TWI753691B - Punching device for optical film, and manufacturing method of film product - Google Patents

Abstract

The present invention relates to a punching device for an optical film that is less likely to produce poor cutting. The punching device utilizes a cutting knife (61) to punch an optical film original sheet (1) to manufacture a plurality of thin film products. The device includes: a conveying part that conveys a blade supporting sheet (2) and the above-mentioned optical film original sheet (1); and a punching part that presses the above-mentioned cutting blade (61) against the above-mentioned optical film original sheet (1) . The blade supporting sheet (2) has a seam (5) formed by contacting the first end face and the second end face of the sheet, and the seam (5) extends along the extension relative to the cutting blade (61). The direction extends in the direction of the cross.

Description

Punching device for optical film, and manufacturing method of film product

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

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

For example, Patent Document 1 discloses a processing method in which an interleaving sheet and a sheet to be cut arranged on the interleaving paper are conveyed between a support table and a cutting blade, and the sheet is cut from the sheet to be cut. The upper part of the material is pressed against the cutting blade, thereby cutting the cut sheet. In this press working, by entering the cutting blade into the sheet to be cut until the cutting edge of the cutting blade reaches the backing paper, a plurality of products of a specific shape can be continuously obtained from the sheet to be cut. In the above-mentioned processing method, the liner rolled on the upstream side in a roll shape is unrolled, conveyed to the press processing section, and the cutting blade is pressed against the sheet to be cut, and then the liner is rewound on the downstream side. In roll shape. Therefore, in order to continuously manufacture a product, a splicing process of adding a new lining paper to the lining paper remaining on the upstream side is performed. [Prior Art Literature] [Patent Literature]

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

However, in the case of punching a film product from an optical film original sheet, if the above-mentioned processing method is applied, the following problems will arise. That is, the backing paper (knife supporting sheet) after the splicing process has a seam formed by contacting and joining the first end surface and the second end surface of the sheet. The seam is the gap between the sheets, so at the seam, there is no backing paper that bears the pressing force of the cutting knife. When the cutting blade just fits on the above-mentioned seam, since there is no backing paper to receive the pressing force of the cutting blade, there is a possibility that the original optical film cannot be cut reliably. [Problems to be Solved by Invention]

An object of the present invention is to provide a punching device for an optical film that is less likely to produce poor cutting, and a method for manufacturing a thin film product. [Technical means to solve problems]

As shown in FIG. 16 , the knife supporting sheet 200 after the first end face 210 and the second end face 220 of the sheet are butted and spliced together is tied with a gap between the first end face 210 and the second end face 220 (the seam 500 ). Usually, the sheets are joined by attaching the splicing tape 510 across the first end portion and the second end portion while covering the seam 500 . When the extending direction of the cutting blade 610 is parallel to the seam 500, when the seam 500 and the cutting blade 610 are overlapped linearly (the seam 500 is parallel to the cutting blade 610, and the entire cutting blade 610 is parallel to it) When the seams 500 are overlapped), as shown in FIG. 16 , the cutting blade 610 enters the seam 500 as a whole. The splicing tape 510 generally does not have the strength to withstand the pressing force of a cutting knife. Therefore, the lower part of the optical film original sheet may be slightly elongated as the cutting blade 610 enters, and the optical film original sheet 100 may not be cut reliably. The inventors of the present invention have found that by designing the shape of the seam of the blade supporting sheet so that the entire cutting blade does not enter the seam, it is possible to suppress defective cutting of the optical film original sheet.

The punching apparatus of the present invention is an apparatus for producing a plurality of thin film products by punching an optical film original sheet with a cutting blade, and includes a conveying section for holding the blade supporting sheet for supporting the cutting edge of the cutting blade, and the optical film The original sheets are conveyed in the longitudinal direction, respectively; and a press processing unit that presses the cutting blade against the optical film original sheet from the side opposite to the blade support sheet; A seam formed by contacting the first end face and the second end face, and the seam extends in a direction intersecting with the extending direction of the cutting blade.

