TWI725209B - Optical film group and manufacturing method thereof - Google Patents

Abstract

The object of the present invention is to provide an optical film set that can appropriately manufacture an optical display panel of the same structure even if a roll-to-panel method and a sheet-to-panel method are used in combination when a thin optical functional film is bonded to an optical unit. The present invention is an optical film set having a roll-shaped optical film and a single-piece optical film. The roll-shaped optical film is a structure in which a release film, an adhesive layer, an optical function film, and a first surface protection film are sequentially laminated, and The single-piece optical film has a structure in which the release film, the adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are laminated in this order.

Description

Optical film group and manufacturing method thereof

The present invention relates to an optical film set having a rolled optical film and a monolithic optical film, and a manufacturing method thereof.

There are methods for attaching the optical film to the optical unit: an optical film system composed of a release film, an adhesive layer, an optical function film (typically a polarizing film), and a surface protection film are laminated in a roll shape. The optical film sent from the roll of optical film is cut in the width direction (half-cut) of the adhesive layer, optical function film and surface protection film while leaving the release film, and the release film is cut from the The obtained optical film is peeled off, and the optical film is bonded to the optical unit via the exposed adhesive layer (hereinafter also referred to as "roll-to-panel method") (for example, refer to Patent Documents 1 and 2).

On the other hand, an optical film bonding method that is different from the roll-to-panel method has the following method: the optical film previously prepared in a single sheet state is bonded to the optical unit through the adhesive layer that has been peeled off the release film and exposed. Hereinafter, it is also referred to as a "sheet-to-panel method") (for example, refer to Patent Document 3).

Prior Art Documents Patent Documents Patent Document 1: Japanese Patent Application Publication No. 2011-123208 Patent Document 2: Japanese Patent Application Publication No. 2015-049115 Patent Document 3: Japanese Patent Application Publication No. 2006-039238

The problem to be solved by the invention However, in the manufacturing sites of optical display panels, including liquid crystal display panels, it has recently emerged that not only the roll-to-panel method but also the sheet-to-panel method are used to manufacture optical display panels of the same structure. For example, Patent Document 2 discloses that an optical display panel is continuously manufactured using a roll-to-panel method, and the optical display panel that has been determined to be defective is subjected to rework processing. In the case that defective products do not occur so often, it is conceivable to use a sheet-to-panel method when laminating a new optical functional film on the optical unit in the heavy industry process. For another example, when it is necessary to mass-produce optical display panels of the same structure in a short time, it is also conceivable that the sheet-to-panel method will be used in combination when the roll-to-panel method cannot supply the full supply.

In recent years, with the development of thinning of optical display panels, the development of thinner optical function films (for example, polarizing films with a thickness of 60 μm or less), including polarizing films, has continued. Such thin optical functional films have low toughness (modulus of elasticity) and are prone to distortion and warpage.

According to the roll-to-panel method, the thin optical function film is transported to the bonding position in the state of being laminated on the carrier film (release film), and the optical function film is removed from the carrier film (release film) at the bonding position. The film) is peeled off, and then the optical functional film is bonded to the optical unit. Therefore, it is possible to continuously bond the thin optical functional film to the optical unit while suppressing the occurrence of distortion, warpage, etc. However, in the sheet-to-panel method, it is difficult to handle the transportation of the single-piece optical function film, the peeling of the release film, and the lamination process of the optical function film to the liquid crystal cell, which may cause poor adhesion and yield. The fear of depression.

The object of the present invention is to provide an optical film set and its manufacturing method, which can properly manufacture the same structure even if the roll-to-panel method and the sheet-to-panel method are used in combination when a thin optical functional film is attached to an optical unit Optical display panel.

Means to Solve the Problem The present invention is an optical film set having a roll-shaped optical film and a single-piece optical film, and the roll-shaped optical film has a release film, an adhesive layer, an optical function film, and a first layer laminated in this order. In the structure of the surface protection film, the monolithic optical film is a structure in which the release film, the adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are sequentially laminated.

In the above invention, the second surface protection film may be the same surface protection film as the first surface protection film, or may be a surface protection film different from the first surface protection film.

In the above invention, the interlayer peeling force of the first surface protection film and the optically functional film may be greater than the interlayer peeling force of the second surface protection film and the first surface protection film.

According to the relationship of the peeling force, the second surface protection film can be peeled off relatively smoothly.

In the above invention, the aforementioned optically functional film may be a polarizing film.

In the above invention, the thickness of the aforementioned polarizing film may be 60 μm or less.

In the above-mentioned invention, the aforementioned polarizing film may have a structure having a polarizing member with a thickness of 10 μm or less.

In the above invention, the first surface protection film may have a first base film and a first adhesive layer and be laminated on the optical function film through the first adhesive layer.

In the above invention, the first surface protection film may be a self-adhesive film.

In the above invention, the second surface protection film may have a second base film and a second adhesive layer, and may be laminated on the first surface protection film through the second adhesive layer.

In the above invention, the second surface protection film may be a self-adhesive film.

The above invention may have the following structure: the roll-shaped optical film has a width corresponding to a set of opposite sides of the optical unit; a set of opposite sides of the monolithic optical film has a length corresponding to a set of opposite sides of the optical unit , And the other set of opposite sides has a length corresponding to the other set of opposite sides of the aforementioned optical unit.

In the above invention, the rolled optical film and the monolithic optical film can be used to manufacture an optical display panel, and the optical display panel is formed by sequentially laminating the adhesive layer, the optical function film, and the optical function film on one surface of the optical unit. The structure of the aforementioned first surface protection film.

In the above invention, the aforementioned roll-shaped optical film can be used to manufacture the aforementioned optical display panel in a roll-to-panel method; the aforementioned monolithic optical film can be used to manufacture the aforementioned optical display panel in a sheet-to-panel method.

In the above invention, the single-piece optical film can be used to reproduce an optical display panel of the following structure: the optical display panel manufactured by the roll-to-panel method using the roll-shaped optical film is judged to be defective and After peeling off the adhesive layer, optical function film, and first surface protection film, an adhesive layer, optical function film, and first surface protection film are sequentially laminated on one surface of the optical unit of the optical display panel.

The "roll-to-panel method" is a method in which the release film is peeled from the optical film output from the roll optical film, and the optical film is bonded to the optical unit through the exposed adhesive layer. Here, until the release film is peeled off, the optical film may be formed with slits at predetermined intervals under the release film in the width direction thereof. In addition, the optical film may have a slit in the width direction before being output from the roll, or may be formed in the width direction after output and before the release film is peeled off.

The "sheet-to-panel method" is a method in which the release film is peeled off from the optical film previously made into a single sheet state, and the optical film is bonded to the optical unit through the exposed adhesive.

Another invention is the manufacturing method of the aforementioned optical film set. The manufacturing method of the aforementioned roll-shaped optical film includes the following steps: a step of preparing an optical film blank, wherein the optical film blank is sequentially laminated with the release film and the adhesive The structure of the agent layer, the optical function film and the first surface protection film, and the step of manufacturing the optical film in the form of a roll, which is to manufacture the optical film in the form of roll by slitting and winding the optical film blank; The manufacturing method of a monolithic optical film includes the following steps: The step of manufacturing an optical film blank is to attach a second surface protection film blank to the first surface protection film side of the optical film blank to produce a laminate with The optical film blank of the second surface protection film and the step of manufacturing a single-piece optical film are by cutting the optical film blank on which the second surface protection film is laminated to produce a single-piece optical film.

In the above-mentioned invention, the "cutting process" is not limited as long as the optical film blank is processed into a single-piece optical film through a cutting process, and it means the following processing: cutting into a single piece; cutting into The end surface is processed after the single sheet; the optical film blank is processed into a predetermined width and then cut in the width direction (except for the end surface).

Another invention is an optical film group on both sides having a first optical film group and a second optical film group, wherein the first optical film group has a roll-shaped first optical film and a single sheet-shaped first optical film, and the roll-shaped The first optical film has a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated. 1 The structure of the release film, the first adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film; the second optical film group has a roll-shaped second optical film and a single sheet The second optical film in the form of a roll is a structure in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are laminated in this order, and the above-mentioned monolithic second optical film The optical film has a structure in which the second release film, the second adhesive layer, the second optical function film, the third surface protection film, and the fourth surface protection film are sequentially laminated.

