TWI709770B - Method for manufacturing optical member with resin film - Google Patents

Abstract

The present invention provides a method for manufacturing an optical member with a resin film, that the optical member is obtained by sticking a resin film to an optical member with an adhesive layer interposed therebetween and has good adhesion between the adhesive layer and the optical member.

The method for manufacturing optical member with resin film comprises: a coating step of applying an adhesive composition onto an elongated resin film to form a coating layer; a drying step of obtaining a resin film having an adhesive layer by introducing the film into the drying means to dry the coating layer while continuously transporting the resin film after the coating step; a smoothing treatment step of pressing a specular mold against the outer surface of the adhesive layer while continuously transporting the resin film having an adhesive layer; a sticking step of laminating a long optical member on the outer surface of the adhesive layer while continuously transporting the resin film after the smoothing treatment step and pressing the laminate from above and below.

Description

Manufacturing method of optical component with resin film

The present invention relates to a method for manufacturing an optical member with a resin film, which is obtained by bonding a resin film to the optical member through an adhesive layer.

Various optical members typified by a polarizing plate are sometimes used by being bonded to other members through an adhesive layer (for example, Patent Document 1). Therefore, an optical member may be distributed in the market in the form of an optical member with an adhesive layer formed by preliminarily providing an adhesive layer on one surface. On the outer surface of the adhesive layer, a peelable separate film (also called a "release film") is generally temporarily attached to protect the surface.

[Prior Technical Literature] [Patent Literature]

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

For bonding optical components to other components The aforementioned adhesive layer is required to have good adhesion to optical components. When the adhesiveness of the adhesive layer used for bonding the optical member to another member is insufficient, the durability and reliability of the composite member formed by pasting the optical member and the other member through the adhesive layer will decrease.

The object of the present invention is to provide a method for manufacturing an optical member with a resin film. The optical member with a resin film is attached to the optical member through the adhesive layer, such as an optical member with an adhesive layer of the above-mentioned release film. In the case of a composite resin film, the adhesive layer and the optical member have good adhesion.

The present invention provides a method of manufacturing an optical member with a resin film as shown below.

[1] A method for manufacturing an optical member with a resin film, which includes the following steps: a coating step, which is to coat an adhesive composition on a long resin film to form a coating layer; and a drying step, which is The film after the aforementioned coating step is continuously conveyed while introducing a drying means to dry the aforementioned coating layer to obtain a resin film with an adhesive layer; the smoothing step is to continue the aforementioned resin film with an adhesive layer During transportation, while pressing the mirror mold on the outer surface of the adhesive layer; and in the laminating step, the resin film after the smoothing treatment step is continuously transported while being stripped on the outer surface of the adhesive layer , And press this laminate from above and below.

[2] The manufacturing method as described in [1], which further includes the following step: an aging step, which is to wind the optical member with a resin film obtained in the aforementioned bonding step into a roll, and perform the aforementioned bonding in a roll state The maturation of the agent layer.

[3] The manufacturing method as described in [1] or [2], wherein, in the smoothing treatment step, the temperature of the adhesive layer in contact with the mirror mold is lower than the glass transition temperature of the adhesive composition .

[4] The manufacturing method as described in any one of [1] to [3], further comprising the following step: a surface activation step, which is prior to the bonding step, for the optical member and the adhesive The bonding surface of the layer is irradiated with energy.

[5] The production method according to any one of [1] to [4], wherein the surface of the optical member that is in contact with the outer surface of the adhesive layer contains (meth)acrylic resin.

[6] The manufacturing method according to any one of [1] to [5], wherein the optical member is a polarizing plate.

[7] The manufacturing method according to any one of [1] to [6], wherein the resin film-based separator.

According to the manufacturing method of the present invention, it is possible to provide an optical member with a resin film that improves the adhesion between the adhesive layer and the optical member.

1‧‧‧The first feed roller

2‧‧‧The second feed roller

3‧‧‧Winding roller

10‧‧‧Resin film

11‧‧‧Coating layer

12‧‧‧Adhesive layer (before energy irradiation)

13‧‧‧Adhesive layer (after smoothing treatment)

15‧‧‧Resin film with coating layer

20‧‧‧Resin film with adhesive layer (before smoothing treatment)

25‧‧‧Resin film with adhesive layer

30‧‧‧Optical components

40‧‧‧Optical components with resin film

50‧‧‧Coating device

60‧‧‧Coating roller

70‧‧‧Drying means

80‧‧‧Smoothing device

90‧‧‧Laminating Roll

Fig. 1 is a schematic diagram showing an example of a method of manufacturing an optical member with a resin film of the present invention and a manufacturing apparatus used for the method.

Fig. 2 is a schematic cross-sectional view showing an example of a resin film having a coating layer (before drying).

Fig. 3 is a schematic cross-sectional view showing an example of a resin film having an adhesive layer (before smoothing treatment).

Fig. 4 is a schematic cross-sectional view showing an example of a resin film with an adhesive layer.

Fig. 5 is a schematic cross-sectional view showing an example of an optical member with a resin film.

The method of manufacturing an optical member with a resin film of the present invention includes the following steps: a coating step, which is to coat an adhesive composition on a long resin film to form a coating layer; and the drying step is to The film after the coating step is continuously transported while introducing a drying means to dry the coating layer to obtain a resin film with an adhesive layer; the smoothing treatment step is to continuously transport the resin film with the aforementioned adhesive layer Pressing the mirror mold on the outer surface of the adhesive layer; and the laminating step, the resin film after the smoothing treatment step is continuously transported while layering a long optical member on the outer surface of the adhesive layer, And press the laminated body from above and below.

The method of manufacturing an optical member with a resin film of the present invention may further include steps other than the above-mentioned steps. Hereinafter, each step will be described with reference to FIGS. 1 to 5. Furthermore, in the following, the "resin film with an adhesive layer" which is a film intermediate that is bonded to the optical member is also referred to as the "resin film with an adhesive layer".

[Coating Step]

This step is a step of forming the coating layer 11 by applying the adhesive composition on the resin film 10 by the coating device 50 to obtain the resin film 15 having the coating layer 11 (refer to Figures 1 and 2) .

(1) Resin film

The resin film 10 is generally a thermoplastic resin film, preferably a thermoplastic resin film having light transmittance (more preferably an optically transparent) thermoplastic resin film. Specific examples of thermoplastic resins include polyolefin resins such as chain polyolefin resins (polyethylene resins, polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.) ; Such as polyvinyl fluoride (Polyvinyl fluoride), polyvinylidene fluoride (Polyvinylidene fluoride), polyvinyl fluoride (Polyethylene fluoride) and other fluorinated polyolefin resin; Polyester resins such as ethylene formate resins; (meth)acrylic resins such as methyl methacrylate resins; such as triacetyl cellulose [TAC], cellulose acetate of diacetyl cellulose Cellulose resins such as resins; polycarbonate resins; polyvinyl alcohol resins; polyvinyl acetate resins; polyarylate resins; polyimide resins; polystyrene resins; polyamide resins Resins; Polyether-based resins; Poly-based resins; and mixtures and copolymers of these. In addition, in this manual, the so-called "(甲 "Acrylic acid" means acrylic acid and/or methacrylic acid, and "(meth)" when describing (meth)acrylate etc. also has the same meaning.

