in Figs. 5 and 6 is constructed. The splicing tape 51 has a base material and an adhesive or adhesive, and is attached to the knife support sheet 2 via the adhesive or adhesive. In addition, adhesives or adhesives are not shown. The splicing tape 51 can be applied across the first end portion 21a and the second end portion 22a only on either the front surface or the back surface of the knife support sheet 2. In order to securely join the seam 5, it is preferable that as shown in FIG. 6, splicing tapes 51 and 51 respectively cover the seam 5 and are attached to the knife support sheet across the first end 21a and the second end 22a. 2 The front and back of the two sides.

As shown in FIG. 5, the splicing tape 51 matches the inclination of the seam 5, and is attached at a specific angle with respect to the short side direction in a plan view. The base material of the splicing tape 51 is not particularly limited, and examples thereof include synthetic resin sheets, paper, synthetic paper, nonwoven fabrics, and laminated sheets thereof. The width 51W of the splicing tape 51 is not particularly limited, and is, for example, 10 mm to 30 mm. The thickness 51T of the splicing tape 51 is not particularly limited. If the thickness is too large, there is a possibility that defects such as film product breakage during punching may occur. Therefore, the thickness of the splicing tape 51 is preferably as small as possible. From the above viewpoint, the thickness of the splicing tape 51 is, for example, 50 μm or less, preferably 40 μm or less, and more preferably 30 μm or less. On the other hand, if the thickness is too small, the splicing tape 51 may easily break. From the above viewpoint, the thickness 51T of the splicing tape 51 is, for example, 10 μm or more, preferably 15 μm or more. Wherein, the thickness 51T of the splicing tape 51 includes the thickness of the adhesive or adhesive.

＜Press Processing Department＞ 1, the press processing unit C has a cutter device 6. The cutter device 6 has a cutting blade 61 and a base plate 62. In addition, a support base 63 is provided opposite to the cutting blade 61. For the support base 63, for example, a steel plate having excellent strength is used. The support table 63 is fixed to the frame of the press device A1 and the like. The support table 63 is arranged on the back side of the knife support sheet 2. As shown in the example, when the belt conveyor 34 that transports the optical film original sheet 1 and the knife support sheet 2 is arranged, the support table 63 is arranged inside the belt conveyor 34. In this case, the support table 63, the conveyor belt of the belt conveyor 34, the knife support sheet 2, the optical film original sheet 1, and the cutting knife 61 are arranged in this order from the lower side of the paper surface of FIG. 1 toward the upper side. In addition, the support stand 63 may be arrange|positioned on the outer side (front side) of the belt conveyor 34. As shown in FIG.

The cutting blade 61 is provided on the base plate 62. The base plate 62 has a flat shape, and a cutting blade 61 is fixedly provided on the base plate 62. The cutter device 6 (cutting blade 61) advances and exits in a vertical direction with respect to the surface of the optical film original sheet 1 by a driving device not shown. The cutter device 6 of this embodiment is a cutter of a pressing method in which the optical film original sheet 1 is punched by retreating in a direction perpendicular to the surface of the optical film original sheet 1. In FIG. 1, the movement of the cutter device 6 is indicated by a thick arrow. As such a cutter device 6, a Thomson knife can be typically used.

Fig. 8 is a top view of the cutter device 6 including the cutting blade 61 (Fig. 8 is a view of the cutter device 6 of Fig. 1 viewed from the lower side of the paper). Figure 9 is an enlarged perspective view thereof. Part of it is omitted in Figure 9. In addition, in FIG. 9, an enlarged view partially showing the three-dimensional shape of the cutting blade 61 is also described. In FIGS. 8 and 9, a cutting knife 61 is protrudingly provided on the surface of the base plate 62 of the cutter device 6. Generally, in order to simultaneously punch a plurality of film products by one pressing, a plurality of cutting blades 61 are provided on one base plate 62. The cutting blade 61 has an endless ring shape in a plan view. A plurality of cutting blades 61 are provided on the base plate 62 at a fixed interval.