In the above invention, the roll-shaped first optical film and the single-piece-shaped first optical film, and the roll-shaped second optical film and the aforementioned single-piece-shaped second optical film may also be used to manufacture an optical display panel of the following structure: The first adhesive layer, the first optical function film, and the first surface protective film are sequentially laminated on one surface of the optical unit, and the second adhesive layer and the first surface protection film are layered on another area of the optical unit. 2 Optical functional film and the aforementioned third surface protection film.

In the above invention, the first optical function film and the second optical function film may have the same optical function, or may have different optical functions.

In the manufacturing method of the aforementioned two-sided optical film group, the manufacturing method of the first optical film in roll form may include the following steps: a step of preparing a first optical film blank, which is sequentially laminated with the first release The structure of the film, the first adhesive layer, the first optical function film, and the first surface protection film, and the step of manufacturing the first optical film in the form of a roll, which is a process of slitting the first optical film blank And winding to manufacture the first optical film in the form of a roll; the manufacturing method of the first optical film in the form of a single sheet may include the following steps: a step of manufacturing a second optical film blank, which is based on the first optical film blank The step of laminating the second surface protection film blank material on the first surface protection film side, manufacturing the second optical film blank material laminated with the second surface protection film, and manufacturing the monolithic first optical film, is based on the foregoing The second optical film blank on which the second surface protection film is laminated is cut to produce a single sheet-like first optical film; the manufacturing method of the roll-shaped second optical film may include the following steps: Preparing the second optical film blank In the step of material, the blank material is a structure in which the second release film, the second adhesive layer, the second optical function film, and the third surface protection film are sequentially laminated, and the roll-shaped second optical film is manufactured The step of manufacturing the second optical film in roll form by slitting and winding the second optical film blank material; the manufacturing method of the single sheet-shaped second optical film may include the following steps: The step of optical film blank material is to attach a fourth surface protective film blank material to the third surface protective film side of the second optical film blank material to produce a fourth optical film blank material laminated with a fourth surface protective film , And the step of manufacturing a single-sheet second optical film, which is to manufacture a single-sheet second optical film by cutting the fourth optical film blank material on which the fourth surface protection film is laminated.

In the above invention, when a polarizing film is used as the optical function film (the first optical function film, the second optical function film), or when a polarizing film is used as a member of the optical function film structure, the roll In the shape and monolithic optical films (first optical film, second optical film) and optical film blanks (first optical film blanks, second optical film blanks), the direction of the absorption axis of the polarizing film does not align with each other The realization of the purpose of the present invention causes obstacles, that is, there is no particular limitation. In other words, even if the roll-to-panel method and the sheet-to-panel method are used in combination, as long as the combination of optical display panels with the same structure can be manufactured, the roll-shaped optical film (first optical film, second optical film) and optical film blanks (The first optical film blank material, the second optical film blank material), the absorption axis direction of the polarizing film can be parallel to the length direction, or orthogonal to it, or oblique (for example, at a 45° angle to the length direction) Direction). In addition, the absorption axis direction of the rectangular monolithic polarizing film may be parallel to the longitudinal direction, or orthogonal, and may be oblique (for example, a direction at an angle of 45° to the longitudinal direction). In addition, the direction of the absorption axis of the square monolithic polarizing film may be parallel to any one side and may be in an oblique direction (for example, a direction at an angle of 45° to one side).

In the present invention, the roll-shaped optical film can keep the release film, the adhesive layer, the optical function film and the surface protection film along the direction (width direction) orthogonal to the length direction of the optical film to correspond to the other of the optical unit. The gap between the opposite sides of the group forms a slit. According to this structure, there is no need to cut (half-cut) the optical film in the roll-to-panel method.

In the above-mentioned invention, the aforementioned optical unit may be a VA type or IPS type liquid crystal unit or an organic EL unit.

The shape of the aforementioned optical unit may be any shape having one set of opposite sides and another set of opposite sides, and it may be square or rectangular, and is not particularly limited. In addition, generally speaking, one set of opposite sides of the optical unit and the other set of opposite sides are orthogonal to each other.

Effects of the Invention The optical film set of the present invention is used to manufacture optical display panels with the same structure. Roll-shaped optical film can be used in a roll-to-panel method. The monolithic optical film can be used in a sheet-to-panel manner. The monolithic optical film may have the same laminated structure as the roll-shaped optical film, except that the second surface protection film is provided. The roll-shaped optical film is used to manufacture an optical display panel using a roll-to-panel method, and the structure of the optical display panel is that an adhesive layer, an optical function film, and a first surface protection film are sequentially laminated on one surface of the optical unit. In addition, the single-sheet optical film provided with the second surface protection film has improved operability, so that the occurrence of distortion, warpage, etc. can be suppressed, and at the same time, it can be suitable for bonding it to an optical unit using a sheet-to-panel method. Moreover, by removing (for example, peeling) the second surface protection film from the single-piece optical film that has been attached to the optical display panel, it is possible to produce the same laminated structure as the optical display panel made by the roll-to-panel method Optical display panel. That is, according to the optical film set of the present invention, when the optical film is bonded to the optical unit, even when the roll-to-panel method and the sheet-to-panel method are used in combination, an optical display panel of the same structure can be suitably manufactured .

(Embodiment 1: Optical film set) Fig. 1 is a schematic diagram showing an optical film set. The upper part of FIG. 1 shows an enlarged cross-sectional view of the side, plane, and part of the first optical film 1 in a rolled form. The lower part of FIG. 1 shows an enlarged cross-sectional view of the side, plane and part of the single-piece first optical film 2. In the roll-shaped first optical film 1, a first release film 11, a first adhesive layer 12, a first optical function film 13 and a first surface protection film 14 are laminated in this order.

The roll-shaped first optical film 1 is used to manufacture an optical display panel by a roll-to-panel method. In this case, the strip-shaped first optical film 10 of the width a that has been output from the roll-shaped first optical film 1 is cut by the cutting means C at a predetermined interval b while leaving the release film 11. The symbol s is a slit formed by the cutting of the first optical film 30 as described above.

In addition, in the monolithic first optical film 2, a first release film 21, a first adhesive layer 22, a first optical function film 23, a first surface protection film 24, and a second surface protection film 25 are laminated in this order. The size of the single sheet-shaped first optical film 2 is longitudinal a and lateral b. The monolithic first optical film 2 is used to manufacture an optical display panel by a sheet-to-panel method.

In this embodiment, the first release film 11 and the first release film 21 have the same structure. The first adhesive layer 12 and the first adhesive layer 22 have the same structure. The first optically functional film 13 and the first optically functional film 23 have the same structure. The first surface protection film 14, the first surface protection film 24, and the second surface protection film 25 have the same structure. The so-called "same structure" only needs to be substantially the same (for example, the same in manufacturing quality), and it is not only necessary that materials, thickness, etc. be completely the same.

In this embodiment, the first surface protection film 14 (or 24) has a first base film and a first adhesive layer, and is laminated on the first optical function film 13 (or 23) through the first adhesive layer. In addition, in another embodiment, the first surface protection film 14 (or 24) may also be a self-adhesive film.

In this embodiment, the second surface protection film 25 has a second base film and a second adhesive layer, and is laminated on the first surface protection film 24 through the second adhesive layer. In addition, in another embodiment, the second surface protection film 25 may be a self-adhesive film.

(Relationship of interlayer peeling force) In addition, structurally, the interlayer peeling force between the first surface protective film 24 and the first optically functional film 23 is greater than the interlayer peeling force between the second surface protective film 25 and the first surface protective film 24. Thereby, the second surface protection film 25 can be peeled off relatively smoothly. For the measurement of the peeling force, for example, a tensile tester can be used. Regarding the peeling conditions, the measurement was performed at 0.3 m/min 180° peeling. The peeling force is controlled by the composition or thickness of the adhesive.