The thickness of the resin film 10 is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The resin film with the adhesive layer of the intermediate film produced in the manufacturing method of the present invention may be, for example, an adhesive layer-attached release film. At this time, the resin film 10 may be a release film that has been subjected to mold release treatment on the surface on the side where the adhesive layer is laminated. Examples of mold release treatments are silicone treatment, long-chain alkyl treatment, fluorine treatment, etc.

Furthermore, the resin film 10 may be an optical member other than the isolation film. The resin film 10, which is an optical member other than the isolation film, may have a single-layer structure or a multilayer structure. Specific examples of the resin film 10 as an optical member include: polarizing film; optical compensation film (retardation film, etc.), light diffusion film (sheet), reflective film (sheet), and other optical functional films; polarizing film protective film ; Polarizing plate etc.

(2) Adhesive composition

The adhesive composition applied to the resin film 10 includes, for example, (meth)acrylic adhesive composition, urethane adhesive composition, silicone adhesive composition, and polysiloxane adhesive composition. Ester-based adhesive composition, polyamide-based adhesive composition, polyether-based adhesive composition, fluorine-based adhesive composition, rubber-based adhesive composition, etc. Among them, from the viewpoints of transparency, adhesion, reliability, reproducibility, etc., it is preferable to use a (meth)acrylic adhesive that uses a (meth)acrylic resin as a base polymer. .

(2-1) Base polymer

Specific examples of (meth)acrylic resins that can be suitably used as the base polymer of the (meth)acrylic adhesive composition are the following (meth)acrylic resins (A-1),

The (meth)acrylic resin (A-1) is a polymer having a structural unit derived from the (meth)acrylate represented by the above formula (I) as a main component (that is, containing 50% by weight or more).

In the above formula (I), R ¹ represents a hydrogen atom or a methyl group, and R ² represents an alkyl group with 1 to 14 carbons which may be substituted by an alkoxy group with 1 to 10 carbons, or an alkyl group with 1 to 14 carbons which may be substituted with 1 to 10 carbons. The alkoxy substituted aralkyl group of 7 to 21 carbons. R ^{2 is} preferably an alkyl group having 1 to 14 carbons which may be substituted by an alkoxy group having 1 to 10 carbons.

Specific examples of the (meth)acrylate represented by the formula (I) include linear ones such as methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, n-octyl acrylate, lauryl acrylate, etc. Alkyl acrylate; branched alkyl acrylate such as isobutyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate, etc.; such as methyl methacrylate, ethyl methacrylate, propyl methacrylate Ester, n-butyl methacrylate, n-octyl methacrylate, lauryl methacrylate and other linear alkyl methacrylates; isobutyl methacrylate, 2-ethylhexyl methacrylate, methyl Branched alkyl methacrylates such as isooctyl acrylate, etc.

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

The (meth)acrylate represented by formula (I) may be used alone or in combination of two or more kinds. Among them, the (meth)acrylate preferably contains n-butyl acrylate. The (meth)acrylic resin (A-1) preferably contains 50% by weight or more of n-butyl acrylate in all monomers constituting it. Of course, in addition to n-butyl acrylate, the (meth)acrylate represented by formula (I) may also be used in combination.

The (meth)acrylic resin (A-1) is usually a copolymer of the (meth)acrylate of the above formula (I) and at least one other monomer represented by a monomer having a polar functional group. The monomer having a polar functional group is preferably a (meth)acrylic compound having a polar functional group. Examples of the polar functional group system include free carboxyl groups, hydroxyl groups, amino groups, and heterocyclic groups represented by epoxy groups.

Specific examples of monomers with polar functional groups include: monomers with free carboxyl groups such as (meth)acrylic acid, β-carboxyethyl (meth)acrylate, etc.; such as 2-hydroxyethyl (meth)acrylate , 3-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-(2-hydroxyethoxy)ethyl (meth)acrylate, 2- or 3 (meth)acrylate -Chloro-2-hydroxypropane Esters, diethylene glycol mono(meth)acrylates and other monomers with hydroxyl groups; such as propylene mopholin, vinyl caprolactam, N-vinyl-2-pyrrolidone, vinyl pyridine, (Meth) tetrahydrofuran methyl acrylate, caprolactone modified tetrahydrofuran methyl acrylate, 3,4-epoxycyclohexylmethyl (meth)acrylate (meth)acrylate, (methyl) Monomers with heterocyclic groups such as glycidyl(meth)acrylate and 2,5-dihydrofuran; such as aminoethyl (meth)acrylate, N,N-di(meth)acrylate Monomers such as methylaminoethyl, dimethylaminopropyl (meth)acrylate and the like having an amino group different from the heterocyclic ring. The monomer having a polar functional group may be used alone or in combination of two or more kinds.

Among the above, from the viewpoint of the reactivity of the (meth)acrylic resin (A-1), one of the monomers containing a polar functional group constituting the (meth)acrylic resin (A-1), preferably To use monomers with hydroxyl groups. In addition to monomers with hydroxyl groups, it is effective to use other monomers with polar functional groups, such as monomers with free carboxyl groups.

The (meth)acrylic resin (A-1) may further contain structural units derived from the following monomers: monomers having one olefinic double bond and at least one aromatic ring in the molecule (except for the equivalent The monomer represented by the above formula (I) and the above monomer having a polar functional group). Preferred examples thereof include (meth)acrylic compounds having an aromatic ring. A preferable example of the (meth)acrylic compound having an aromatic ring is (meth)acrylate having an aryloxyalkyl group,

For example, the phenoxyethyl-containing (meth)acrylate represented by the above formula (II).

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

In the formula (II), the alkyl group having 1 to 9 carbon atoms constituting R ⁴ includes methyl, butyl, nonyl, etc., and the aralkyl group having 7 to 11 carbon atoms includes benzyl, phenethyl, and naphthyl. Examples of aryl groups having 6 to 10 carbon atoms include phenyl, tolyl, and naphthyl.

Specific examples of (meth)acrylate containing phenoxyethyl represented by formula (II) include: 2-phenoxyethyl (meth)acrylate, 2-(2-benzene) (meth)acrylate Oxyethoxy) ethyl ester, ethylene oxide modified nonylphenol (meth)acrylate, (meth)acrylate 2-(o-phenylphenoxy)ethyl, etc. The (meth)acrylate containing a phenoxyethyl group may be used alone or in combination of two or more kinds. Among them, the (meth)acrylate containing phenoxyethyl group preferably contains 2-phenoxyethyl (meth)acrylate and 2-(o-phenylphenoxy)ethyl (meth)acrylate. Ester and/or 2-(2-phenoxyethoxy)ethyl (meth)acrylate.

In (meth)acrylic resin (A-1), its solid content is all Based on the volume, the structural unit derived from the (meth)acrylate represented by the above formula (I) may preferably be contained in a proportion of 60 to 99.9% by weight, more preferably in a proportion of 80 to 99.6% by weight; source The structural unit from a monomer having a polar functional group may preferably be contained in a proportion of 0.1 to 20% by weight, more preferably in a proportion of 0.4 to 10% by weight; derived from having one olefinic double bond in the molecule and The structural unit of the monomer having at least one aromatic ring may preferably be contained in a ratio of 0 to 40% by weight, more preferably 6 to 12% by weight.