As shown in the enlarged view of FIG. 9, the cutting blade 61 generally has a sharp tip 61 a, and its thickness becomes thicker toward the base plate 62 side. The angle β of the blade edge 61a is not particularly limited, and is, for example, 20 degrees to 40 degrees. The cutting knife 61 of the cutter device 6 is arranged so as to cross the seam 5 of the knife support sheet 2 described above. In addition, the cutting blade 61 is arranged non-parallel to the extending direction of the seam 5 of the knife support sheet 2 (not parallel to the extending direction of the seam 5). For example, each cutting blade 61 has a first portion 611 extending substantially parallel to the short-side direction of the blade supporting sheet 2 and a second portion 612 extending substantially parallel to the long-side direction of the blade supporting sheet 2. Both the first part 611 and the second part 612 of the cutting blade 61 extend in a direction intersecting with the extending direction of the seam 5. The plan shape of each cutting blade 61 is, for example, as shown in FIG.

As described above, the knife support sheet 2 is transported to the press processing section C in a state where the knife support sheet 2 overlaps with the back surface of the optical film original sheet 1. In the press processing part C, the cutting blade 61 of the cutter device 6 is pressed against the original optical film 1 from the front side of the original optical film 1. In addition, the front side of the above-mentioned optical film original sheet 1 is the surface on the opposite side to the overlapped knife support sheet 2 among both surfaces of the optical film original sheet 1. By pressing the cutting blade 61 against the optical film original sheet 1, a cutting line having the same shape as the plan view shape of the cutting blade 61 is generated in the surface of the optical film original sheet 1. The part surrounded by the cutting line is a film product.

＜Punching residual edge removal part＞ The punching residual edge removal part D removes the punching residual edges remaining around the film product (the part surrounded by the cutting line) formed in the surface of the optical film original sheet 1 by the pressing processing part C. The punching residual edge removal section D has: a pressing roller 71 that presses the optical film original sheet 1 punched by the cutting blade 61; and a recovery roller 72 that reverses the punching residual after the pressing roller 71 is a fulcrum Edge recycling. The optical film original sheet 1 after the punching is conveyed to the downstream side by the belt conveyor 35 and separated into the blanking residual 91 and the film product 9 at the pressing roller 71. The blanking edge 91 is recovered by the recovery roller 72. The film product 9 is conveyed to the downstream side by the belt conveyor 36.

＜Product Recycling Department＞ The product collection part E has a collection part 37 which collects the film product 9 obtained by removing the blanking edge 91 at the above-mentioned blanking edge removal part D. As shown in FIG.

[Method of manufacturing film products using punching device] The top views shown in S1 to S4 of FIG. 10 are the top views when viewed from the direction of the hollow arrows S1 to S4 in FIG. 1 (wherein, both sides in the longitudinal direction are omitted). 1 and S1 of FIG. 10, the optical film original sheet 1 and the knife support sheet 2 are conveyed toward the downstream side in the longitudinal direction by the conveying section B (a conveying step). In addition, the thin arrow in FIG. 1 indicates the conveying direction of the optical film original sheet 1 and the like. 1 and S2 of FIG. 10, in the middle of conveyance, the optical film original sheet 1 is superimposed on the surface of the knife support sheet 2 and conveyed to the press processing section C in this state.

In the press processing section C, the cutting blade 61 of the cutter device 6 is pressed against the optical film original sheet 1 from the side (front side) opposite to the blade support sheet 2 (pressing step). By inserting the cutting blade 61 in the thickness direction of the original optical film 1 until the tip 61a of the cutting blade 61 reaches the blade support sheet 2, the original optical film 1 can be punched into the top view shape of the cutting blade 61 The same shape. The knife support sheet 2 that has passed through the press processing section C is wound up to the winding section 332.

Referring to S3 of FIG. 10, the symbol X indicates the cutting line formed in the surface of the optical film original sheet 1 by the cutting blade 61, and the portion with countless dots indicates the blanking residual 91. The pressed optical film original sheet 1 is conveyed to the downstream side by a belt conveyor 35. In the punching residual edge removal part D, the punching residual edge 91 in the optical film original sheet 1 after the punching is reversed at the pressing roller 71 and recovered to the recovery roller 72 (removal step). In this way, the film product 9 as shown in S4 of FIG. 1 and FIG. 10 can be continuously manufactured. Any edge of the obtained film product 9 extends in a direction crossing the seam 5 of the knife support sheet 2. In other words, the seam 5 of the knife support sheet 2 extends in a direction that crosses any edge of the stamped film product 9. Furthermore, the shape of the edge of the film product 9 is the same as the cutting line X described above.