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

According to another aspect of the present invention, a method for manufacturing a film product is provided. The manufacturing method of the film product of the present invention is a method for obtaining a plurality of film products by punching an optical film original sheet with a cutting knife, and comprises the following steps: a knife supporting sheet supporting the cutting edge of the cutting knife, and the optical film The original film sheet is respectively conveyed in the longitudinal direction; the above-mentioned cutting blade is pressed against the above-mentioned optical film original sheet from the side opposite to the above-mentioned blade supporting sheet, whereby a plurality of film products are punched out from the above-mentioned optical film original sheet; The above-mentioned knife supporting sheet has a seam formed by joining the first end face and the second end face of the sheet, and the seam of the above-mentioned knife supporting sheet is in a direction intersecting with either edge of the above-mentioned punched film product extend.

In the preferable manufacturing method of this invention, the seam of the said knife support sheet extends obliquely with respect to the short side direction orthogonal to the longitudinal direction of the said knife support sheet. In a preferred manufacturing method of the present invention, the film product is substantially quadrilateral in plan view, and the substantially quadrilateral in plan view has a longitudinal side substantially parallel to the longitudinal direction of the optical film original sheet and a longitudinal side substantially parallel to the short side direction of the optical film original sheet. horizontal edge. In a preferred manufacturing method of the present invention, a splicing tape covers the seam and is attached to the knife supporting sheet across the first end and the second end of the sheet, and the thickness of the splicing tape is 50 μm the following. In a preferred manufacturing method of the present invention, the above-mentioned film product includes a surface protective film laminated through an adhesive layer. A preferred manufacturing method of the present invention is that the above-mentioned film product includes a polarizing element. [Effect of invention]

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

In this specification, "top view" refers to the shape of the object when viewed from a direction perpendicular to the surface of the object, and "planar shape" and "plan view" refer to the shape of the object when viewed from a direction perpendicular to the surface of the object. Schema. In addition, in this specification, the expression "substantially" means the range permissible in the technical field including the present invention. Furthermore, in this specification, the numerical range represented by "the lower limit X to the upper limit Y" means the lower limit X or more and the upper limit Y or less. When a plurality of the above-mentioned numerical ranges are individually described, an arbitrary lower limit value and an arbitrary upper limit value can be selected, and "arbitrary lower limit value to arbitrary upper limit value" can be set.

[First Embodiment] <Outline of Pressing Equipment for Optical Films> Fig. 1 shows a punching apparatus A1 for an optical film. 1, the press apparatus A1 has the conveyance part B which conveys the optical film original sheet 1 and the knife support sheet 2, the press processing part C, the blanking removal part D, and the product collection part E. The press processing part C has a cutting blade.

＜Conveying Department＞ The conveyance part B of the press apparatus A1 has the guide roller 31 which conveys the optical film original sheet 1, the knife support sheet 2, etc., and a drive apparatus (not shown). The said conveyance part B unwinds the optical film original sheet 1 from the unwinding part 321, and conveys this optical film original sheet 1 in the longitudinal direction. Moreover, the said conveyance part B unwinds the knife support sheet 2 from the unwinding part 322, and conveys this knife support sheet 2 in the longitudinal direction. In addition, the long-side direction of the optical film original sheet 1 and the long-side direction of the knife supporting sheet 2 are the same direction, and the short-side direction of the optical film original sheet 1 and the short-side direction of the knife supporting sheet 2 are the same direction. The optical film original sheet 1 and the blade support sheet 2 independently conveyed by the conveyance part B are overlapped in the middle, and are conveyed to the press processing part C in the overlapped state. For example, the optical film original sheet 1 is overlapped on the front surface of the blade supporting sheet 2 . The superposed optical film original sheet 1 is conveyed to the press processing part C in synchronization with the blade support sheet 2 . The conveyance part B is equipped with the belt conveyor 34 which conveys the optical film original sheet 1 and the knife support sheet 2 which were superimposed as needed.

After the optical film original sheet 1 conveyed to the above-mentioned press processing part C is punched by the cutting blade 61, it is divided into a punching stub and a film product. After the blade support sheet 2 conveyed to the above-mentioned press processing part C receives the cutting edge of the cutting blade 61 , it is conveyed to the downstream side and wound up by the winding part 332 .