The magnitude relationship of the peeling force between the layers in the single-sheet first optical film 2 is as follows. Set as the interlayer peeling force A between the first release film 21 and the first adhesive layer 22, the interlayer peeling force B between the first adhesive layer 22 and the first optically functional film 23, the first optically functional film 23 and the first surface When the interlayer peeling force C of the protective film 24 and the interlayer peeling force D of the first surface protective film 24 and the second surface protective film 25 are A<B, A<C, A<D. And preferably A<D<C≦B, or A<D<B≦C. Preferably, A<D<C<B. According to the relationship of the above-mentioned interlayer peeling force, when the first release film is peeled off, the peeling of the second surface protection film can be suppressed.

<Optical Function Film> The first optical function films 13, 23 are not particularly limited as long as they are films with optical functions. Examples include polarizing films, retardation films, brightness enhancement films, diffusion films, etc. The representative ones are polarizing films .

(Polarizing film) From the viewpoint of thinning, it is preferable to use a polarizing film having a thickness (total thickness) of 60 μm or less, preferably 55 μm or less, and more preferably 50 μm or less. Examples of polarizing films include: (1) a structure in which protective films (also known as "polarizer protective film") are laminated on both sides of the polarizer (also known as "double-sided protective polarizing film"); (2) only on one side of the polarizer A structure in which a protective film is laminated (also known as a "single-side protective polarizing film"), etc.

(Polarizer) The polarizer is made of polyvinyl alcohol resin. Examples of polarizers include hydrophilic polymer films such as polyvinyl alcohol-based films, partially formalized polyvinyl alcohol-based films, and ethylene-vinyl acetate copolymer-based partially saponified films that adsorb iodine or dichroic dyes. Chromatic materials and uniaxially stretched, and polyolefin-based alignment films such as dehydrated polyvinyl alcohol or dehydrochloric acid treated polyvinyl chloride. Among them, a polarizer composed of a polyvinyl alcohol-based film and a dichroic substance such as iodine is suitable.

A polarizer made of polyvinyl alcohol-based film dyed with iodine and then uniaxially stretched can be produced, for example, in the following way: the polyvinyl alcohol film is immersed in an aqueous solution of iodine to dye, and then stretched to 3-7 of the original length. Times. It can also be immersed in aqueous solutions such as boric acid or potassium iodide that may contain zinc sulfate or zinc chloride. Furthermore, if necessary, the polyvinyl alcohol-based film may be immersed in water for washing before dyeing. By washing the polyvinyl alcohol-based film with water, the dirt and anti-caking agent on the surface of the polyvinyl alcohol-based film can be cleaned. In addition, the polyvinyl alcohol-based film can be swollen, which also has the effect of preventing uneven dyeing. The extension can be performed after dyeing with iodine, or it can be extended while dyeing, or it can be dyed with iodine after extension. It can also be extended in aqueous solutions such as boric acid or potassium iodide or in a water bath.

From the viewpoint of thinning, the thickness of the polarizer is preferably 10 μm or less, preferably 8 μm or less, preferably 7 μm or less, and preferably 6 μm or less. On the other hand, the thickness of the polarizer is preferably 2 μm or more, more preferably 3 μm or more. Such a thin polarizer has less variation in thickness, excellent visibility (visibility), and low dimensional change, so it has excellent durability against thermal shock. On the other hand, a polarizing film containing a polarizer with a thickness of 10 μm or less has a significantly lower film toughness (modulus of elasticity), so that distortion, warping, etc. are likely to occur in the sheet-to-panel method. Therefore, the polarizing film in the present invention is particularly suitable.

As a thin polarizer, representative ones include Japanese Patent No. 4751486, Japanese Patent No. 4751481, Japanese Patent No. 4815544, Japanese Patent No. 5048120, International Publication No. 2014/077599, International Publication The thin polarizer described in the manual such as the 2014/077636 manual, or the thin polarizer obtained by the manufacturing method described in the manual.

The aforementioned polarizer should be constructed so that its optical characteristics expressed by monomer transmittance T and polarization degree P satisfy the conditions of the following formula: P>-(10 ^0.929T-42.4 -1)×100 (but T<42.3), or P≧99.9 (but T≧42.3). A polarizer configured to satisfy the aforementioned conditions will undoubtedly have the performance required for a liquid crystal television display using a large display element. Specifically, the contrast ratio is 1000:1 or more and the maximum brightness is 500cd/m2 or more. For other uses, for example, it can be attached to the viewing side of the organic EL unit.

As the aforementioned thin polarizer, in the manufacturing method including the stretching step and the dyeing step in the state of a laminate, in terms of high-magnification stretching and improved polarization performance, it is preferable to use the Japanese Patent No. 4751486 and the Japanese Patent As described in the specification No. 4751481 and the specification No. 4815544 of the Japanese Patent No. 4815544, the preparation method including the step of extending in an aqueous solution of boric acid is preferably obtained through the specification of the specification No. 4751481 and the specification No. 4815544. Obtained from the manufacturing method of performing auxiliary aerial stretching step before stretching in aqueous solution. These thin polarizers can be produced by a manufacturing method containing the following steps: the step of extending the polyvinyl alcohol resin (hereinafter also referred to as PVA resin) layer and the resin substrate for stretching in the state of a laminate and performing dyeing A step of. According to this manufacturing method, even if the PVA-based resin layer is thin, it can still be stretched and supported by the resin base material, so that it can be stretched without problems such as breakage caused by stretching.

(Protective film (polarizer protective film)) The material constituting the protective film is preferably one that is excellent in transparency, mechanical strength, thermal stability, moisture barrier properties, and isotropy. Examples include polyester-based polymers such as polyethylene terephthalate and polyethylene naphthalate; cellulosic polymers such as cellulose diacetate and cellulose triacetate; acrylic acid such as polymethyl methacrylate -Based polymers; styrene-based polymers such as polystyrene and acrylonitrile-styrene copolymer (AS resin); and polycarbonate-based polymers. In addition, the following polymers can also be cited as examples of polymers forming the above-mentioned protective film: polyethylene, polypropylene, polyolefins having cyclic or even norbornene structures, such as polyolefin polymerization of ethylene-propylene copolymers Compounds, chlorinated vinyl polymers, amide-based polymers such as nylon and aromatic polyamides, imine-based polymers, turbid polymers, polyether-based polymers, polyether ether ketone-based polymers, Polyphenylene sulfide polymer, vinyl alcohol polymer, chlorinated vinylidene polymer, vinyl butyral polymer, aryl ester polymer, polyoxymethylene polymer, epoxy polymer or the above-mentioned polymerization Blends of materials, etc.

In addition, the protective film may contain one or more arbitrary appropriate additives. Examples of additives include ultraviolet absorbers, antioxidants, lubricants, plasticizers, release agents, coloring inhibitors, flame retardants, nucleating agents, antistatic agents, pigments, colorants, and the like. The content of the above-mentioned thermoplastic resin in the protective film is preferably 50-100% by weight, preferably 50-99% by weight, more preferably 60-98% by weight, and particularly preferably 70-97% by weight. In the transparent protective film, when the content of the thermoplastic resin is 50% by weight or less, the thermoplastic resin may not fully exhibit its inherent high transparency.

The aforementioned protective film may also use a retardation film, a brightness enhancement film, a diffusion film, and the like.

Functional layers such as hard coating, anti-reflection layer, anti-adhesion layer, diffusion layer and anti-glare layer can be provided on the surface of the aforementioned protective film that is not bonded to the polarizer. In addition, the above-mentioned functional layers such as the hard coat layer, the anti-reflection layer, the anti-adhesion layer, the diffusion layer, and the anti-glare layer can be provided on the transparent protective film itself, or can be provided separately from the transparent protective film and be another entity.