For example, the film product 9 has an edge extending substantially parallel to the long side direction of the optical film original sheet 1 (knife supporting sheet 2) and substantially parallel to the short side direction of the optical film original sheet 1 (knife supporting sheet 2) The edge of the earth's extension. In the example shown in the figure, the film product 9 has a longitudinal side 9a substantially parallel to the long side direction of the optical film original sheet 1 and a horizontal side 9b substantially parallel to the short side direction of the optical film original sheet 1 in plan view. . Furthermore, in the example shown in the figure, it is shown that the film product 9 having 5 pieces (5 rows) in the short-side direction is manufactured, but it is not limited to this number. The number of film products 9 in the short-side direction (the number of cutting blades 61 in the short-side direction) at the time of manufacture is set according to the relationship between the length of the optical film original sheet 1 in the short-side direction and the length of the film product 9. Therefore, the number of film products 9 in the short-side direction is 1 or more, which can be set appropriately.

The obtained film product 9 is recovered in the product recovery section E. In this way, the film product 9 can be continuously manufactured from the long strip-shaped optical film original sheet 1. In addition, when the remaining amount of the knife support sheet 2 wound around the unwinding portion 322 decreases during the above manufacturing process, the film product 9 can be continuously manufactured by splicing the new knife support sheet 2 . When splicing the new knife support sheet 2 also, in the same manner as described above, a seam 5 extending in a direction intersecting with the extending direction of the cutting knife 61 is formed.

The punching device A1 of the present invention can suppress the punching defects of the optical film original sheet 1. 11 is a reference plan view showing a state when the vicinity of the joint 5 of the knife support sheet 2 is conveyed to the press processing section C. In FIG. 11, the cutting blade 61 is represented by a two-dot chain line, and the original optical film 1 is represented by a small dotted line. FIG. 12 is a cross-sectional view obtained by cutting the cutting knife 61 at a position that intersects the seam 5, and FIG. 13 is a cross-sectional view obtained by cutting the cutting knife 61 at a position that does not intersect the seam 5. 11, in the middle of continuously punching the film product 9 from the long strip-shaped optical film original sheet 1, the vicinity of the seam 5 of the knife support sheet 2 reaches the punching processing part C. Since the seam 5 of the knife support sheet 2 of the present invention extends in a direction that intersects with the extending direction of the cutting knife 61, the seam 5 and the cutting knife 61 do not overlap in a linear manner, and the seams 5 and 1 The two cutting knives 61 intersect at the intersection point. The symbol Y in FIG. 11 indicates the intersection point where the first part 611 of one cutting blade 61 (the first part 611 extending substantially parallel to the short-side direction of the blade support sheet 2) and the seam 5 intersect.

The cutting edge 61a of the first part 611 of the cutting knife 61 at the intersection point Y enters the seam 5 (refer to FIG. 12). The support sheet 2 receives the cutting edge 61a (refer to FIG. 13). Therefore, the pressing force of the first part 611 of the cutting blade 61 acts on the entire thickness direction of the optical film original sheet 1, and it is unlikely that the optical film original sheet 1 is cut off. Since the cutting line X can be formed in the optical film original sheet 1 without cutting defects, the blanking residual edge 91 can be easily recovered in the blanking residual edge removal part D. Furthermore, even if a slight cutting defect occurs at the above-mentioned intersection point, since the defective part is a point, it will not hinder the recovery of the punching residual edge 91. The penetration amount of the blade edge 61a with respect to the blade supporting sheet 2 can be appropriately set, and is, for example, 0 μm to 200 μm. In addition, the above-mentioned penetration amount refers to the distance between the front end of the knife tip 61a and the surface of the knife support sheet 2. When the above-mentioned entry amount is zero, it means that the front end of the blade edge 61a is in contact with the surface of the blade supporting sheet 2. In FIGS. 12 and 13, the case where the first part 611 of one cutting knife 61 intersects the seam 5 is described, but the same applies when the first part 611 of the other cutting knife 61 intersects the seam 5 The reason is not easy to produce bad cutting. The same applies when the second portion 612 of the cutting blade 61 intersects the seam 5.