The (meth)acrylic resin (A-1) may contain a (meth)acrylate derived from the formula (I), a monomer having a polar functional group, and an olefinic double bond and A structural unit of a monomer other than "a monomer having at least one aromatic ring" (hereinafter, also referred to as "other monomer"). Specific examples of other monomers include: structural units derived from (meth)acrylates having an alicyclic structure in the molecule, structural units derived from styrene monomers, and structural units derived from vinyl monomers , Derived from structural units having multiple (meth)acrylic acid monomers in the molecule, structural units derived from (meth)acrylic acid amine monomers, etc. The other monomers may be used alone or in combination of two or more.

The carbon number of the alicyclic structure is usually 5 or more, preferably about 5-7. Specific examples of (meth)acrylates having an alicyclic structure include: isobornyl (meth)acrylate, cyclohexyl (meth)acrylate, dicyclopentyl (meth)acrylate, (meth) )Cyclododecyl acrylate, methylcyclohexyl (meth)acrylate, trimethylcyclohexyl (meth)acrylate, tert-butylcyclohexyl (meth)acrylate, cyclohexyl (meth)acrylate Phenyl ester, α-ethoxy propyl Cyclohexyl enoate, etc.

Specific examples of styrene monomers include: styrene; methyl styrene, dimethyl styrene, trimethyl styrene, ethyl styrene, diethyl styrene, triethyl styrene, Alkyl styrenes such as propyl styrene, butyl styrene, hexyl styrene, heptyl styrene, and octyl styrene; such as fluorostyrene, chlorostyrene, bromostyrene, dibromostyrene, iodostyrene Such as halogenated styrene; nitrostyrene, acetoxystyrene, methoxystyrene, divinylbenzene, etc.

Specific examples of vinyl monomers include: vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, vinyl laurate and other fatty acid vinyl esters; such as vinyl chloride and vinyl bromide Such as halogenated vinyl; such as vinylidene chloride (vinylidene chloride) and other halogenated vinylidene; such as vinyl pyridine, vinyl pyrrolidone, vinyl carbazole and other nitrogen-containing aromatic vinyl; such as butadiene, isoprene, Conjugated diene monomers such as chloroprene; acrylonitrile, methacrylonitrile, etc.

Specific examples of monomers having a plurality of (meth)acrylic acid groups in the molecule include: 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(methyl) ) Acrylate, 1,9-nonanediol di(meth)acrylate, ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate ) Acrylate, tripropylene glycol di(meth)acrylate, etc. have 2 (meth)acrylic acid monomers in the molecule; trimethylolpropane tri(meth)acrylate, etc. have 3 in the molecule (Meth) acrylic monomers, etc.

Specific examples of (meth)acrylamide compounds include: N-hydroxymethyl(meth)acrylamide, N-(2-hydroxyethyl)(meth)acrylamide, N-(3-hydroxypropyl)(meth)acrylamide, N-( 4-hydroxybutyl)(meth)acrylamide, N-(5-hydroxypentyl)(meth)acrylamide, N-(6-hydroxyhexyl)(meth)acrylamide, N,N -Dimethyl(meth)acrylamide, N,N-diethyl(meth)acrylamide, N-isopropyl(meth)acrylamide, N-(3-dimethylamino) Propyl)(meth)acrylamide, N-(1,1-dimethyl-3-oxobutyl)(meth)acrylamide, N-[2-(2-oxo- 1-imidazolidinyl) ethyl) (meth) acrylamide, 2-propenylamino-2-methyl-1-propionic acid, N-(methoxymethyl) acrylamide, N -(Ethoxymethyl)(meth)acrylamide, N-(propoxymethyl)(meth)acrylamide, N-(1-methylethoxymethyl)(methyl) Allylamide, N-(1-methylpropoxymethyl)(meth)acrylamide, N-(2-methylpropoxymethyl)(meth)acrylamide [alias: N- (Isobutoxymethyl)(meth)acrylamide), N-(butoxymethyl)(meth)acrylamide, N-(1,1-dimethylethoxymethyl) (Meth)acrylamide, N-(2-methoxyethyl)(meth)acrylamide, N-(2-ethoxyethyl)(meth)acrylamide, N-(2 -Propoxyethyl)(meth)acrylamide, N-[2-(1-methylethoxy)ethyl](meth)acrylamide, N-[2-(1-methyl Propoxy)ethyl](meth)acrylamide, N-[2-(2-methylpropoxy)ethyl](meth)acrylamide [alias: N-(2-isobutoxy) Ethyl)(meth)acrylamide], N-(2-butoxyethyl)(meth)acrylamide, N-[2-(1,1-dimethylethoxy)ethyl Group] (meth)acrylamide and the like.

In the (meth)acrylic resin (A-1), based on the total amount of solid content, other monomers are usually contained in a proportion of 0 to 20% by weight, preferably in a proportion of 0 to 10% by weight .

From the viewpoint of the adhesion between the adhesive layer and the optical member, the (meth)acrylic resin (A-1) is based on the weight average molecular weight (GPC) converted to standard polyethylene ( Mw) is preferably 500,000 or more, more preferably 600,000 or more. The Mw of the (meth)acrylic resin (A-1) is usually 1.7 million or less.

The base polymer of the (meth)acrylic adhesive composition may contain two or more (meth)acrylic resins (A-1). Furthermore, the base polymer may not only contain (meth)acrylic resin (A-1), but may also contain (meth)acrylic resins different from this, such as (meth)acrylic resins derived from formula (I) (Meth)acrylic resin (A-2) which is a structural unit of meth)acrylate and does not have a polar functional group, or a structural unit derived from (meth)acrylate represented by the above formula (I) as the main (Meth)acrylic resin (A-3) etc. whose composition and Mw are in the range of 5,000 to 120,000.

(2-2) Crosslinking agent

The adhesive composition may further contain a crosslinking agent (B). The crosslinking agent is a compound that reacts with the structural unit of the base polymer such as (meth)acrylic resin, especially derived from a monomer containing a polar functional group, to crosslink the base polymer. Specifically, isocyanate-based compounds, epoxy-based compounds, aziridine-based compounds, metal chelate-based compounds, and the like can be exemplified. Among these, isocyanate-based compounds, epoxy-based compounds, and aziridine-based compounds have at least two functional groups in the molecule that can react with polar functional groups in the base polymer. The crosslinking agent (B) may be used alone or in combination of two or more kinds.

Isocyanate compounds, which have at least 2 in the molecule One isocyanate group (-NCO) compound. Specific examples of isocyanate compounds include: toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, xylene diisocyanate, hydrogenated xylene diisocyanate, diphenylmethane diisocyanate, hydrogenated diphenyl Methane diisocyanate, naphthalene diisocyanate, triphenylmethane triisocyanate, etc. Furthermore, the adducts formed by reacting these isocyanate compounds with polyols such as glycerin and trimethylolpropane, or the isocyanate compounds into diploid, triploid, etc., can also be cross-linked剂(B).