＜Original Optical Film＞ The punching device A1 of the present invention is a film product obtained by punching the optical film original sheet 1 . The original optical film used to obtain film products is generally a long strip-shaped film or a large-sized film. In the example shown in the figure, the case of punching a film product using a long strip-shaped optical film original sheet 1 is shown. However, in FIG. 2, one side in the longitudinal direction of the long strip-shaped optical film original sheet 1 is omitted. The long strip-shaped optical film original sheet 1 is installed in the unwinding part 321 of the punching device A1 in a state of being wound into a roll shape. Here, in this specification, the elongated strip|belt shape means the substantially rectangular shape in plan view whose length in the longitudinal direction is shorter than the length in the side direction. The length in the longitudinal direction of the optical film original sheet 1 is, for example, 5 m or more, or preferably 10 m or more in the longitudinal direction. In addition, the short-side direction is a direction orthogonal to the long-side direction.

The optical film original sheet 1 contains an optical film. The optical film original sheet 1 may be comprised only by an optical film, and may have components other than an optical film and an optical film. 3 and 4 illustrate the layer structure of the optical film original sheet 1 . The optical film original sheet 1 has an optical film 11 , an isolation film 13 , and an adhesive layer 12 interposed between the optical film 11 and the isolation film 13 and bonding the two films 11 and 13 . The adhesive layer 12 is firmly adhered to the optical film 11 and is releasably adhered to the release film 13 . The release film 13 can be peeled off at the interface with the adhesive layer 12 . Moreover, the optical film original sheet (not shown) which does not have the said adhesive bond layer 12 and the isolation|separation film 13 can also be used.

The optical film 11 includes an optical functional film. As said optical function film, a polarizing element, a retardation film, a light-diffusion film, a brightness enhancement film, an antiglare film, a light reflection film, etc. are mentioned. The polarizer is a film having a property of transmitting light (polarized light) vibrating in one specific direction and blocking light vibrating in other directions. The retardation film is a film that expresses optical anisotropy, and typically, for example, stretched films such as acrylic resins, cycloolefin resins, and cellulose resins are exemplified. Moreover, the optical film 11 may contain a protective film. A protective film is laminated|stacked in order to protect the said optical function film. Typically, a colorless transparent film can be used as the protective film.

In the optical film original sheet 1 illustrated in FIG. 3 , the optical film 11 has a first protective film 111 , a polarizing element 112 and a second protective film 113 in this order from the bottom to the top of the drawing. One laminated film (optical film 11 ) is formed by adhering the above-mentioned films 111 to 113 to each other. Furthermore, in the illustrated example, the first protective film 111 and the polarizing element 112, and the polarizing element 112 and the second protective film 113 are directly bonded, respectively, but an adhesive layer (or an adhesive layer) may also be interposed between these films as required. adhesive layer) and each film is adhered (not shown) via an adhesive layer (or adhesive layer). Moreover, the surface protective film 14 is laminated|stacked via the adhesive bond layer 15 on the surface of the said optical film 11 (the surface of the 2nd protective film 113). For example, the surface protective film 14 can be peeled off from the surface of the optical film 11 together with the adhesive layer 15 . In addition, the surface protection film 14 and the adhesive layer 15 are provided as needed, therefore, the optical film original sheet 1 which does not have the surface protection film 14 and the adhesive layer 15 can also be used.

In the optical film original sheet 1 illustrated in FIG. 4 , the optical film 11 has a retardation film 115 . Moreover, the surface protective film 16 is laminated|stacked via the adhesive bond layer 17 on the surface of the said optical film 11 (surface of the retardation film 115). For example, the surface protective film 16 can be peeled off from the surface of the optical film 11 (retardation film 115 ) together with the adhesive layer 17 . In addition, the surface protective film 16 and the adhesive layer 17 are provided as needed, therefore, the optical film original sheet 1 without the surface protective film 16 and the adhesive layer 17 can also be used. In addition, the optical film 11 is not limited to the layer structure of FIG. 3 and FIG. 4, Various changes are possible. For example, the optical film may include two or more layers of optically functional films, or may consist of only one layer of optically functional films.

