TWI693136B - Polarizer with different shape having hole and manufacturing method thereof - Google Patents

Abstract

A manufacturing method of a polarizer with different shape having a hole includes steps below is provided. Providing a knife mold, a buffer layer, and an optical film assembly. The knife mold includes a base and a knife. The base includes a plurality of stamping parts having a pore. The pore is substantially located in a center of gravity of the corresponding stamping part. The knife is disposed on the base. The knife includes a first knife and a second knife. The first knife forms a plurality of closed structures on a surface of the base to define the plurality of stamping parts. The second knife surrounds the pore. The plurality of closed structures have a different shape. Proceeding a stamping process to the buffer layer and the optical film assembly by the knife mold, and the polarizer with different shape having the hole is formed. During a period of the stamping process, the buffer layer is located between the polarizer and the optical film assembly. The buffer layer has a compression force of 0.03~0.035 Mpa after proceeding the stamping process. A polarizer with different shape having a hole is also provided.

Description

Special-shaped polarizer with holes and forming method thereof

The present invention relates to a polarizer and a method for forming the same, and in particular to a polarizer with holes and a method for forming the same.

The forming method of the polarizer is usually to combine it with other film layers to form an optical film group, and then perform a stamping process on the optical film group. However, after the punching of the optical film group composed of multilayer films each having a different hardness, the stress generated by the multilayer films will be different, and the polarizer formed will have warpage and cracking problems, thereby reducing the yield.

The invention provides a shaped polarizer with holes and a method for forming the same. The shaped polarizer formed by this method has a flat surface.

The method for forming a special-shaped polarizer with holes according to the present invention includes the following steps. First, provide a knife mold, a buffer layer, and an optical film group including a polarizing film. The cutter mold includes a base and a cutter. The base includes a plurality of punched portions with small holes. Xiao Kongshi It is qualitatively located at the center of gravity of the corresponding punching part. The cutter is arranged on the base. The tool includes a first tool and a second tool. The first cutter forms a plurality of closed structures on the surface of the base to define a plurality of stamping parts. The second cutter surrounds the small hole. The shapes of the multiple closed structures are irregular. Next, the buffer layer and the optical film group are stamped by a knife mold to form a plurality of shaped polarizers with holes. During the stamping process, the buffer layer is located between the knife mold and the optical film group. The compression force of the buffer layer after the stamping process is 0.03~0.035Mpa.

In an embodiment of the present invention, the shapes of the plurality of closed structures are symmetrical or asymmetrical geometric figures.

In an embodiment of the present invention, the height of the above-mentioned first cutter and the second cutter is 0.9-1.2 mm.

In an embodiment of the invention, the first cutter and the second cutter are double oblique cutters, and the inclination angle of the blades of the first cutter and the second cutter is 30 degrees.

In an embodiment of the present invention, in the step of punching the buffer layer and the optical film group by the knife mold, the knife mold is disposed on the first platform, the optical film group is disposed above the knife mold, and provides The second platform moves the first platform toward the second platform to perform the stamping process.

In an embodiment of the invention, the buffer layer is foam.

In an embodiment of the invention, the thickness of the buffer layer is 0.7-1.5 mm.

In an embodiment of the invention, the above-mentioned optical film set includes a quarter-wave film, a half-wave film, a polarizing film, and a protective film stacked in this order.

In an embodiment of the invention, the above-mentioned optical film set further includes a light control film, and the quarter-wave film is located between the light control film and the half-wave film.

In an embodiment of the invention, the above optical film set further includes a brightness enhancement film, and the brightness enhancement film is located between the polarizing film and the protective film.

In an embodiment of the invention, the profile of the hole of the above-mentioned shaped polarizer corresponds to the blade surface of the second cutter.

The shaped polarizer with holes of the present invention is formed, for example, by the method for forming the shaped polarizer with holes described above.

In an embodiment of the present invention, the cross-section of the hole is a bright surface band having an aperture of the vertical hole, and the bright surface band penetrates both edges of the hole.

Based on the above, the present invention selects a suitable buffer layer (for example, the compression force after the stamping process is 0.03~0.035Mpa) so that the stress generated by the optical film group including the polarizing film during the stamping process is absorbed, Thereby, the formed shaped polarizer can avoid warpage and cracks and have a flat surface.

In order to make the above-mentioned features and advantages of the present invention more obvious and understandable, the embodiments are specifically described below in conjunction with the accompanying drawings for detailed description as follows.