Epoxy compounds are compounds having at least two epoxy groups in the molecule. Specific examples of epoxy compounds include: bisphenol A type epoxy resin, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerol diglycidyl ether , Glycerol triglycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, N,N-diglycidyl aniline, N, N,N',N'-tetraepoxypropyl-m-xylylenediamine, 1,3-bis(N,N'-diglycidylaminomethyl)cyclohexane, etc.

The aziridine-based compound is a compound having at least two 3-membered ring skeletons, also called ethyleneimine, composed of one nitrogen atom and two carbon atoms in the molecule. Specific examples of aziridine compounds include: diphenylmethane-4,4'-bis(1-aziridine carboxamide), toluene-2,4-bis(1-aziridine carboxamide) ), triethylene melamine, isophthaloyl bis-1-(2-methylaziridine), ginseng-1-aziridinyl phosphine oxide, hexamethylene-1,6-bis(1-nitrogen Propidium methamide), trimethylolpropane-ginseng-β-aziridinyl propionate, tetramethylolmethane-ginseng-β-aziridinyl propionate, etc.

Specific examples of metal chelate compounds include: Aluminum, iron, copper, zinc, tin, titanium, nickel, antimony, magnesium, vanadium, chromium, zirconium and other polyvalent metals coordinated with acetone and ethyl acetate.

The crosslinking agent (B) is usually contained in a proportion of 0.05 to 5 parts by weight, preferably 0.1 to 5 parts by weight relative to 100 parts by weight of the solid content of the base polymer (when two or more are used in total) The ratio contains. When the content of the crosslinking agent (B) is 0.05 parts by weight or more, the durability of the adhesive layer tends to be improved.

(2-3) Ionic compounds

The adhesive composition may further contain an ionic compound (C) as an antistatic agent. The ionic compound (C) is, for example, a compound having an inorganic cation or organic cation and an inorganic anion or organic anion.

Examples of inorganic cations include alkali metal ions such as lithium cation [Li ⁺ ], sodium cation [Na ⁺ ], potassium cation [K ⁺ ], and beryllium cation [Be ²⁺ ], magnesium cation [Mg ²⁺ ], Alkaline earth metal ions such as calcium cation [Ca ²⁺ ], etc.

Examples of organic cations include imidazolium cations, pyridinium cations, pyrrolidinium cations, ammonium cations, sulfonium cations, and phosphonium cations.

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

Examples thereof include inorganic anions: chlorine anions [Cl ^-], bromine anion [Br ^-], iodide anion [I ^-], tetrachloroaluminate anion [AlCl ₄ ^-], heptachlorodialuminate anion [Al ₂ Cl ^_7--], tetrafluoroborate anion [BF ₄ ^-], hexafluorophosphate anions [PF ₆ ^-], perchlorate anion [ClO ₄ ^{- -],} nitrate anion [NO ₃ ^-], hexafluoro arsenic anions [AsF ₆ ^-], hexafluoroantimonate anion [SbF ₆ ^-], hexafluoro niobate anions [NbF ₆ ^-], six tantalum fluoride anions [TaF ₆ ^-], dicyanimide anion [(CN) ₂ N ^-] and the like.

Examples thereof include an organic anion: acetate anion [CH ₃ COO ^-], trifluoroacetate anion [CF ₃ COO ^-], methanesulfonate anion [CH ₃ SO ₃ ^-], trifluoromethanesulfonate anion [CF ₃ SO ₃ ^-], p-toluenesulfonate anion _{[p-CH 3 C 6 H} 4 SO 3 -], bis (sulfo-fluoro-acyl) acyl imide anion ^{_{[(FSO 2) 2 N -}} ], bis (C fluoro methanesulfonamide acyl) acyl imide anion _{[(CF 3 SO 2) 2} N -], reference (trifluoromethane sulfonic acyl) methanide (methanide) anion _{[(CF 3 SO 2) 3} C -], two methylsulfinyl phosphonate (dimethylphosphinate) anion ^{_{[(CH 3) 2 POO -}} ], ( poly) hydrofluoric acid fluoride anion ^{_{[F (HF) n -]}} (n is about 1 to 3), thiocyanate anion [SCN ^-], perfluorobutanesulfonate anion ^{_{[C 4 F 9 SO 3 -}} ], bis (pentafluoroethane sulfonic acyl) acyl imide anion _{[(C 2 F 5 SO 2} ) 2 N - ], perfluoro butyrate anion ^{_{[C 3 F 7 COO -]}} , ( trifluoromethane sulfonic acyl) (trifluoromethane-carbonyl) acyl imide anion _{[(CF 3 SO 2) (} CF 3 CO) N -] , perfluoro-1,3-disulfonate anion ^{_{[- O 3 S (CF 2}} ) 3 SO 3 -], the anion carbonate [CO ₃ ^2-] and the like. Among the above-mentioned anion components, the anion component containing a fluorine atom is advantageous from the viewpoint of antistatic properties.

Specific examples of the ionic compound (C) can be appropriately selected from the combination of the above-mentioned cationic component and anionic component. Examples of ionic compounds (C) with organic cations are classified according to the structure of organic cations and Listed as follows: pyridinium salts: N-hexylpyridinium hexafluorophosphate, N-octylpyridinium hexafluorophosphate, N-octyl-4-methylpyridinium hexafluorophosphate, N-butyl hexafluorophosphate 4-methylpyridinium, tetrabutylammonium hexafluorophosphate, bis(fluorosulfonyl)imide N-decylpyridinium, bis(fluorosulfonyl)imide N-dodecyl Pyridinium, bis(fluorosulfonyl)imide N-tetradecylpyridinium, bis(fluorosulfonyl)imide N-hexadecylpyridinium, bis(fluorosulfonyl)imide Amine N-dodecyl-4-methylpyridinium, bis(fluorosulfonyl) imide N-tetradecyl-4-methylpyridinium, bis(fluorosulfonyl) imide N -Hexadecyl-4-methylpyridinium, bis(fluorosulfonyl)imid N-benzyl-2-methylpyridinium, bis(fluorosulfonyl)imid N-benzyl- 4-methylpyridinium, bis(trifluoromethanesulfonyl)imide N-hexylpyridinium, bis(trifluoromethanesulfonyl)imide N-octylpyridinium, bis(trifluoromethanesulfonyl) (Acetyl)imidine N-octyl-4-methylpyridinium, bis(trifluoromethanesulfonyl)imidine N-butyl-4-methylpyridinium.

Imidazolium salt: 1-ethyl-3-methylimidazolium hexafluorophosphate, 1-ethyl-3-methylimidazolium p-toluenesulfonate, bis(fluorosulfonyl)imide 1-ethyl- 3-methylimidazolium, Bis(trifluoromethanesulfonyl)imide 1-ethyl-3-methylimidazolium, 1-butyl-3-methylimidazolium methanesulfonate, bis(fluorosulfonyl)imide 1 -Butyl-3-methylimidazolium.

Pyrrolidinium salt: N-butyl-N-methylpyrrolidinium hexafluorophosphate, bis(fluorosulfonyl)imine N-butyl-N-methylpyrrolidinium, bis(trifluoromethanesulfon) (Amino)amido N-butyl-N-methylpyrrolidinium.