(Intermediary layer) The aforementioned protective film and polarizer are laminated via an intermediary layer such as an adhesive layer, an adhesive layer, and an undercoat layer (primer layer). At this time, it is ideal to use an interposer to laminate the two without air gaps. The adhesive layer is formed by the adhesive. The type of adhesive is not particularly limited, and various types can be used. The aforementioned adhesive layer is not particularly limited as long as it is optically transparent, and various forms such as water-based, solvent-based, hot-melt adhesive-based, active energy ray hardening type, etc. can be used as the adhesive. However, water-based adhesives are ideal. Agent or active energy ray hardening adhesive. Examples of water-based adhesives include isocyanate-based adhesives, polyvinyl alcohol-based adhesives, gelatin-based adhesives, vinyl-based latex-based adhesives, and water-based polyesters. The water-based adhesive is usually used in the form of an adhesive composed of an aqueous solution, and usually contains 0.5 to 60% by weight of solid content. The active energy ray hardening type adhesive is an adhesive that is hardened with active energy rays such as electron beams and ultraviolet rays (radical hardening type, cation hardening type). For example, electron beam hardening type and ultraviolet hardening type can be used. As the active energy ray curable adhesive agent, for example, a light radical curable adhesive agent can be used. When the photoradical curable active energy ray curable adhesive is used as the ultraviolet curable adhesive, the adhesive contains a radical polymerizable compound and a photopolymerization initiator.

In addition, when the polarizer and the protective film are laminated, an easy-to-bond layer can be provided between the transparent protective film and the adhesive layer. The easy-adhesive layer can be formed using various resins having, for example, the following skeletons: polyester skeleton, polyether skeleton, polycarbonate skeleton, polyurethane skeleton, polysiloxane, polyamide skeleton, polyimide Skeleton, polyvinyl alcohol skeleton, etc. These polymer resins can be used individually by 1 type or in combination of 2 or more types. In addition, other additives may be added in the formation of the easy-to-bond layer. Specifically, stabilizers such as tackifiers, ultraviolet absorbers, antioxidants, and heat-resistant stabilizers can be further used.

The adhesive layer is formed of an adhesive. Various adhesives can be used for the adhesive, such as rubber adhesives, acrylic adhesives, silicone adhesives, urethane adhesives, vinyl alkyl ether adhesives, polyvinylpyrrole Pyridone-based adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, etc. The adhesive base polymer can be selected according to the types of the aforementioned adhesives. Among the aforementioned adhesives, it is preferable to use an acrylic adhesive in terms of excellent optical transparency, exhibiting suitable adhesive properties such as wettability, cohesiveness, and adhesiveness, and excellent weather resistance and heat resistance.

The primer layer (primer layer) is formed to improve the adhesion between the polarizer and the protective film. The material constituting the primer layer is not particularly limited as long as it exhibits a certain degree of strong adhesion to both the base film and the polyvinyl alcohol-based resin layer. For example, a thermoplastic resin excellent in transparency, thermal stability, extensibility, etc. can be used. Examples of thermoplastic resins include acrylic resins, polyolefin resins, polyester resins, polyvinyl alcohol resins, or mixtures thereof.

(Surface protection film) The first and second surface protection films are set on one side of the polarizing film (the side without an adhesive layer) in the optical film to protect the polarizing film and other optical functional films. As the base film of the first and second surface protection films, a film material having isotropy or nearly isotropy is selected from the viewpoints of inspectability and manageability. The film material may include, for example, polyester resins such as polyethylene terephthalate films, cellulose resins, acetate resins, polyether turpentine resins, polycarbonate resins, polyamide resins, etc. Transparent polymers like polyimide resins, polyolefin resins, and acrylic resins. Among them, polyester-based resins are suitable. The base film can also be a laminate of one or more than two types of film materials, and in addition, an extension of the aforementioned film can also be used. The thickness of the base film film is preferably 10 μm to 150 μm or less, more preferably 20 to 100 μm.

For the first and second surface protection films, in addition to using the aforementioned base film as a self-adhesive film, those having the aforementioned base film and adhesive layer can also be used. From the viewpoint of protecting optically functional films such as polarizing films, it is preferable to use those having an adhesive layer for the first and second surface protection films.

The adhesive layer used to laminate the first and second surface protection films, for example, can be appropriately selected and used with (meth)acrylic polymer, silicone polymer, polyester, polyurethane Ester, polyamide, polyether, fluorine-based and rubber-based polymers are used as adhesives for the base polymer. From the viewpoints of transparency, weather resistance, heat resistance, etc., an acrylic adhesive having an acrylic polymer as a base polymer is suitable. The thickness of the adhesive layer (dry film thickness) is determined according to the required adhesive force. It is usually about 1-100μm, and preferably 5-50μm.

In addition, the first and second surface protection films can be provided with a release treatment layer on the opposite side of the surface where the adhesive layer is provided, using low-adhesion materials such as silicone treatment, long-chain alkyl treatment, fluorine treatment, etc.

<Adhesive layer> For the formation of the first adhesive layers 12 and 22, an appropriate adhesive can be used, and the type is not particularly limited. Examples of adhesives include rubber adhesives, acrylic adhesives, silicone adhesives, urethane adhesives, vinyl alkyl ether adhesives, polyvinyl alcohol adhesives, and polysiloxane adhesives. Vinylpyrrolidone-based adhesives, polyacrylamide-based adhesives, cellulose-based adhesives, etc.

Among these adhesives, it is suitable to use those having good optical transparency, exhibiting adhesive properties such as proper wettability, cohesiveness, and adhesiveness, and excellent weather resistance and heat resistance. As those exhibiting these characteristics, acrylic adhesives are preferably used.

The first method of forming the adhesive layers 12 and 22 can be produced by, for example, the following method: applying the aforementioned adhesive to a release film (separator, etc.) that has undergone a peeling treatment, and drying to remove the polymerization solvent, etc. After forming the adhesive layer, transfer to the polarizer (or transparent protective film) method; or apply the aforementioned adhesive to the polarizer (or transparent protective film), dry and remove the polymerization solvent, etc., to form an adhesive on the polarizer Layer methods, etc. In addition, when applying the adhesive, one or more solvents other than the polymerization solvent may be appropriately added.

It is advisable to use silicone release liner as the release film after release treatment. In the step of coating and drying the adhesive of the present invention on such a lining material to form an adhesive layer, a suitable and appropriate method can be used as a method for drying the adhesive according to the purpose. It is preferable to use a method of overheating and drying the above-mentioned coating film. The heating and drying temperature is preferably 40°C to 200°C, more preferably 50°C to 180°C, and particularly preferably 70°C to 170°C. By setting the heating temperature to the above range, an adhesive with excellent adhesive properties can be obtained.

Suitable drying time can be adopted. The drying time is preferably 5 seconds to 20 minutes, more preferably 5 seconds to 10 minutes, and particularly preferably 10 seconds to 5 minutes.

Various methods can be used to form the first adhesive layers 12 and 22. Specifically, for example, roller coating method, contact sizing roller coating method, gravure coating method, reverse coating method, roller brush method, spraying method, dip roller coating method, bar coating method, knife coating method, gas Knife coating method, curtain coating method, lip die coating method, extrusion coating method using mold coater, etc.

The thickness of the first adhesive layers 12 and 22 is not particularly limited, and is, for example, about 1-100 μm. It is preferably 2 to 50 μm, preferably 2 to 40 μm, and more preferably 5 to 35 μm.

<Release Film> The first release films 11 and 21 protect the adhesive layer until it is used for actual use. The constituent materials of the release film include, for example, plastic films such as polyethylene, polypropylene, polyethylene terephthalate and polyester films, porous materials such as paper, cloth, and non-woven fabrics, nets, foam sheets, and metals. Suitable monolithic bodies such as foils and laminates, etc., but from the viewpoint of excellent surface smoothness, a plastic film is preferably used.

The plastic film is not particularly limited as long as it is a film that can protect the aforementioned adhesive layer. Examples include polyethylene film, polypropylene film, polybutene film, polybutadiene film, polymethylpentene film, and polymethylpentene film. Vinyl chloride film, vinyl chloride copolymer film, polyethylene terephthalate film, polybutylene terephthalate film, polyurethane film, ethylene-vinyl acetate copolymer film, etc.

The thickness of the first release films 11 and 21 is usually about 5 to 200 μm, and preferably about 5 to 100 μm. If necessary, the aforementioned separating parts can be subjected to release and antifouling treatments, coating type, kneading type, etc., using polysiloxane-based, fluorine-based, long-chain alkyl-based or fatty acid amide-based release agents, silica powder, etc. , Evaporation type and other antistatic treatment. In particular, by appropriately applying release treatments such as silicone treatment, long-chain alkyl treatment, fluorine treatment, etc., on the surface of the release film, the releasability from the adhesive layer can be further improved.