In addition, when the splicing tape 51 is attached to the surface of the knife support sheet 2, as shown in FIGS. 12 and 13, a portion where the optical film original sheet 1 overlaps the splicing tape 51 is generated. The portion overlapping with the splicing tape 51 in the original optical film 1 is raised by an amount equivalent to the thickness of the splicing tape 51. Therefore, the cutting blade 61 pressed to this part enters the original optical film 1 more deeply than the other parts. Since the cutting blade 61 gradually becomes thicker from the blade edge 61a toward the base plate 62 side, if the cutting blade 61 enters deeper, the width of the cutting line becomes larger correspondingly, and cracks may occur in the film product 9 The fear of waiting. In view of this aspect, as described above, by using the splicing tape 51 having a thickness of 50 μm or less, cracks and the like of the above-mentioned film product 9 can be prevented. In particular, when the optical film original sheet 1 with a protective film is punched with the cutting blade 61, peeling of the protective film may occur, but the use of the splicing tape 51 described above can prevent the peeling of the protective film, etc.

The layer composition of the obtained film product 9 is the same as the layer composition of the optical film original sheet 1 described above. When the film product 9 is composed of, for example, the optical film 11/adhesive layer 12/isolation film 13, by peeling off the isolation film 13, the film product 9 can be attached to any member (such as the screen of an image display device, etc.) ). However, the film product 9 is not limited to the use of being attached to any member and used.

Hereinafter, the second embodiment of the present invention will be described. However, in the description, the configuration and effects that are different from the above-mentioned embodiments will be mainly described. For the same configuration, etc., the terms or symbols may be directly quoted and the configuration may be omitted. The description.

[Second Embodiment] In the first embodiment described above, the knife support sheet 2 is wound from the unwinding section 322, and after passing through the press processing section C, is wound to the winding section 332, but it is not limited to this. For example, as shown in FIG. 14, the knife support sheet 2 may be formed in an endless shape like the conveyor belt of a belt conveyor. The endless knife support sheet 2 has a ring shape in a side view as shown in the figure, and is circulated in the press processing part C. As shown in FIG. The endless knife support sheet 2 is formed by making the strip-shaped knife support sheet 2 into a ring shape, and the first end face and the second end face of the joint 5 are joined by splicing tape 51 Obtained. Regarding the endless blade support sheet 2 also, similarly to the above-mentioned first embodiment, a seam 5 extending in a direction intersecting with the extending direction of the cutting blade 61 is formed. Also in the press device A2 of this embodiment, similarly to the above-mentioned first embodiment, the cutting failure of the optical film original sheet 1 is less likely to occur. Furthermore, in this embodiment, since the endless blade support sheet 2 is circulated in the press processing part C, the usage amount of the blade support sheet 2 can be reduced. Furthermore, if the endless knife support sheet 2 is recycled, multiple marks of the cutting edges 61a of the cutting knife 61 will be generated on the surface of the knife support sheet 2. Therefore, it is better to replace the knife at an appropriate time. Support sheet 2.

[Third Embodiment] In the above-mentioned first and second embodiments, the cutter device 6 of the pressing method is exemplified, but for example, as shown in FIG. 15, a rotary die head 65 may also be used. The rotary die head 65 is provided with a cutting blade 61 protruding from its peripheral surface. In the press device A3 of this embodiment, the cutting blade 61 provided on the peripheral surface of the rotary die head 65 is also arranged so as to cross the seam 5 of the blade support sheet 2 in the same manner as in the first embodiment. . In addition, when the rotary die 65 is used, the anvil roller 66 is arranged opposite to the support table 63 described above.

[Fourth Embodiment] In the first to third embodiments described above, the case of manufacturing the film product 9 having a substantially quadrangular shape in plan view is illustrated, but the shape of the film product 9 (that is, the shape of the cutting blade 61 in plan view) is not limited to this, and may be It is appropriately changed within the intended scope of the present invention.

1: Original optical film 2: Knife support sheet 5: Seam 5W: width 6: Cutter device 9: Film products 9a: Longitudinal 9b: horizontal edge 11: Optical film 12: Adhesive layer 13: Isolation film 14: Surface protective film 15: Adhesive layer 16: Surface protective film 17: Adhesive layer 21: 1st end face 21a: first end 22: 2nd end face 22a: 2nd end 31: Guide roller 34: Belt conveyor 35: Belt conveyor 36: Belt conveyor 37: Recycling Department 51: Splicing tape 51T: Thickness 51W: width 61: Cutting Knife 61a: The tip of the cutting knife 62: base plate 63: support table 65: Rotating die 66: Anvil Roll 71: pressure roller 72: recovery roller 91: Punching the residual edge 100: Original optical film 111: The first protective film 112: Polarizing element 113: The second protective film 115: retardation film 200: Knife support sheet 210: 1st end face 220: 2nd end face 321: Roll Out 322: Roll out part 332: Coiling Department 500: seam 510: Splicing tape 610: Cutting Knife 611: Part 1 612: Part 2 A1, A2, A3: stamping device B: Transport Department C: Stamping processing department D: Punching residual edge removal part E: Product Recycling Department S1: Hollow arrow S2: Hollow arrow S3: Hollow arrow S4: Hollow arrow X: cut line Y: intersection α: Angle β: Angle