Quaternary ammonium salt: tetrabutylammonium p-toluenesulfonate, bis(trifluoromethanesulfonyl) imide (2-hydroxyethyl) trimethylammonium, dimethyl phosphonite (2-hydroxyethyl) ) Trimethylammonium.

Furthermore, if an ionic compound (C) with an inorganic cation is to be cited, there are the following: lithium bromide, lithium iodide, lithium tetrafluoroborate, lithium hexafluorophosphate, lithium thiocyanate, lithium perchlorate, trifluoro Lithium methanesulfonate, lithium bis(fluorosulfonyl) imide, lithium bis(trifluoromethanesulfonyl) imide, lithium bis(pentafluoroethanesulfonyl) imide, ginseng (trifluoromethanesulfonyl) lithium Methanesulfonyl) lithium methanide, Lithium p-toluenesulfonate, sodium hexafluorophosphate, sodium bis(fluorosulfonyl) imide, sodium bis(trifluoromethanesulfonyl) imide, sodium p-toluenesulfonate, potassium hexafluorophosphate, bis( Potassium fluorosulfonyl)imidate, potassium bis(trifluoromethanesulfonyl)imidate, potassium p-toluenesulfonate.

From the viewpoint of continuity of antistatic properties, the ionic compound (C) has a melting point of 30°C or higher, more preferably a melting point of 35°C or higher. On the other hand, from the viewpoint of compatibility with the base polymer, the ionic compound (C) preferably has a melting point of 90°C or less, more preferably a melting point of 70°C or less, and still more preferably less than 50°C The melting point.

The ionic compound (C) is preferably formulated in a ratio of 0.2 to 8 parts by weight, more preferably 0.2 to 5 parts by weight relative to 100 parts by weight of the solid content of the base polymer (when two or more are used in total) The proportion of parts by weight is deployed. When the content of the ionic compound (C) is 0.2 parts by weight or more, it is advantageous to improve the antistatic properties, and when the content is 8 parts by weight or less, it is advantageous to improve the durability of the adhesive layer.

(2-4) Silane compounds

When the adhesive layer of the resin film of the adhesive layer is attached to an optical member made of glass, in order to improve the adhesion between the adhesive layer and the glass, the adhesive composition may further contain a silane compound (D).

Examples of the silane compound (D) include vinyl trimethoxy silane, vinyl triethoxy silane, vinyl ginseng (2-methoxyethoxy) silane, and N-(2-aminoethyl)- 3-Aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3- Glycidoxy propyl trimethoxy silane, 3-glycidoxy propyl methyl dimethoxy silane, 2-(3,4-epoxycyclohexyl) ethyl trimethoxy silane, 3- Chloropropylmethyldimethoxysilane, 3-chloropropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-ring Oxypropoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethoxymethylsilane, 3-glycidoxypropoxy Propyl ethoxy dimethyl silane and so on. Two or more silane compounds can also be used.

The silane compound (D) can also be a silicone oligomer. Examples of the polysiloxane oligomer include the following: 3-mercaptopropyltrimethoxysilane-tetramethoxysilane copolymer, 3-mercaptopropyltrimethoxysilane-tetraethoxysilane copolymer, 3 -Mercaptopropyltriethoxysilane-tetramethoxysilane copolymer, 3-mercaptopropyltriethoxysilane-tetraethoxysilane copolymer and other copolymers containing mercaptopropyl; mercaptomethyltrimethoxy Methoxysilane-tetramethoxysilane copolymer, mercaptomethyltrimethoxysilane-tetraethoxysilane copolymer, mercaptomethyltriethoxysilane-tetramethoxysilane copolymer, mercaptomethyltriethoxy Silane-tetraethoxy silane copolymer Copolymers containing mercaptomethyl groups; 3-glycidoxypropyltrimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltrimethoxysilane-tetraethoxysilane Copolymer, 3-glycidoxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltriethoxysilane-tetraethoxysilane copolymer, 3 -Glycidoxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3 -Glycidoxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldiethoxysilane-tetraethoxysilane copolymer, etc. Copolymer of 3-glycidoxypropyl; 3-methacryloxypropyl trimethoxysilane-tetramethoxysilane copolymer, 3-methacryloxypropyl trimethoxy Silane-tetraethoxysilane copolymer, 3-methacryloxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-methacryloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-methacryloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer Compound, 3-methacryloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-methacryloxypropylmethyldiethoxysilane-tetramethyl Oxysilane copolymer, 3-methacryloxypropylmethyldiethoxysilane-tetraethoxysilane copolymer and other copolymers containing methacryloxypropyl; 3-propylene Acrylicoxypropyl trimethoxysilane-tetramethoxysilane copolymer, 3-propenyloxypropyl trimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropyl Triethoxysilane-tetramethoxysilane copolymer, 3-propenyloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldimethyldimethyl Oxysilane-tetramethoxysilane copolymer, 3-propenyloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldiethyl Oxysilane-tetramethoxysilane Alkyl copolymers, 3-propenyloxypropylmethyl diethoxysilane-tetraethoxysilane copolymers and other copolymers containing acrylicyloxypropyl; vinyl trimethoxysilane-tetramethyl Oxysilane copolymer, vinyl trimethoxysilane-tetraethoxysilane copolymer, vinyl triethoxysilane-tetramethoxysilane copolymer, vinyl triethoxysilane-tetraethoxysilane copolymer Copolymer, vinyl methyl dimethoxy silane-tetramethoxy silane copolymer, vinyl methyl dimethoxy silane-tetraethoxy silane copolymer, vinyl methyl diethoxy silane-tetra Methoxysilane copolymer, vinyl methyl diethoxysilane-tetraethoxysilane copolymer and other copolymers containing vinyl groups; 3-aminopropyl trimethoxysilane-tetramethoxysilane copolymer , 3-Aminopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-aminopropyltriethoxysilane-tetramethoxysilane copolymer, 3-aminopropyltriethoxy Silane-tetraethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetraethoxy Silane copolymer, 3-aminopropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldiethoxysilane-tetraethoxysilane copolymer, etc. Contain amines Base copolymer, etc.

Relative to 100 parts by weight of the solid content of the base polymer (when two or more types are used, the total amount), the silane compound (D) is usually 0.01 It is contained in a ratio of to 10 parts by weight, preferably in a ratio of 0.05 to 5 parts by weight. When the content of the silane compound (D) is 0.01 parts by weight or more, the adhesion improvement effect between the adhesive layer and the glass can be easily obtained. Furthermore, when the content is 10 parts by weight or less, the silane compound (D) can be suppressed from exuding from the adhesive layer.

(2-5) Other ingredients

The adhesive composition may contain additives such as crosslinking catalysts, weathering stabilizers, tackifiers, plasticizers, softeners, dyes, pigments, inorganic fillers, light scattering particles, and adhesion imparting agents.

In addition, an ultraviolet curable compound may be blended into the adhesive composition to form an adhesive layer and then irradiated with ultraviolet rays to harden it to form a harder adhesive layer.