(Embodiment 2: Two-sided optical film group) The two-sided optical film group of Embodiment 2 is composed of a first optical film group and a second optical film group. The first optical film group is the same as the first optical film group of the first embodiment, so the description thereof is omitted. The second optical film group will be described with reference to FIG. 2. The second optical film group includes a roll-shaped second optical film 3 and a single-sheet-shaped second optical film 4.

The upper part of FIG. 2 shows an enlarged view of the side, plane, and partial cross-section of the second optical film 3 in the form of a roll. The lower part of FIG. 2 shows an enlarged cross-sectional view of the side, plane and part of the single-piece second optical film 4. In the roll-shaped second optical film 3, a second release film 31, a second adhesive layer 32, a second optical function film 33, and a third surface protection film 34 are laminated in this order. The strip-shaped optical film 30 of the width b that has been output from the roll-shaped second optical film 3 is cut by the cutting means C at a predetermined interval a while leaving the second release film 31. The symbol s is a slit formed by the above-mentioned cutting of the optical film 30.

In the second optical film 4 in the form of a single sheet, a second release film 41, a second adhesive layer 42, a second optical function film 43, a third surface protection film 44, and a fourth surface protection film 45 are laminated in this order. The size of the second optical film 4 in the form of a single sheet is horizontal a and vertical b.

In this embodiment, the second release film 31 and the second release film 41 have the same structure. The second adhesive layer 32 and the second adhesive layer 42 have the same structure. The second optically functional film 33 and the second optically functional film 43 have the same structure. The third surface protection film 34, the third surface protection film 44, and the fourth surface protection film 45 have the same structure. The so-called "same structure" should be substantially the same (for example, the same in manufacturing quality), not only the material, thickness, etc. are completely the same.

In this embodiment, the third surface protection film 34 (or 44) has a third base film and a third adhesive layer, and is laminated on the second optical function film 33 (or 43) through the third adhesive layer. In addition, in another embodiment, the third surface protection film 34 (or 44) may also be a self-adhesive film.

In this embodiment, the fourth surface protection film 45 has a fourth base film and a fourth adhesive layer, and is laminated on the third surface protection film 34 through the fourth adhesive layer. In addition, in another embodiment, the fourth surface protection film 45 may be a self-adhesive film.

(Relationship of interlayer peeling force) In addition, structurally, the interlayer peeling force of the third surface protective film 34 and the second optically functional film 33 is greater than the interlayer peeling force of the fourth surface protective film 45 and the third surface protective film 44. Thereby, the fourth surface protection film 45 can be peeled off relatively smoothly.

The magnitude relationship of the peeling force between each layer in the second optical film 4 in the form of a single sheet is as follows. Set as the interlayer peeling force A1 between the second release film 41 and the second adhesive layer 42, the interlayer peeling force B1 between the second adhesive layer 42 and the second optically functional film 43, the second optically functional film 43 and the third surface When the interlayer peeling force C1 of the protective film 44 and the interlayer peeling force D1 between the third surface protective film 44 and the fourth surface protective film 45 are A1<B1, A1<C1, A<D1. It should be A1<D1<C1≦B1, or A1<D1<B1≦C1. Preferably, it is A1<D1<C1<B1. According to the relationship of the above-mentioned interlayer peeling force, when the second release film is peeled off, the peeling of the fourth surface protection film can be suppressed.

In the second optical film group, each member constituting the roll-shaped second optical film and the single-sheet-shaped second optical film may be the same as the optical function film, release film, adhesive layer, and surface protection film described in Embodiment 1. Structure.

(Embodiment 3: Manufacturing of optical film group) Next, the manufacturing method of the 1st optical film group and the 2nd optical film group is demonstrated. FIG. 3A is a schematic diagram showing a method of manufacturing the first optical film 1 in a roll form. FIG. 3B is a schematic diagram showing the manufacturing method of the first optical film 2 in the form of a single sheet.

In FIG. 3A, a roll-shaped first optical film blank material 5 is prepared, which is a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated. Next, the first optical film is output from the first optical film blank material 5, and is processed into three strip-shaped optical films with a predetermined width a using the slitting section sc. The three strip-shaped optical films that have undergone slitting are respectively wound to produce a roll-shaped first optical film.

Although this embodiment is processed into three strip-shaped optical films, it is not limited to this. In addition, in the present embodiment, both ends e1 and e2 are trimmed (end trimming), but trimming may be performed at either end, or both ends may be trimmed.

In FIG. 3B, the first surface protection film 14 side of the roll-shaped first optical film 1 (corresponding to the first optical film blank) is bonded from the second surface by bonding means (a pair of bonding rolls R1, R2) The second surface protection film 25 output from the protective film stock S25 is protected to produce an optical film stock S2 in which the second surface protection film 25 is laminated. Next, the optical film blank material S2 on which the second surface protection film 25 is laminated is subjected to a full cutting process using the cutting means FC at a predetermined interval b to produce the single-piece-shaped first optical film 2. The single-piece first optical film 2 may be stored in a predetermined storage portion, or may be laminated on a carrier film. The first optical film group can be manufactured by the above method.

In another embodiment, it may be a step of winding the optical film blank S2, and outputting a strip-shaped first optical film from the optical film blank S2, and performing cutting processing at a predetermined interval b using the cutting means FC.

The second optical film group can be manufactured by the same steps as in FIGS. 3A and 3B.

In another embodiment, it may further include the step of cutting (half-cutting) the adhesive layer 12 and the first optical function at predetermined intervals while leaving the strip-shaped first release film 11 after the slitting process. The film and the first surface protection film have multiple cuts.

(Liquid crystal cell, liquid crystal display panel) The liquid crystal cell has a structure in which a liquid crystal layer is sealed between a pair of substrates (a first substrate (view side) Pa and a second substrate (rear surface) Pb) arranged opposite to each other. Any type of liquid crystal cell can be used, but in order to achieve high contrast, vertical alignment (VA) mode and in-plane switching (IPS) mode liquid crystal cells should be used. The liquid crystal display panel is a thing with a polarizing film attached to one or both sides of the liquid crystal cell, and a driving circuit is installed as needed.

(Organic EL unit, organic EL display panel) The organic EL unit has a structure in which an electroluminescent layer is sandwiched between a pair of electrodes. The organic EL unit can be any type such as a top emission type, a bottom emission type, and a dual emission type. The organic EL display panel is a thing with a polarizing film attached to one or both sides of the organic EL unit, and a drive circuit is installed as needed.

(Embodiment 4: Remanufacturing using the first optical film group) Fig. 4 is a schematic diagram of a continuous manufacturing system of an optical display panel. In this embodiment, the roll-shaped first optical film 1 is used to manufacture an optical display panel by a roll-to-panel method. The monolithic first optical film 2 is used to re-manufacture an optical display panel with the following structure: the optical display panel manufactured by using the roll-shaped first optical film 1 is judged to be defective and the first adhesive layer is peeled off , The optical display panel of the first optical function film and the first surface protection film, in which the first adhesive layer, the first optical function film and the first surface protection film are sequentially laminated on one surface of the optical unit. Specifically, the first adhesive layer 22, the first optical function film 23, and the first surface protective film 24 are peeled off on one side of the optical unit using a sheet-to-panel method to bond, that is, from a single sheet of the first optical The film 2 peels off the first release film 21 and sequentially bonds the first adhesive layer 22, the first optical function film 23, the first surface protection film 24, and the second surface protection film 25, and then the second surface protection film 25 Peel off. In this embodiment, the liquid crystal cell is an optical unit and the liquid crystal display panel is an optical display panel.

In the roll-shaped first optical film 1, a first release film 11, a first adhesive layer 12, a first optical function film 13 and a first surface protection film 14 are laminated in this order. As shown in FIG. 1, the roll-shaped first optical film 1 has a width a, and has a width corresponding to the long side of the liquid crystal panel (a width substantially shorter than the long side of the liquid crystal cell P).