10: knife mold

100: Dock

100a: stamping department

100b: small hole

200: Tool

210: the first tool

212, 222: inner blade surface

214, 224: outer blade surface

220: second cutter

300: buffer layer

400a: Optical diaphragm group

410a: protective film

420: polarizer

420a: Polarizing film

420b: holes

430a: Half-wavelength film

440a: quarter wave film

450a: light control film

460a: Brightening film

1000: the first platform

2000: Second platform

A-A’: section line

H1: height

H2, H3: thickness

L: aperture

S100, S110, S120, S130: steps

FIG. 1A is a schematic top view of a knife mold according to an embodiment of the invention.

FIG. 1B is a schematic cross-sectional view taken along line A-A' of FIG. 1A.

FIG. 2 is a forming method of a shaped polarizer with holes according to an embodiment of the invention Flow chart.

3 is a schematic diagram of an optical film assembly according to an embodiment of the present invention when punching.

4A is a schematic cross-sectional view of an optical film assembly according to an embodiment of the invention.

4B is a schematic cross-sectional view of an optical film assembly according to another embodiment of the invention.

FIG. 5 is a schematic top view of a shaped polarizer with holes according to an embodiment of the invention.

In the drawings, the thickness of layers, films, regions, etc., are exaggerated for clarity. Throughout the specification, the same reference numerals denote the same components. It should be understood that when a member such as a layer, film, or region is referred to as being “on” or “connected to” another member, it can be directly on or connected to the other member, or intervening members It can also exist. In contrast, when a component is referred to as being "directly on" or "directly connected to" another component, there are no intervening components.

FIG. 1A is a schematic top view of a knife mold according to an embodiment of the invention. FIG. 1B is a schematic cross-sectional view taken along line A-A' of FIG. 1A. FIG. 2 is a flowchart of a method for forming a shaped polarizer with holes according to an embodiment of the invention. 3 is a schematic diagram of an optical film assembly according to an embodiment of the present invention when punching.

Please refer to FIG. 1A, FIG. 1B, FIG. 2 and FIG. 3 at the same time. For example, the method for forming a shaped polarizer with holes in this embodiment has the following steps, but the invention is not limited thereto.

In step S100, the knife mold 10 is provided.

The knife mold 10 can be used, for example, in a die cutting process to cut a plate. In this embodiment, the knife mold 10 is used to cut an optical film group 400a including a polarizing film 420a. In some embodiments, the knife mold 10 includes a base 100 and a knife 200. The base 100 and the cutter 200 are made of the same material, for example. That is, the base 100 and the cutter 200 may be integrally formed, for example.

In some embodiments, the cutter 200 includes a first cutter 210 and a second cutter 220. The first cutter 210 and the second cutter 220 are, for example, double diagonal cutters. That is, the first cutter 210 and the second cutter 220 each have two cutter faces. In detail, the first cutter 210 has, for example, an inner cutter surface 212 and an outer cutter surface 214, and the second cutter 220 also has, for example, an inner cutter surface 222 and an outer cutter surface 224. Here, the inner blade surface 212 (or the inner blade surface 222) means the blade surfaces facing each other in the first cutter 210 (or the second cutter 220), and the outer blade surface 214 (or the outer blade surface 224) means the The blade surface opposed to the inner blade surface 212 (or the inner blade surface 222). The first cutter 210 and the second cutter 220 have substantially the same height, for example. In some embodiments, the height H1 of the first cutter 210 and the second cutter 220 is 0.9-1.2 mm. Preferably, the height H1 of the first cutter 210 and the second cutter 220 is 1.2 mm. The first cutter 210 and the second cutter 220 also have substantially the same blade tilt angle, for example. In some embodiments, the blade tilt angle of the first cutter 210 and the second cutter 220 is 30 degrees.

The base 100 has, for example, a plurality of punching portions 100 a defined by the cutter 200. In detail, the cutter 200 is disposed on a surface of the base 100 and surrounds an area, that is, the cutter 200 can be disposed on the base 100 A closed structure is formed on one surface. In some embodiments, the first cutter 210 forms a plurality of closed structures on a surface of the base 100, that is, each of the above-mentioned closed structures is a stamping portion 100a. In this embodiment, the die 10 has ten stamping portions 100a, but the invention is not limited thereto. In some embodiments, the thickness H2 of the base 100 is 0.8 mm to 1.3 mm.