The adhesive composition is usually prepared as an adhesive liquid in which the compounding components are dissolved or dispersed by containing an organic solvent. The organic solvent is preferably selected according to the type of the base polymer. Specific examples of organic solvents include: aromatic hydrocarbons such as toluene and xylene; aliphatic hydrocarbons such as hexane, heptane, and pentane; ketones such as methyl ethyl ketone and methyl isobutyl ketone Class; such as ethyl acetate, butyl acetate and other esters. The concentration of the base polymer in the adhesive liquid is usually 3 to 20% by weight.

(3) Coating of adhesive composition

The method of applying the adhesive composition to the resin film 10 using the coating device 50 is not particularly limited. For example, a slot die method, a reverse gravure method, a microgravure method, a dipping method, Roll coating method, flexographic printing method, etc. The thickness of the coating layer 11 formed by the adhesive composition is It is adjusted so that the thickness of the adhesive layer 13 of the resin film 25 of an adhesive layer may become the range mentioned later.

As shown in FIG. 1, more specifically, the coating step may be a step of continuously coating the adhesive composition on one side of the long resin film 10 continuously rolled out from the first feed roller 1. At this time, as shown in FIG. 1, the adhesive composition may be applied while winding the resin film 10 around the application roller 60.

For the purpose of improving the adhesion between the resin film 10 and the adhesive layer, the coating surface of the resin film 10 may also be subjected to corona treatment, plasma treatment, ultraviolet radiation treatment, flame treatment, saponification treatment, Surface treatment such as primer formation treatment.

[Drying step]

This step is a step of drying the coating layer 11 of the resin film 15 having the coating layer 11 (solvent volatilization) to obtain the resin film 20 having the adhesive layer 12 (refer to Figs. 1 and 3). 1, the drying step can be performed by continuously conveying the long resin film 15 with the coating layer 11 obtained in the coating step and passing (introducing) the drying means 70.

The drying means 70 is not particularly limited as long as it can volatilize the solvent, and is, for example, a drying furnace (heating furnace). In addition to heating means, the drying furnace may further include pressure reducing means. Drying conditions such as the amount of hot air supplied to the drying oven, the temperature and pressure in the drying oven, etc. can be appropriately set in consideration of the type of solvent contained in the coating layer 11, or the state of the dried surface such as smoothness and condensation. The drying temperature (for example, the temperature in the drying furnace) is usually 50 to 120°C, preferably 60 to 110°C.

[Smoothing processing steps]

This step is a step of smoothing the surface of the adhesive layer 12 of the resin film 20 having the adhesive layer 12 by pressing a mirror mold (refer to FIG. 1 and FIG. 4). Through this step, the resin film 25 with the adhesive layer with the adhesive layer 13 (after the smoothing process) belonging to the "intermediate of the optical member with the resin film" is continuously manufactured. By this smoothing treatment, the adhesion of the adhesive layer 13 to the optical member can be improved. One of the features of the present invention is that the adhesive layer 12 obtained by drying the coating layer 11 is not supplied to the maturation step (the curing reaction of the adhesive is not sufficiently advanced), but is a characteristic of the smoothing process. In this way, a more memorable effect of improving adhesion can be obtained.

The above-mentioned smoothing treatment can be implemented by continuously conveying the long resin film 20 with the adhesive layer 12 obtained through the drying step and passing it through the smoothing treatment device 80. In the smoothing processing device 80, the mirror mold is pressed against the outer surface of the adhesive layer 12. At this time, the temperature of the adhesive layer 12 in contact with the mirror mold is preferably lower than the glass transition temperature of the adhesive layer composition. By keeping the temperature below the glass transition temperature, the adhesive composition can be prevented from adhering to the surface of the mirror mold when the adhesive layer 12 is peeled from the mirror mold. The temperature of the adhesive layer 12 can be adjusted by controlling the ambient temperature in the smoothing processing device 80 or the surface temperature of the mirror mold. In order to prevent condensation on the surface of the adhesive layer and the surface of the mirror mold, it is preferable to make the inside of the smoothing treatment device 80 an environment that does not contain moisture such as dry air or nitrogen. The pressing strength of the mirror mold is not particularly limited as long as it can transfer the surface shape of the mirror mold. It can be based on the adhesion The degree of hardening of the agent layer 12 is appropriately adjusted.

As long as the surface shape of the mirror mold is a mirror surface, the overall shape is not particularly limited, and it may be a flat plate, or a cylindrical or cylindrical roller. From the viewpoint of continuous productivity, a mirror roller belonging to a cylindrical or cylindrical mold is preferable. Among the mirror rollers, a cooling roller whose surface temperature can be controlled by the refrigerant inside the roller is preferable.

The substrate material of the mirror mold is not particularly limited, and can be appropriately selected from metal, glass, carbon, resin, or a composite of these. From the viewpoint of workability and the like, it is preferable to use metal. From a cost point of view, suitable metal materials include aluminum, iron, or alloys mainly composed of aluminum or iron. From the viewpoint of the releasability from the adhesive layer, it is preferable to use a fluorine-based resin. On the surface of the mirror mold, in order to make it easy to separate from the adhesive layer, mold release treatment can also be applied. Examples of mold release treatment are fluorine treatment and the like.

In the smoothing processing device 80, after the surface shape of the mirror mold is transferred to the outer surface of the adhesive layer 12, the mirror mold is peeled off from the resin film 25 having the adhesive layer 13. There are no special restrictions on the peeling method. For example, when the mirror mold is a mirror roller, a more suitable method is to install a pressing device such as a roller at the separation point between the resin film 25 with the adhesive layer 13 and the mirror mold, and The pressing device is a method of peeling the resin film 25 with the adhesive layer 13 from the mirror mold. Thereby, the resin film 25 which reached the said fulcrum can be peeled efficiently and stably.

The thickness of the adhesive layer 13 of the adhesive layer-attached resin film 25 obtained through the smoothing treatment step is, for example, 10 to 45 μm, preferably 10 to 35 μm. The thickness of the adhesive layer 13 is 45μm In the following cases, it is beneficial to the adhesion between the optical member and the optical member. Furthermore, when the thickness is 10 μm or more, the adhesive layer 13 has good tracking properties to the dimensional change of the optical member.

[Fitting steps]

This step is a step of bonding the optical member 30 to the outer surface of the adhesive layer 13 of the resin film 25 with the adhesive layer to obtain the optical member 40 with the resin film (refer to Figs. 1 and 5). As shown in FIG. 5, the optical member 40 with a resin film is obtained by laminating and bonding the resin film 25 with an adhesive layer through the adhesive layer 13 to the surface of the optical member 30. According to the present invention, it is possible to manufacture the optical member 40 with a resin film having good adhesion between the adhesive layer 13 and the optical member 30.

Specifically, the bonding step can be implemented as follows. While the long-length adhesive layer-attached resin film 25 obtained through the smoothing process is continuously transported, the long optical member 30 is continuously transported while being unrolled from the second feed roller 2, and the adhesive layer is attached. The optical member 30 is laminated on the outer surface (smoothing treatment surface) of the adhesive layer 13 of the resin film 25 to form a laminated body. This laminated body is pressed from above and below using a pair of bonding rolls 90 and the like to continuously manufacture the optical member 40 with a resin film. From the viewpoint of the adhesion between the adhesive layer 13 and the optical member 30, the adhesive layer-attached resin film 25 obtained through the smoothing treatment step is preferably not temporarily wound into a roll shape or subjected to other treatments, but It is directly supplied to the step of bonding with the optical member 30.