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

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

<Knife Support Sheet> The blade supporting sheet 2 is a sheet supporting the cutting edge of the cutting blade 61 . The cutting edge of the cutting blade 61 which penetrates through the optical film original sheet 1 and is exposed to the back side of the optical film original sheet 1 bites into the blade supporting sheet 2, thereby reliably cutting the optical film original sheet and preventing the above-mentioned optical film original sheet. The cutting edge of the cutting blade 61 is deteriorated. As the blade supporting sheet 2, there can be used a sheet having flexibility to receive the cutting edge of the cutting blade 61, and having strength and thickness such that the cutting edge does not break even if the cutting edge enters. For example, as the blade supporting sheet 2, a synthetic resin sheet, a rubber sheet, a nonwoven fabric, etc. can be used, and a synthetic resin sheet is particularly preferable. Examples of the synthetic resin sheet include styrene-based resin sheets such as polystyrene; polyolefin-based resin sheets such as polyethylene and polypropylene; polyester-based resin sheets such as polyethylene terephthalate; 66 Polyamide resin sheets such as nylon; polyvinyl chloride resin sheets such as polyvinyl chloride, etc. Moreover, the laminated sheet which laminated|stacked 2 or more types of resin sheets can also be used. The thickness of the blade support sheet 2 is not particularly limited. If the thickness of the blade support sheet 2 is too small, the cutting blade 61 may be easily broken. Therefore, the thickness of the blade support sheet 2 is preferably larger than the amount of entry of the cutting blade 61 . From the above viewpoint, the thickness of the blade support sheet 2 is, for example, 0.4 mm or more, or preferably 0.5 mm or more. Moreover, if the thickness of the blade support sheet 2 is too large, it becomes difficult to handle, and the material cost also increases. From the above viewpoint, the thickness of the blade support sheet 2 is, for example, 2 mm or less, preferably 1 mm or less, and more preferably 0.8 mm or less.

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

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

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

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

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

The above-mentioned cutting blade 61 is provided on the base plate 62 . The base plate 62 has a flat shape, and the cutting blade 61 is fixedly provided on the base plate 62 . The cutter device 6 (cutting blade 61 ) is advanced and retracted in a direction perpendicular to the surface of the optical film original sheet 1 by a driving device not shown. The cutter device 6 of the present embodiment is a cutter of a pressing method for punching the optical film original sheet 1 by withdrawing and retracting in a direction perpendicular to the surface of the optical film original sheet 1 . In FIG. 1, the movement of the cutter device 6 is indicated by thick arrows. As such a cutter device 6, a Thomson knife can be used typically.

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

As shown in the enlarged view of FIG. 9 , the cutting blade 61 usually has a sharp blade edge 61a and becomes thicker toward the base plate 62 side. The angle β of the blade edge 61a is not particularly limited, but is, for example, 20 degrees to 40 degrees. The cutting blade 61 of the cutter device 6 is arranged so as to intersect with the seam 5 of the above-mentioned blade supporting sheet 2 . Moreover, the cutting blade 61 is arrange|positioned not parallel with respect to the extending direction of the seam 5 of the said blade support sheet 2 (non-parallel with respect to the extending direction of the seam 5). For example, each cutting blade 61 has a first portion 611 extending substantially parallel to the short side direction of the blade support sheet 2 and a second portion 612 extending substantially parallel to the longitudinal direction of the blade support sheet 2 . Both the first portion 611 and the second portion 612 of the cutting blade 61 extend in a direction intersecting with the extending direction of the seam 5 . The plan view shape of each cutting blade 61 is, for example, as shown in FIG. 8 , which is a substantially quadrangle (substantially rectangular or substantially square).

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

<Punching stub removal part> The punching edge removal part D removes the remaining punching edge around the film product (the part surrounded by the cutting line) formed in the surface of the optical film original sheet 1 by the punching part C. The punching residue removing section D includes a pressing roller 71 that presses the optical film original sheet 1 punched by the cutting blade 61 and a recovery roller 72 that reverses the punching residue after the pressing roller 71 is used as a fulcrum. side recycling. The punched optical film original sheet 1 is conveyed downstream by the belt conveyor 35 , and is separated into the punching stub 91 and the film product 9 at the pressing roller 71 . The die cut stub 91 is recovered by the recovery roller 72 . The film product 9 is conveyed downstream by the belt conveyor 36 .

＜Product Recycling Department＞ The product recovery section E has a recovery section 37 that recovers the film product 9 obtained by removing the punching stubs 91 in the above-described punching stub removal section D. As shown in FIG.