The manufacturing system of the liquid crystal display panel of this embodiment, as shown in FIG. 4, has: a first conveying section 81 to convey the liquid crystal cell P to the first attaching section 64; and a second conveying section 82 to convey the used roll The first optical film 1 is a liquid crystal cell P with an optical film attached to the first surface P1 of the liquid crystal cell P. Each conveying section is configured to have a plurality of conveying rollers R for conveying the liquid crystal cell P by rotating around a rotating shaft, wherein the rotating shaft is parallel to the orthogonal direction of the conveying direction. Moreover, in addition to the conveying roller, it can also be configured to have a suction tray or the like.

(Liquid crystal cell conveying step) From the accommodating section 91 accommodating the liquid crystal cell P, the liquid crystal cell P is arranged to the first conveying section 81 with the first surface P1 as the top surface, and the conveying roller R is rotated to the first attaching section 64 delivery.

(First optical film output step, first optical film cutting step) The strip-shaped first optical film 10 output from the roll-shaped first optical film 1 is cut while the first release film 11 side is sucked and fixed. The slit portion s is formed, and the cutting is performed while leaving the first release film 11 uncut, and the strip-shaped adhesive layer 12, the strip-shaped first optical functional film 13 and the strip-shaped first film are separated by the cutting portion 61. The surface protection film 14 is cut into a predetermined size (corresponding to the length of the shorter side of the liquid crystal cell P (substantially shorter length of the shorter side)). The cutting by the cutting portion 61 includes, for example, cutting using a blade (cutting by a cutting blade) and cutting using a laser device. The arrow in Fig. 4 shows an example of the cut seam s after cutting, but for the convenience of explanation, the cut seam has been enlarged and drawn. There may be a structure in which a nip roller (not shown) is arranged on the upstream or downstream side of the cutting portion 61 to convey the belt-shaped first optical film 10. In addition, the nip rollers may be arranged on the upstream side and the downstream side of the cutting portion 61.

(Tension adjustment step) In the cutting process of the tape-shaped first optical film 10 and the subsequent attaching process, in order to be able to continue processing without interrupting the process over a long period of time, and to adjust the tension of the film, the first tension is provided Adjusting part 62. The first tension adjusting part 62 is configured to have a dancer mechanism using a spindle, for example. The not-shown nip roller may be arranged on the upstream side or the downstream side of the first tension adjusting part 62 to convey the first optical film 10. In addition, the nip rollers can be arranged on the upstream side and the downstream side of the first tension adjusting portion 62.

(Peeling step) The first optical film 10 is wound and inverted at the first peeling portion 63 to peel the first optical film 10 from the first release film 11. The first release film 11 is wound by a roller via the first winding section 65. The first winding part 65 has a roller and a rotation driving part, and the rotation driving part drives the rotation of the roller to wind the first release film 11 on the roller. In addition, a nip roller (not shown) may be arranged on the upstream side or the downstream side of the peeling part 63 to convey the first optical film 10 or the first release film 11. In addition, the nip rollers may be arranged on the upstream side and the downstream side of the peeling part 63.

(The first attaching step) The first attaching part 64 is a device for attaching the first optical film 10 from which the first release film 11 has been peeled to the liquid crystal cell P through the first adhesive layer 12 while transporting the liquid crystal cell P On the first side P1. The first attaching portion 64 is composed of a pair of a first roller member 64a and a second roller member 64b. Either one of them may be a driving roller and the other may be a driven roller, or both of the rollers may be driving rollers. The paired first roller member 64a and second roller member 64b are fed downstream while sandwiching the first optical film 10 and the liquid crystal cell P, so that the first optical film 10 is pasted against the first surface P1 of the liquid crystal cell P Attached. The liquid crystal cell P with the single sheet-like first optical film 10 attached to the first surface P1 of the liquid crystal cell P is conveyed downstream by the second conveying unit 82.

(First inspection step) The first inspection unit 70 optically inspects the liquid crystal cell P. The first inspection section 70 has: a light source 71 arranged on one side of the liquid crystal cell P to allow light to pass through the liquid crystal cell P; and a first imaging section 72 arranged on the opposite side of the light source via the liquid crystal cell P, facing the liquid crystal cell P The penetrating light image for shooting. The first imaging unit 72 may be an area sensor or a line sensor. In addition, the first inspection unit 70 may include a second imaging unit (not shown), which captures a reflected light image for inspecting the adhesion position of the first optical film 10. The image captured by the first inspection unit 70 is analyzed by the first image analysis unit 51. The control unit 50 controls the operation timing and the like of each component of the continuous manufacturing system.

(First determination step) The first determination unit 52 determines whether the liquid crystal cell P is a good product or a defective product based on the result of the image analysis by the first image analysis unit 51. Examples of defective products include misalignment, mixed air bubbles, and so on. The liquid crystal cell P determined to be a good product is collected to the first good product collection unit 92. The liquid crystal cell P determined to be a defective product is collected in the first defective product collection unit 93.

(First Defective Film Peeling Step) With reference to Fig. 5, the processing operation of reproducing a defective liquid crystal panel into a good liquid crystal panel will be described. As shown in FIG. 5, the first optical film 10 is removed from the liquid crystal cell P determined as defective by the first determination unit 52. The removal process can be performed manually or by a peeling device. Next, it will be described how to use a single-piece bonding device to attach the single-piece-shaped first optical film 2 to the first surface P1 of the liquid crystal cell P for remanufacturing (also referred to as "heavy industry").

(First re-attachment step) Next, the single-sheet-shaped first optical film 2 after peeling off the first release film 21 by a sheet-to-panel method (for example, a single-sheet laminating device) is attached to the And on the first surface P1 of the liquid crystal cell P after the first optical film 10 is peeled off. The single-piece laminating device can use a conventional device. Refer to the monolithic first optical film 2 in FIG. 1.

(Peeling step of the second surface protection film) After the first reattachment step, the second surface protection film 25 is peeled off from the single sheet-shaped first optical film 2. The peeling process can be implemented manually or by a peeling device. Through the above steps, it is possible to manufacture (remanufacture) a liquid crystal panel having the same layered structure as the liquid crystal panel manufactured by the roll-to-panel method.

(Remanufacturing using the first and second optical film groups) The remanufacturing using the second optical film group can be performed in the same way as the remanufacturing using the first optical film group described above. The roll-shaped second optical film 3 is used to manufacture an optical display panel by a roll-to-panel method. The second optical film 4 in the form of a single sheet is used to re-manufacture an optical display panel of the following structure: the optical display panel manufactured by using the second optical film 3 in a roll form is judged to be defective and the second adhesive layer is peeled off 2. An optical display panel with a second optical function film and a third surface protection film, in which a second adhesive layer, a second optical function film and a third surface protection film are sequentially laminated on one surface of the optical unit. Specifically, the second adhesive layer 31, the second optical function film 32, and the third surface protection film 33 are peeled off on one side of the optical unit using a sheet-to-panel method to bond, that is, from a single sheet to a single sheet. The second optical film 4 peels off the second release film 41 and sequentially bonds the second adhesive layer 42, the second optical function film 43, the third surface protection film 44, and the fourth surface protection film 45, and then the fourth surface The protective film 45 peels off.

The continuous manufacturing system of the optical display panel is configured as the following system: the manufacturing equipment using the roll-to-panel method of the roll-shaped first optical film 1 is further equipped with a roll-to-roll pair using the roll-shaped second optical film 3 Panel-based manufacturing equipment. The manufacturing equipment of the roll-to-panel method using the roll-shaped second optical film 3 can be configured by substantially the same equipment as the aforementioned manufacturing equipment of the roll-to-panel method using the roll-shaped first optical film 1. The different manufacturing equipment is described below.

The liquid crystal cell P judged as good in the first inspection section 70 is sent to the later stage, and the optical cell is attached to the second surface P2 of the liquid crystal cell P using a roll-shaped second optical film. The second conveying unit 82 is provided with a configuration exchange unit (not shown). The configuration exchange unit turns the liquid crystal cell P transported by the second transport unit 82 into the upper and lower surfaces (P1, P2) and reverses it in the conveying direction. The short side and the long side of the liquid crystal cell P are swapped. A known mechanism can be used for the configuration exchange unit. In this embodiment, the arrangement exchange part has a rotating part that sucks and rotates the liquid crystal cell P by 90° horizontally, and a reversing part that sucks and inverts the front and back of the liquid crystal cell P.