Figure 1 shows an example of bonding the adhesive layer-attached resin film 25 on one side of the optical member 30, but it can also be on both sides of the optical member 30 The resin film 25 with the adhesive layer is attached. When the resin film 25 with the adhesive layer is attached on both sides of the optical member 30, the resin film 25 with the adhesive layer on both sides may be attached at the same time or may be attached step by step.

The optical member 30 may be a single-layer or multi-layer optical film. Specific examples of optical films include: polarizing films; optical compensation films (phase difference films, etc.), light diffusion films (sheets), reflective films (sheets) and other optical functional films; protective films for polarizing films; polarizing plates; glass films (Including glass sheet and glass substrate); isolation film; base film for protective film, etc. The optical member 30 is preferably a polarizing plate. In addition, when the adhesive layer-attached resin film 25 is an adhesive layer-attached isolation film and the optical member 30 is an isolation film, an adhesive layer (adhesive sheet) with a double-sided isolation film is obtained as the optical resin film attached. Component 40. Furthermore, when the adhesive layer-attached resin film 25 is an adhesive layer-attached isolation film and the optical member 30 is a base film for a protective film, the isolation film-attached protective film is obtained as the resin film-attached optical member 40 .

In addition, a protective film (also referred to as a "surface protective film") is a peelable film temporarily attached to an optical member for the purpose of protecting the surface of the optical member from damage or contamination. Usually, it is made of a thermoplastic resin It is composed of a base film and an adhesive layer laminated on it.

The material of the surface of the optical member 30 that is in contact with the outer surface of the adhesive layer 13 is not particularly limited. However, if it is even after the usual corona treatment or other energy irradiation treatment on the surface, the adhesive layer When a surface material with sufficient adhesion between 13 and the optical member 30 is not yet obtained, the manufacturing method of the present invention is particularly effective. If the smoothing process is not performed, it is difficult to obtain an optical structure with sufficient adhesion to the adhesive layer 13 The surface of the member 30 may be, for example, a surface containing (meth)acrylic resin (typically composed of the resin). When the optical member 30 is a polarizing plate, such a surface is mostly formed by a protective film bonded to a polarizing film or an optical compensation film (phase difference film, etc.).

The polarizing plate may be a protective film attached to at least one side of the polarizing film through the adhesive layer. The protective film may also have a function as an optical compensation film such as a retardation film. The polarizing plate may also have a cured resin layer formed of a curable resin on at least one area of the polarizing film. In addition, other optically functional films such as retardation film and brightness enhancement film may be laminated on the polarizing film, protective film, or cured resin layer through the adhesive layer or adhesive layer.

The polarizing film is a film having a function of extracting linearly polarized light from incident natural light, and a preferred example is one that adsorbs and aligns a dichroic dye such as iodine or a dichroic dye to a uniaxially stretched polyvinyl alcohol resin film. The thickness of the polarizing film is not particularly limited, and is usually 2 to 35 μm.

The protective film may be a light-transmitting (preferably optically transparent) thermoplastic resin film. Specific examples of thermoplastic resins include: polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.); polyester resins (poly Ethylene terephthalate, etc.); (meth)acrylic resins (methyl methacrylate resins, etc.); cellulose resins (such as triacetyl cellulose, diacetyl cellulose and other cellulose acetate Series resins, etc.); polycarbonate series resins; polyvinyl alcohol series resins; polyvinyl acetate series resins; polyarylate series resins; polystyrene series resins; polyether series resins; polysulfide series resins; polyamides Resin; Polyamide Amine resins; and their mixtures and copolymers. The thickness of the protective film is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The curable resin layer is formed of curable resin such as thermosetting resin or active energy ray curable resin. The curable resin may include a thermopolymerizable compound, or a cation polymerizable compound, or a radical polymerizable compound, and may include these plural types. The thickness of the hardened resin layer is, for example, about 0.1 to 10 μm, preferably 1 to 5 μm.

When protective films are attached to both sides of the polarizing film, the protective films may be made of the same kind of thermoplastic resin, or may be made of different kinds of thermoplastic resins. Furthermore, the thickness may be the same or different. When the two-area layer of the polarizing film has a hardened resin layer, the hardened resin layers may be made of the same kind of hardening resin, or may be made of different kinds of hardening resins. Furthermore, the thickness may be the same or different. The protective film and the hardened resin layer may have surface treatment layers (coating layers) such as a hard coat layer, an anti-glare layer, an anti-reflection layer, a light diffusion layer, an antistatic layer, an antifouling layer, and a conductive layer. When a protective film is attached to one side of the polarizing film or a hardened resin layer is laminated, the adhesive layer 13 of the resin film 25 with the adhesive layer can be directly attached to the surface of the polarizing film.

The retardation film is an optical film showing optical anisotropy, which can be the following film: a uniaxially or biaxially stretched film of a thermoplastic resin film composed of resin or the like that can be used in the protective film; Plastic resin film coating, aligning liquid crystal compounds to exhibit optical anisotropy; or A film exhibiting optical anisotropy by coating an inorganic layered compound on a thermoplastic resin film.

The protective film (or retardation film, etc.) can be attached to the polarizing film through the adhesive layer. As the adhesive for forming the adhesive layer, a water-based adhesive, an active energy ray-curable adhesive or a thermosetting adhesive can be used, and a water-based adhesive or an active energy ray-curable adhesive is preferable.

Examples of water-based adhesives include adhesives containing polyvinyl alcohol-based resin aqueous solutions, water-based two-component urethane emulsion adhesives, and the like. Among them, it is preferable to use an aqueous adhesive containing a polyvinyl alcohol-based resin aqueous solution. Regarding polyvinyl alcohol resins, in addition to vinyl alcohol homopolymers obtained by saponifying polyvinyl acetate which is a homopolymer of vinyl acetate, it is also possible to use vinyl acetate and those with Copolymerized copolymers of other monomers are saponified to obtain polyvinyl alcohol-based copolymers, or modified polyvinyl alcohol-based polymers obtained by partially modifying the hydroxyl groups. The water-based adhesive system includes crosslinking agents such as aldehyde compounds (glyoxal, etc.), epoxy compounds, melamine compounds, methylol compounds, isocyanate compounds, amine compounds, and polyvalent metal salts.

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

The above-mentioned active energy ray-curable adhesive means an adhesive that can be cured by irradiating active energy rays such as ultraviolet rays, visible rays, X-rays, electron rays, etc., and examples include: polymerizable compounds and A curable composition of a photopolymerization initiator, a curable composition of a photoreactive resin, a curable composition of an adhesive resin and a photoreactive crosslinking agent, etc. Preferably, it is an ultraviolet curable adhesive. Examples of polymerizable compounds include photopolymerizable monomers such as photocurable epoxy monomers, photocurable (meth)acrylic monomers, and photocurable urethane monomers, or photopolymerizable monomers derived from photopolymerization. Oligomers of sexual monomers. Examples of the photopolymerization initiator include those that contain active species such as neutral radicals, anionic radicals, and cationic radicals due to irradiation with active energy rays. The active energy ray curable adhesive containing a polymerizable compound and a photopolymerization initiator, preferably the following composition can be used: a curable composition containing a photocurable epoxy monomer and a photocationic polymerization initiator ; A curable composition containing a photocurable (meth)acrylic monomer and a photo-radical polymerization initiator; or a photocurable epoxy monomer, a photocurable (meth)acrylic monomer, Curable composition of photocationic polymerization initiator and photoradical polymerization initiator.