The shape of the punching portion 100a (ie, the closed structure) is defined, for example, according to the shape to be formed after the sheet material is subjected to the punching process. In some embodiments, the shape of the stamping portion 100a is irregular, which is, for example, a symmetrical or asymmetrical geometric figure. In this embodiment, the shape of the punching portion 100a is an octagon. Therefore, the shaped polarizer formed by the die-cutting process using the die 10 of this embodiment also has an octagonal shape, but the invention is not limited thereto. In some embodiments, each punching portion 100a has a small hole 100b. The small hole 100b is located substantially at the center of gravity of the punching portion 100a, and is surrounded by the second cutter 220, for example. That is, the second cutter 220 also forms a plurality of closed structures on a surface of the base 100. Therefore, the shaped polarizer formed by the die-cutting process of the knife mold 10 of this embodiment also has a hole substantially at the center of gravity. In addition, since the punching portion 100a has a small hole 100b, the debris generated in the vicinity of the hole of the shaped polarizer during the cutting process can be discharged from the small hole 100b to improve the convenience of the manufacturing process.

In step S110, a buffer layer 300 is provided.

The buffer layer 300 can be used, for example, in the punching process to alleviate the stress caused by the characteristics of the optical film group 400a during cutting. In addition, the buffer layer 300 can also be used to prevent the blade die 10 from making improper contact with the optical film group 400a, thereby prolonging the use time of the blade die 10. The buffer layer 300 can use, for example, foam or micro cell polymerization It is made of compressible materials such as closed or non-closed air chambers and other types of materials. In this embodiment, the material of the buffer layer 300 is foam. In some embodiments, the thickness H3 of the buffer layer 300 is 0.7-1.5 mm. Preferably, the thickness H3 of the buffer layer 300 is 1.5 mm.

In step S120, an optical film group 400a is provided.

4A is a schematic cross-sectional view of an optical film assembly according to an embodiment of the invention. 4B is a schematic cross-sectional view of an optical film assembly according to another embodiment of the invention.

4A and 4B, the optical film group 400a has, for example, a structure in which multiple films are stacked on each other, and has a thickness of about 0.2 to 0.8 mm. In some embodiments, the optical film group 400a may include a light control film 450a, a quarter-wave film 440a, a half-wave film 430a, a polarizing film 420a, and a protective film 410a stacked in this order, but the present invention Not limited to this. In other embodiments, the optical film group 400a may include a quarter-wave film 440a, a half-wave film 430a, a polarizing film 420a, a brightness enhancement film 460a, and a protective film 410a stacked in this order. The invention is not limited to this.

In step S130, the buffer layer 300 and the optical film group 400a are stamped by the knife mold 10 to form a plurality of shaped polarizers with holes.

Please refer to FIG. 3, during the stamping process, the buffer layer 300 is placed between the knife mold 10 and the optical film group 400a. Since the optical film group 400a is composed of multilayer films each having a different hardness, the optical film group 400a may have a problem of warpage due to different stresses generated by the multilayer films after being punched. In order to solve the above problems, in this embodiment, an appropriate buffer layer 300 is selected to absorb the above stress, so as to Avoid warping of the formed polarizer. The material and thickness of the buffer layer 300 have been described in detail in the embodiments, and will not be repeated here. In this embodiment, the thickness H3 of the buffer layer 300 is greater than the height H1 of the tool 200. In some embodiments, the compression force of the buffer layer 300 after the stamping process is 0.03~0.035Mpa. When the compression force of the buffer layer 300 after performing the stamping process is within the above range, it can be ensured that the buffer layer 300 completely absorbs the stress generated by the optical film group 400a after stamping.

The stamping process of the buffer layer 300 and the optical film group 400a by the knife mold 10 includes, for example, the following steps. First, the knife mold 10 is placed on the first platform 1000, and the buffer layer 300 and the optical film group 400a are placed above the knife mold 10. Next, a second platform 2000 is provided, which is, for example, a stamping platform. After that, the first platform 1000 is moved in the direction of the second platform 2000, so that the buffer layer 300 first contacts the knife mold 10 and then is compressed. When the die 10 contacts the optical film group 400a and is punched, the buffer layer 300 generates a compressive force of 0.03~0.035Mpa between the die 10 and the optical film group 400a due to compression to offset the The stress generated by the diaphragm group 400a. Based on this, it is possible to prevent the formed polarizer from being warped and deformed. In other embodiments, the first platform 1000 can also be moved in the direction of the second platform 2000, and the present invention is not limited thereto.

FIG. 5 is a schematic diagram of a shaped polarizer with holes according to an embodiment of the invention.