Fig. 1 is a schematic side view showing the optical film punching device according to the first embodiment of the present invention. Figure 2 is a top view of the original optical film. Fig. 3 is a schematic side view showing an example of the layer structure of an optical film original sheet. Fig. 4 is a schematic side view showing another example of the layer structure of an optical film original sheet. Figure 5 is a top view of a knife support sheet including seams. Fig. 6 is an enlarged cross-sectional view taken along the VI-VI line of Fig. 5. "Cross-sectional view" is a diagram showing only the shape of the cut surface and does not show the shape of the inner side of the cut surface. Fig. 7 is a plan view showing the seam of the knife support sheet before the splicing tape is attached. Figure 8 is a top view of the cutting knife. Figure 9 is an enlarged perspective view of the cutting knife. Fig. 10 is a plan view showing the state of the knife support sheet and the like in each step when the optical film original sheet is punched. Fig. 11 is a plan view showing a state where a part of the cutting blade crosses the seam of the blade support sheet. Fig. 12 is a cross-sectional view taken along the line XII-XII of Fig. 11. Fig. 13 is a cross-sectional view taken along the line XIII-XIII of Fig. 11. Fig. 14 is a schematic side view showing the optical film press device of the second embodiment. Fig. 15 is a schematic side view showing the optical film press device of the third embodiment. Figure 16 is a reference diagram showing the previous problem.

1: Original optical film

2: Knife support sheet

5: Seam

51: Splicing tape

61: Cutting Knife

611: Part 1

612: Part 2

Y: intersection

Claims (9)

A punching device for optical film, which uses a cutting knife to punch the original optical film to produce a plurality of thin film products, and includes: A conveying section that conveys the knife support sheet supporting the blade tip of the cutting knife and the optical film original sheet in the longitudinal direction, respectively; and A stamping processing section, which presses the cutting knife to the original optical film from the side opposite to the knife support sheet; The knife support sheet has a seam formed by joining the first end face and the second end face of the sheet, and The seam extends in a direction crossing with the extending direction of the cutting blade. The optical film punching device of claim 1, wherein the seam of the knife support sheet extends obliquely with respect to the short side direction orthogonal to the longitudinal direction of the knife support sheet. The optical film punching device of claim 1 or 2, wherein the splicing tape is attached to the knife support sheet across the first end and the second end of the sheet while covering the seam, and The thickness of the splicing tape mentioned above is 50 μm or less. A method for manufacturing a film product, which is a method of using a cutting knife to punch an optical film original sheet to obtain a plurality of film products, and includes the following steps: The knife support sheet supporting the tip of the cutting knife and the original optical film are respectively transported in the longitudinal direction; By pressing the cutting knife against the original optical film from the side opposite to the knife support sheet, punching out a plurality of film products from the original optical film; The knife support sheet has a seam formed by joining the first end face and the second end face of the sheet, and The seam of the knife support sheet extends in a direction crossing with any edge of the punched film product. The method of manufacturing a film product according to claim 4, wherein the seam of the knife support sheet extends obliquely with respect to the short side direction orthogonal to the longitudinal direction of the knife support sheet. The method for manufacturing a film product of claim 4 or 5, wherein the film product is a substantially quadrilateral in plan view, and the substantially quadrilateral in plan view has longitudinal sides that are substantially parallel to the longitudinal direction of the optical film original sheet and A horizontal side that is roughly parallel to the short side direction. The method of manufacturing a film product according to claim 4 or 5, wherein the splicing tape is attached to the knife support sheet across the first end and the second end of the sheet, covering the seam, and The thickness of the splicing tape mentioned above is 50 μm or less. The method for manufacturing a film product according to claim 4 or 5, wherein the film product includes a surface protection film laminated through an adhesive layer. The method for manufacturing a film product of claim 4 or 5, wherein the film product includes a polarizing element.

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