[Manufacturing method of film product using punching device] The plan views shown in S1 to S4 of FIG. 10 are plan views when viewed from the directions of the hollow arrows S1 to S4 in FIG. 1 (both sides in the longitudinal direction are omitted). 1 and S1 of FIG. 10, by the conveyance part B, the optical film original sheet 1 and the blade support sheet 2 are conveyed to the longitudinal direction downstream side (a conveyance process). In addition, the thin arrow of FIG. 1 shows the conveyance direction of the optical film original sheet 1 etc.. FIG. 1 and S2 of FIG. 10, in the middle of conveyance, the optical film original sheet 1 is superimposed on the surface of the blade support sheet 2, and is conveyed to the press processing part C in this state.

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

Referring to S3 of FIG. 10 , the symbol X represents the cutting line formed in the surface of the optical film original sheet 1 by the cutting blade 61 , and the portion to which an infinite number of dots are added represents the blanking 91 . The optical film original sheet 1 after punching is conveyed by the belt conveyor 35 toward the downstream side. In the punching stub removal part D, the punching stub 91 in the optical film original sheet 1 after punching is reversed at the pressing roller 71 and recovered to the recovery roller 72 (removal step). In this way, the film product 9 shown in Fig. 1 and S4 of Fig. 10 can be continuously produced. Either edge of the film product 9 obtained extends in a direction that intersects with the seam 5 of the knife support sheet 2 . In other words, the seam 5 of the knife support sheet 2 extends in a direction that intersects with either edge of the punched film product 9 . In addition, the shape of the edge of the film product 9 is the same as that of the cutting line X described above.

For example, the film product 9 has an edge extending substantially parallel to the long-side direction of the optical film original sheet 1 (knife supporting sheet 2 ) and substantially parallel to the short-side direction of the optical film original sheet 1 (knife supporting sheet 2 ). The edge of the earth's extension. In the illustrated example, the film product 9 is in a plan view substantially quadrilateral having a longitudinal side 9a substantially parallel to the longitudinal direction of the optical film original sheet 1 and a lateral side 9b substantially parallel to the short side direction of the optical film original sheet 1. . In addition, in the example of illustration, although the case where the film product 9 of 5 pieces (5 rows) is manufactured in the short-side direction is shown, it is not limited to this number. The number of the film products 9 in the transversal direction during manufacture (the number of cutting blades 61 in the transversal direction) is set according to the relationship between the length of the optical film original sheet 1 in the transversal direction and the length of the film products 9 . Therefore, the number of the film products 9 in the short-side direction is 1 or more and can be appropriately set.

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

The punching device A1 of the present invention can suppress the poor punching of the optical film original sheet 1 . FIG. 11 is a reference plan view showing a state in which the vicinity of the joint 5 of the knife supporting sheet 2 is conveyed to the press processing unit C. FIG. In FIG. 11 , the cutting blade 61 is indicated by a two-dot chain line, and the optical film original sheet 1 is indicated by a small dotted line. FIG. 12 is a sectional view of the cutting blade 61 obtained by cutting at a portion intersecting with the seam 5 , and FIG. 13 is a sectional view of the cutting blade 61 obtained by cutting at a position not intersecting with the seam 5 . 11 , in the middle of continuously punching the film product 9 from the long strip-shaped optical film original sheet 1 , the vicinity of the seam 5 of the blade support sheet 2 reaches the punching part C. Since the seam 5 of the knife supporting sheet 2 of the present invention extends in a direction intersecting with the extending direction of the cutting blade 61, the seam 5 and the cutting blade 61 do not overlap in a line shape. The two cutting knives 61 intersect at the intersection. Symbol Y in FIG. 11 represents the intersection point where the first portion 611 of one cutting blade 61 (the first portion 611 extending substantially parallel to the short-side direction of the blade support sheet 2 ) and the seam 5 intersect.

The cutting edge 61a of the first portion 611 of the cutting blade 61 at the intersection Y enters the joint 5 (see FIG. 12 ), and the first portion 611 excluding the above-mentioned intersection penetrates the entire thickness direction of the optical film original sheet 1, The support sheet 2 receives the blade edge 61a (see FIG. 13 ). Therefore, the pressing force of the first portion 611 of the cutting blade 61 acts on the entire thickness direction of the optical film original sheet 1, so that the cutting failure of the optical film original sheet 1 is less likely to occur. Since the cutting line X can be formed in the optical film original sheet 1 without generating a cutting defect, the punching rim 91 can be easily recovered in the punching rim removal part D. Furthermore, even if a slight cutting defect occurs at the above-mentioned intersection, since the defect is a point, the recovery of the blanking stub 91 is not hindered. The entry amount of the blade edge 61a with respect to the blade support sheet 2 can be appropriately set, and is, for example, 0 μm to 200 μm. In addition, the said entry amount means the distance between the front end of the blade edge|tip 61a and the surface of the blade support sheet 2. As shown in FIG. In the case where the above-mentioned entering amount is zero, it means a state where the front end of the blade edge 61a is in contact with the surface of the blade support sheet 2 . In FIGS. 12 and 13 , the case where the first portion 611 of one cutting blade 61 intersects the seam 5 has been described, but the same applies when the first portion 611 of the other cutting blade 61 intersects the seam 5 . For this reason, it is not easy to produce poor cutting. The same applies when the second portion 612 of the cutting blade 61 intersects the seam 5 .