When using an active energy ray curable adhesive, after bonding the polarizing film and the protective film, a drying step is carried out if necessary (However, the active energy ray curable adhesive may be a solvent-free adhesive that does not substantially contain solvent components ), and then implement the curing step of curing the active energy ray curable adhesive by irradiating the active energy rays. The light source of the active energy ray is not particularly limited. It is preferably ultraviolet light having a luminous distribution at a wavelength of 400 nm or less. Specifically, low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, chemical lamps, black light lamps, microwaves Exciting mercury lamps, metal halide lamps, etc.

Before laminating the protective film, in order to improve the adhesion, you can also Surface activation treatments such as corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, saponification treatment, and undercoat layer formation treatment are performed on the bonding surface of at least any one of the polarizing film and the protective film.

When the protective film is attached to both sides of the polarizing film, the adhesive system used for attaching the protective film may be the same type of adhesive or different types of adhesives.

[Other steps]

The manufacturing method of the present invention may further include a surface activation step in which energy irradiation is performed on the bonding surface of the optical member 30 and the adhesive layer 13. From the viewpoint of the adhesiveness of the adhesive layer 13 and the optical member 30, from "energy irradiation in the surface activation step" to "pressing the above-mentioned laminate with a pair of bonding rollers 90 etc. in the bonding step" The time is preferably 5 seconds or less. The energy irradiation treatment system may be, for example, corona treatment, plasma treatment, ultraviolet irradiation treatment, or the like. Among them, corona treatment is more suitable due to the improvement effect of adhesion and the simplicity of the equipment.

The manufacturing method of the present invention may include a winding step by winding the long optical member 40 with a resin film obtained through the laminating step on the winding roller 3 to wind the film forming roller in a roll shape (Refer to Figure 1). Furthermore, the manufacturing method of the present invention may also include a curing step, which is to perform curing (ageing) of the adhesive layer 13 in the roll state after the winding step. By implementing the curing step, the curing reaction of the adhesive layer 13 can be promoted, and the adhesive force of the adhesive layer 13 can be improved. Furthermore, by curing the adhesive layer 13 in a state in which it is in close contact with the optical member 30 (curing reaction of the adhesive), the interaction with the optical member 30 (including chemical reaction) and the light exposure of the adhesive are improved. The wettability of the academic member 30 can further improve the adhesion between the adhesive layer 13 and the optical member 30. The aging temperature is, for example, 20 to 45°C.

Furthermore, the manufacturing method of the present invention may also include a substitution step, which is to bond the optical member 30 (this optical member is also attached to the adhesive layer 13 of the adhesive layer-attached resin film 25 in the bonding step) It is referred to as the "first optical member"), and is replaced by another optical member (this optical member is also referred to as the "second optical member").

Specifically, for example, when the adhesive layer-attached resin film 25 is an adhesive layer-attached isolation film and the first optical member is an isolation film, the replacement step may include the following step: a peeling step, which will belong to the first optical component The separation film of the component is peeled and removed; and the bonding step (the second bonding step), which is followed by bonding a second optical member such as a polarizing plate to the adhesive layer 13 of the resin film 25 with the adhesive layer. After the peeling step, before the second bonding step, at least any one of the adhesive layer 13 and the bonding surface of the second optical member may be subjected to corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, and saponification Surface treatment such as treatment, primer formation treatment, etc.

As described above, according to the present invention, the adhesion between the adhesive layer 13 of the resin film 25 of the adhesive layer and the optical member 30 (first optical member) can be improved, which is caused by the adhesive layer 12 after the drying step. The smoothing treatment step is performed in a state where the curing reaction of the resin is not sufficiently advanced, and the adhesion between the second optical member that replaces the first optical member and the adhesive layer 13 can also be improved.

Furthermore, the manufacturing method of the present invention may include the following steps: as in the case when the resin film 10 is an isolating film, the bonding step The resin film 10 of the obtained optical member 40 with a resin film is peeled and removed, and an optical member different from the optical member 30 is bonded to the outer surface of the exposed adhesive layer 13. For example, when the adhesive layer-attached resin film 25 is an adhesive layer-attached isolation film and the optical member 30 is a base film for a protective film, although the isolation film-attached protective film is obtained as the resin film-attached optical member 40 However, by peeling and removing the isolation film from the protective film, and attaching a polarizing plate to the outer surface of the exposed adhesive layer 13, a polarizing plate with a protective film can be obtained.

1‧‧‧The first feed roller

2‧‧‧The second feed roller

3‧‧‧Winding roller

10‧‧‧Resin film

15‧‧‧Resin film with coating layer

20‧‧‧Resin film with adhesive layer (before smoothing treatment)

25‧‧‧Resin film with adhesive layer

30‧‧‧Optical components

40‧‧‧Optical components with resin film

50‧‧‧Coating device

60‧‧‧Coating roller

70‧‧‧Drying means

80‧‧‧Smoothing device

90‧‧‧Laminating Roll

Claims (7)

A method for manufacturing an optical component with a resin film includes the following steps: a coating step, which is to coat an adhesive composition on a long resin film to form a coating layer; and a drying step, to After the coating step, the film is continuously transported while introducing a drying means to dry the coating layer to obtain a resin film with an adhesive layer; the smoothing treatment step is to continuously transport the aforementioned resin film with an adhesive layer Press the fluorine-treated mirror surface mold on the outer surface of the adhesive layer; and the laminating step is to continuously transport the resin film after the smoothing treatment step while growing on the outer surface of the adhesive layer Strip the optical member, and press this laminate from above and below. The manufacturing method described in claim 1 further includes the following steps: the curing step is to wind the optical member with the resin film obtained in the aforementioned bonding step into a roll shape, and apply the aforementioned adhesive in the roll state Layer maturation. The manufacturing method described in item 1 or 2 of the scope of patent application, wherein in the aforementioned smoothing treatment step, the temperature of the adhesive layer in contact with the mirror mold is lower than the glass transition temperature of the aforementioned adhesive composition. For example, the manufacturing method described in item 1 or 2 of the scope of patent application further includes the following steps: The surface activation step is performed before the bonding step to perform energy irradiation on the bonding surface of the optical member and the adhesive layer. According to the manufacturing method described in claim 1 or 2, wherein the surface of the optical member in contact with the outer surface of the adhesive layer contains (meth)acrylic resin. According to the manufacturing method described in item 1 or 2 of the scope of patent application, the aforementioned optical member is a polarizing plate. The manufacturing method described in item 1 or 2 of the scope of patent application, wherein the aforementioned resin film is a separate film.

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