Please refer to FIG. 5. The shaped polarizer 420 having a hole 420b in this embodiment is formed by the aforementioned manufacturing method. The shape of the special-shaped polarizer 420 may be, for example, a symmetrical or asymmetrical geometric figure, which depends on the shape of the punching portion 100a of the knife die 10 Depending on the situation. In this embodiment, the shape of the shaped polarizer 420 is an octagon. The hole diameter 420b of the hole 420b of the shaped polarizer 420 is, for example, 1.8 mm to 3.0 mm. The hole 420b is formed by cutting the second cutter 220 of the die 10, so the outline of the hole 420b corresponds to the inner blade surface 222 of the second cutter 220. In detail, the cross section of the hole 420b is a bright band with an aperture perpendicular to the hole 420b, and the bright band passes through both edges of the hole 420b. The shaped polarizer 420 of this embodiment is formed by using a suitable buffer layer 300 after the aforementioned stamping process, wherein the compressive force of the buffer layer 300 after the stamping process is 0.03~0.035Mpa. Based on this, the shaped polarizer 420 of this embodiment can avoid warpage and have a flat surface. In addition, the holes 420b of the shaped polarizer 420 of this embodiment are also formed by performing the above-mentioned stamping process, thereby reducing the number of process steps and reducing the manufacturing cost.

In summary, the present invention selects a suitable buffer layer (for example, the compression force after the stamping process is 0.03~0.035Mpa) so that the stress generated by the optical film group including the polarizing film during the stamping process is Absorption, so that the formed shaped polarizer can avoid warping and have a flat surface. In addition, the holes of the shaped polarizer of the present invention are also formed by performing the above-mentioned stamping process, thereby reducing the number of process steps and reducing the manufacturing cost.

Although the present invention has been disclosed as above with examples, it is not intended to limit the present invention. Any person with ordinary knowledge in the technical field can make some changes and modifications without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be subject to the scope defined in the appended patent application.

S100, S110, S120, S130: steps

Claims (13)

A method for forming a shaped polarizer with holes, including: A knife mold is provided, wherein the knife mold includes: The base includes a plurality of punching parts having small holes, wherein the small holes are located substantially at the center of gravity of the corresponding punching parts; and A cutter is provided on the base, wherein the cutter includes a first cutter and a second cutter, the first cutter forms a plurality of closed structures on the surface of the base to define the plurality of stamping parts , And the second cutter surrounds the small hole, wherein the shapes of the plurality of closed structures are irregular; Provide a buffer layer; Providing an optical diaphragm set including a polarizing film; and Performing a stamping process on the buffer layer and the optical film group by the knife mold to form a plurality of the shaped polarizers having the holes, During the stamping process, the buffer layer is located between the knife mold and the optical film group, and The compression force of the buffer layer after performing the stamping process is 0.03~0.035Mpa. The method for forming a shaped polarizer with holes as described in item 1 of the patent application scope, wherein the shapes of the plurality of closed structures are symmetrical or asymmetrical geometric figures. The method for forming a shaped polarizer with holes as described in item 1 of the patent application range, wherein the heights of the first cutter and the second cutter are 0.9-1.2 mm. The method for forming a shaped polarizer with holes as described in item 1 of the patent application scope, wherein the first cutter and the second cutter are double oblique cutters, and the first cutter and the second cutter The blade tilt angle is 30 degrees. The method for forming a shaped polarizer with holes as described in item 1 of the patent application scope, wherein in the step of performing the stamping process on the buffer layer and the optical film group with the knife mold, the The knife mold is disposed on the first platform, the optical film set is disposed above the knife mold, and a second platform is provided, which is performed by moving the first platform in the direction of the second platform Describe the stamping process. The method for forming a shaped polarizer with holes as described in item 1 of the patent application range, wherein the buffer layer is foam. The method for forming a shaped polarizer with holes as described in item 1 of the patent application, wherein the thickness of the buffer layer is 0.7 to 1.5 mm. The method for forming a shaped polarizer with holes as described in item 1 of the patent application range, wherein the optical film group includes a quarter-wave film, a half-wave film, and the polarized light stacked in this order Membrane and protective film. The method for forming a shaped polarizer with holes as described in item 8 of the patent application range, wherein the optical film group further includes a light control film, and the quarter-wavelength film is located between the light control film and the Between half-wavelength films. The method for forming a shaped polarizer with holes as described in item 8 of the patent application range, wherein the optical film group further includes a brightness enhancement film, and the brightness enhancement film is located between the polarizing film and the protective film . The method for forming a shaped polarizer with holes as described in item 1 of the patent application range, wherein the outline of the holes possessed by the shaped polarizer corresponds to the blade surface of the second cutter. A shaped polarizer with holes is formed using the method for forming a shaped polarizer with holes as described in any one of claims 1 to 11. As described in Item 12 of the patent application scope, the polarized polarizer with holes has a cross section of a bright surface band having an aperture perpendicular to the hole, and the bright surface band penetrates both edges of the hole.

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