After the process of disposing the replacement part, the liquid crystal cell P is sent to the second attaching part. It has the same second cutting portion as the first cutting portion 61, the second tension adjusting portion the same as the first tension adjusting portion 62, the second peeling portion the same as the first peeling portion 63, and the same as the first roll Take the same second winding part.

The second cutting part is to remove the second optical film 30 in the form of a strip from the roll-shaped second optical film 3 while holding the second release film 31 while sucking the second release film 31. The film 30 is cut into a predetermined size (corresponding to the length of the long side of the liquid crystal cell P (the length of which the longer side is substantially shorter)). The strip-shaped second optical film 30 is sent to the second peeling part through the second tension adjusting part, and is wound and inverted at the second peeling part, so that the second optical film 30 is peeled from the second release film 31. The second release film 31 is wound by a roller via a second winding section.

The second attaching portion has the same structure as the first attaching portion 64. The second attaching part attaches the second optical film 30 from which the second release film 31 has been peeled to the second surface P2 of the liquid crystal cell P through the second adhesive layer 32 while conveying the liquid crystal cell P.

The second inspection unit has the same structure as the first inspection unit 70. The second inspection section optically inspects the liquid crystal cell P. The second inspection part has: a light source arranged on one side of the liquid crystal cell P to allow light to pass through the liquid crystal cell P; and an imaging part arranged on the opposite side of the light source via the liquid crystal cell P to image the transmitted light of the liquid crystal cell P Take a video. The second inspection unit may have an imaging unit (not shown) that captures a reflected light image for inspecting the adhesion position of the second optical film 30. The image captured by the second inspection section is processed by the second image analysis section for image analysis.

The second determination unit determines whether the liquid crystal cell P is a good product or a defective product based on the result of the image analysis by the second image analysis unit. Examples of defective products include misalignment, mixed air bubbles, and so on. The liquid crystal cell P determined to be a defective product is collected in the second defective collection part. On the other hand, in a case where the second determination unit has been determined as a good product, the liquid crystal cell P that has been determined as a good product is sent to the good product storage unit for storage.

The remanufacturing using the single-piece optical film 4 is the same as the above-mentioned remanufacturing using the single-piece optical film 2. That is, the second optical film 30 is removed from the liquid crystal cell P judged as defective. Next, the second optical film 4 in the form of a single sheet after the second release film 31 has been peeled off by a sheet-to-panel method (for example, a single sheet laminating device) is attached to the second optical film 30 which has been judged as defective and peeled off. On the second surface P2 of the subsequent liquid crystal cell P. Next, the fourth surface protection film 45 is peeled off from the second optical film 4 in the form of a single sheet.

(Embodiment 5: Manufacturing of an optical display panel using an optical film roll and a single-piece optical film optical film group) Embodiment 5 is a continuous manufacturing system for an optical display panel using an optical film group. Hereinafter, referring to FIG. 6, the continuous manufacturing system of the optical display panel of the fifth embodiment will be described in detail.

The roll-shaped first optical film 1 is used in the same roll-to-panel method as in the fourth embodiment (see FIG. 4) described above, and the first optical film 10 is attached to the first surface P1 of the liquid crystal cell P. The same symbols in FIG. 4 and FIG. 6 have the same functions. The liquid crystal cell P on which the first optical film 10 is pasted is reversed in the arrangement exchange section 821, and the short side and the long side of the liquid crystal cell P are exchanged in the conveying direction (Y).

Next, the procedure for attaching the second optical film 4 in the form of a single sheet to the second surface P2 of the liquid crystal cell P will be described as follows. The single-piece bonding apparatus 164 sucks the single-piece-shaped second optical film 4 from the container 100 containing the single-piece-shaped second optical film 4 by the suction part 164a of the single-piece bonding device 164, and supplies it to the bonding position. The second release film 41 is peeled from the single sheet-shaped second optical film 4 by a peeling means. The suction surface of the suction portion 164a has an arc shape in cross section. The peeling means may be, for example, by using an adhesive tape, sticking the adhesive tape on the surface of the second release film 41, and moving the adhesive tape by a moving mechanism to peel the second release film 41.

The single-piece bonding device 164 has a fixed surface 164b, and the fixed surface 164b sucks and fixes the first surface P1 side of the liquid crystal cell P. In a state where the second release film 41 has been peeled off and the second adhesive layer 42 is exposed, the single-piece second optical film 4 is attached to the second surface P2 of the liquid crystal cell P such that the suction portion 164a is rotated.

(Fourth surface protection film peeling step) After the single sheet-shaped second optical film 4 is attached, the fourth surface protection film 45 is peeled off. The peeling process can be implemented manually or by a peeling device.

(Other embodiments of the fifth embodiment) In the fifth embodiment described above, a single sheet of the first optical film 2 may be used instead of the roll-shaped first optical film 1 and attached to the liquid crystal cell in a sheet-to-panel manner, or a roll may be used. The second optical film 3 in the form of a single sheet replaces the second optical film 4 in the form of a single sheet and is affixed to the liquid crystal cell in a roll-to-panel method.

(Variations) This embodiment 4 and 5 illustrate the continuous manufacturing method of using the optical film group of the roll optical film and the monolithic optical film in the liquid crystal display panel, but it is not limited to this, and can also be used in the organic EL display. Continuous manufacturing method for panels.

In Embodiments 4 and 5, the above-mentioned optical film is used as a roll optical film, but the structure of the roll optical film is not limited to this. For example, in addition to the release film, a strip-shaped optical film having a plurality of slit lines formed in the width direction (optical film including slits) can be used.

In Embodiments 4 and 5, the strip-shaped optical film is cut (half-cut) in the width direction at predetermined intervals. However, from the viewpoint of improving the yield rate, the strip-shaped optical film is made to avoid defects in the strip-shaped optical film. The film can also be cut in the width direction (skip cut), and the optical film containing defective parts can be cut in a smaller size (preferably as small as possible) than the predetermined interval (the size of the optical unit). can.

Embodiments 4 and 5 take oblate rectangular liquid crystal cells and liquid crystal display panels as examples. However, the shapes of the liquid crystal cells and liquid crystal display panels only need to have one set of opposite sides and another set of opposite sides. Specially limited.

1‧‧‧Roll Optical Film 10‧‧‧Ribbon optical film 11‧‧‧Release film 12‧‧‧Adhesive layer 13‧‧‧Optical function film 14‧‧‧The first surface protective film 2‧‧‧Single sheet optical film 21‧‧‧Release film 22‧‧‧Adhesive layer 23‧‧‧Optical function film 24‧‧‧The first surface protective film 25‧‧‧Second surface protective film a‧‧‧Width, vertical b‧‧‧Predetermined interval, horizontal s‧‧‧Cutting part C‧‧‧cutting method sc‧‧‧Slitting and cutting department e1, e2‧‧‧end S25‧‧‧Second surface protection film blank material S2‧‧‧Optical film blank FC‧‧‧cutting method R‧‧‧Conveying roller R1, R2‧‧‧Laminating roller 4‧‧‧Single second optical film 41‧‧‧Second release film 45‧‧‧4th surface protective film 5‧‧‧The first optical film blank in roll form 50‧‧‧Control Department 51‧‧‧The first image analysis section 52‧‧‧First Judgment Section 61‧‧‧Cut off 62‧‧‧The first tension adjustment part 63‧‧‧The first peeling part 64‧‧‧Part 1 Attachment 64a‧‧‧The first roller 64b‧‧‧The second roller 65‧‧‧Volume 1 70‧‧‧Inspection Department 1 71‧‧‧Light source 72‧‧‧The first camera department 81‧‧‧The first conveying department 82‧‧‧The second conveying department 91‧‧‧Receiving Department 92‧‧‧First Goods Recycling Department 93‧‧‧Defective Product Recycling Department 1 P1‧‧‧The first side of LCD unit P P2‧‧‧Second side of LCD unit P P‧‧‧LCD unit Y‧‧‧Conveying direction 100‧‧‧Container 164‧‧‧Single piece bonding device 164a‧‧‧Adsorption part 164b‧‧‧Fixed surface 821‧‧‧Configuration Exchange Department

Fig. 1 is a schematic diagram showing the optical film set of the first embodiment. Fig. 2 is a schematic diagram showing the optical film groups on both sides of the second embodiment. Fig. 3A is a schematic diagram showing a method of manufacturing a roll-shaped first optical film. Fig. 3B is a schematic diagram showing the manufacturing method of the monolithic first optical film. Fig. 4 is a schematic diagram of a continuous manufacturing system of an optical display panel according to the fourth embodiment. Fig. 5 is a diagram showing remanufacturing steps. Fig. 6 is a schematic diagram of a continuous manufacturing system of an optical display panel according to the fifth embodiment.

1‧‧‧Roll Optical Film

10‧‧‧Ribbon optical film

11‧‧‧Release film

12‧‧‧Adhesive layer

13‧‧‧Optical function film

14‧‧‧The first surface protective film

2‧‧‧Single sheet optical film

21‧‧‧Release film

22‧‧‧Adhesive layer

23‧‧‧Optical function film

24‧‧‧The first surface protective film

25‧‧‧Second surface protective film

a‧‧‧Width, vertical

b‧‧‧Predetermined interval, horizontal

s‧‧‧Cutting part

C‧‧‧cutting method

Claims (17)

An optical film set having a roll-shaped optical film and a single-piece optical film, and the roll-shaped optical film is a structure in which a release film, an adhesive layer, an optical function film, and a first surface protection film are sequentially laminated. The sheet-shaped optical film has a structure in which the release film, the adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are sequentially laminated, and the first surface protection film has an adhesive layer or The first surface protection film is a self-adhesive film, the second surface protection film has an adhesive layer or the second surface protection film is a self-adhesive film, and the interlayer peeling force between the release film and the adhesive layer is interlayer peeling Force A, the interlayer peeling force between the adhesive layer and the optical function film is the interlayer peeling force B, the interlayer peeling force between the optical function film and the first surface protection film is the interlayer peeling force C, the first surface protection film and the second surface protection film When the interlayer peeling force is the interlayer peeling force D, the size relationship of the peeling force between the layers in the monolithic optical film is A<D<C<B. The optical film set of claim 1, wherein the first surface protection film and the second surface protection film have the same structure. The optical film set of claim 1, wherein the aforementioned optically functional film is a polarizing film. The optical film set of claim 2, wherein the thickness of the aforementioned polarizing film is 60 μm or less. The optical film set of claim 2, wherein the aforementioned polarizing film has a polarizing member with a thickness of 10 μm or less. The optical film set of any one of claims 1 to 5, wherein the first surface protection film has a first substrate film and a first adhesive layer, and is laminated on the optical function film through the first adhesive layer. According to the optical film set of claim 2, wherein the first surface protection film and the second surface protection film are made of the same material and/or the same thickness. The optical film set of any one of claims 1 to 5, wherein the second surface protection film has a second substrate film and a second adhesive layer, and is laminated on the first surface through the second adhesive layer film. The optical film set of any one of claims 1 to 5, wherein the roll-shaped optical film has a width corresponding to a set of opposite sides of the optical unit; and, a set of opposite sides of the single-piece optical film has Corresponds to the length of one set of opposite sides of the aforementioned optical unit, and the other set of opposite sides has a length corresponding to the other set of opposite sides of the aforementioned optical unit. The optical film set of any one of claims 1 to 5, wherein the roll-shaped optical film and the single-piece optical film are used to manufacture an optical display panel, and the optical display panel is arranged on one side of the optical unit The sequential layer has a structure of the adhesive layer, the optical function film, and the first surface protection film. The optical film set of claim 9, wherein the rolled optical film is used to manufacture the optical display panel in a roll-to-panel manner, and the monolithic optical film is used to manufacture the optical display panel in a sheet-to-panel manner. Learn the display panel. Such as the optical film set of claim 11, wherein the aforementioned single-piece optical film is used to reproduce the aforementioned optical display panel of the following structure: the aforementioned optical display manufactured by the aforementioned roll-to-panel method using the aforementioned rolled optical film In the panel, the optical display panel after the adhesive layer, the optical function film, and the first surface protection film are removed after being judged to be defective, and one of the optical units is remanufactured sequentially using the monolithic optical film The aforementioned optical display panel in which an adhesive layer, an optical function film, and a first surface protection film are laminated. A method for manufacturing an optical film set, the optical film set is as described in any one of claims 1 to 5, and the manufacturing method of the aforementioned roll-shaped optical film includes the following steps: a step of preparing an optical film blank, The optical film blank has a structure in which the release film, the adhesive layer, the optical function film, and the first surface protection film are sequentially laminated, and the steps of manufacturing the roll-shaped optical film are based on the optical film blank The material is slit and wound to manufacture the aforementioned roll-shaped optical film; the manufacturing method of the aforementioned monolithic optical film includes the following steps: a step of manufacturing an optical film blank material laminated with a second surface protection film, which is based on the aforementioned The first surface protection film side of the optical film blank is laminated with the second surface protection film blank to produce an optical film blank laminated with a second surface protection film, and the steps of manufacturing a monolithic optical film are correct The optical film blank material laminated with the second surface protection film is cut and processed to produce a single sheet Optical film. An optical film group on both sides, having a first optical film group and a second optical film group, wherein the first optical film group has a roll-shaped first optical film and a monolithic first optical film, and the roll-shaped first optical film The film is a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated. The monolithic first optical film is laminated with the first release film in sequence The structure of the film, the first adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film, the first surface protection film has an adhesive layer or the first surface protection film is self Adhesive film, the second surface protection film has an adhesive layer or the second surface protection film is a self-adhesive film, the interlayer peeling force between the release film and the adhesive layer is interlayer peeling force A, the adhesive layer and optical The interlayer peeling force of the functional film is the interlayer peeling force B, the interlayer peeling force of the optical function film and the first surface protection film is the interlayer peeling force C, and the interlayer peeling force of the first surface protection film and the second surface protection film is the interlayer peeling force. At D, the size relationship of the peeling force between the layers in the monolithic optical film is A<D<C<B; the second optical film group has a roll-shaped second optical film and a monolithic second optical film, the roll-shaped The second optical film has a structure in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are sequentially laminated. The monolithic second optical film has a structure in which the second release film, the second adhesive layer, the second optical function film, the third surface protection film, and the fourth surface protection film are laminated in this order. The third surface protection film has an adhesive layer or the third surface protection film is a self-adhesive film, the fourth surface protection film has an adhesive layer or the fourth surface protection film is a self-adhesive film, and a release film and The interlayer peeling force of the adhesive layer is the interlayer peeling force A, the interlayer peeling force between the adhesive layer and the optical function film is the interlayer peeling force B, and the interlayer peeling force of the optical function film and the third surface protection film is the interlayer peeling force C, the first 3 When the interlayer peeling force between the surface protective film and the fourth surface protective film is the interlayer peeling force D, the size relationship of the peeling force between the layers in the monolithic optical film is A<D<C<B. Such as the two-sided optical film set of claim 14, wherein the first optical film in the form of a roll and the first optical film in the form of a single sheet, and the second optical film in the form of a roll and the second optical film in the form of a single sheet are used for manufacturing An optical display panel having the following structure: the first adhesive layer, the first optical function film, and the first surface protective film are sequentially laminated on one side of the optical unit, and the other side of the optical unit is sequentially laminated There are the second adhesive layer, the second optical function film, and the third surface protection film. Such as the two-sided optical film group of claim 14, wherein the first surface protection film and the second surface protection film have the same structure; and/or The third surface protection film and the fourth surface protection film have the same structure. The optical film group on both sides of claim 16, wherein the first surface protection film and the second surface protection film are the same material and/or the same thickness; the third surface protection film and the fourth surface protection film are the same material And/or the same thickness.

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