Moreover, when the splicing tape 51 is attached to the surface of the knife supporting sheet 2, as shown in FIGS. The portion overlapping the splicing tape 51 in the original optical film 1 is raised by an amount corresponding to the thickness of the splicing tape 51 . Therefore, the cutting blade 61 pressed against this part penetrates into the optical film original sheet 1 deeper than other parts. Since the thickness of the cutting blade 61 gradually increases from the cutting edge 61a toward the base plate 62 side, if the cutting blade 61 penetrates deeper, the width of the cutting line increases accordingly, which may cause cracks in the film product 9 Danger of waiting. In view of this aspect, as described above, by using the splicing tape 51 having a thickness of 50 μm or less, cracks and the like of the above-mentioned film product 9 can be prevented. In particular, when the original optical film sheet 1 with a protective film is punched with the cutting blade 61, there is a possibility of peeling of the protective film, but by using the above-mentioned splicing tape 51, the peeling of the protective film can be prevented.

The layer constitution of the obtained film product 9 is the same as that of the above-mentioned optical film original sheet 1 . When the film product 9 is composed of, for example, the optical film 11/adhesive layer 12/separator film 13, the film product 9 can be attached to any component (such as the screen of an image display device, etc.) by peeling off the release film 13. ). However, the film product 9 is not limited to the application used by being attached to an arbitrary member.

Hereinafter, the second embodiment of the present invention and the like will be described, but in the description, the configuration and effects different from those of the above-described embodiment will be mainly described, and the same configuration, etc., may be directly referred to by terms or symbols, and the configuration may be omitted. description.

[Second Embodiment] In the above-described first embodiment, the blade support sheet 2 is unwound from the unwinding part 322 and passed through the press processing part C and wound into the winding part 332, but it is not limited to this. For example, as shown in FIG. 14, the blade support sheet 2 may be formed in an endless shape like a conveyor belt of a belt conveyor. The endless knife supporting sheet 2 is annular in the side view shown in the figure, and is in the form of circulation in the stamping processing section C. As shown in FIG. The endless knife supporting sheet 2 is formed by making the long strip-shaped knife supporting sheet 2 ring-shaped, and the joint 5 formed by contacting the first end face and the second end face thereof is joined with a splicing tape 51. obtained. Also about the endless blade support sheet 2, the seam 5 extending in the direction intersecting with the extending direction of the cutting blade 61 is formed similarly to the above-mentioned first embodiment. Also in the press apparatus A2 of this embodiment, similarly to the said 1st Embodiment, the cutting|disconnection defect of the optical film original sheet 1 is hard to generate|occur|produce. Furthermore, in this embodiment, since the endless blade support sheet 2 is circulated in the press processing part C, the usage-amount of the blade support sheet 2 can be reduced. Furthermore, if the endless knife support sheet 2 is used repeatedly, a plurality of traces of the cutting edge 61a of the cutting knife 61 will be produced on the surface of the knife support sheet 2, so it is preferable to replace the knife at an appropriate time. Support sheet 2 .

[Third Embodiment] In the above-described first and second embodiments, the cutter device 6 of the pressing method is shown as an example, but a rotary die 65 may be used, for example, as shown in FIG. 15 . The rotary die 65 is provided with a cutting blade 61 protruding from its peripheral surface. In the press apparatus A3 of this embodiment, the cutting blade 61 provided on the peripheral surface of the rotary die 65 is also arranged to intersect with the seam 5 of the blade support sheet 2, similarly to the above-mentioned first embodiment. . In addition, when the rotary die 65 is used, the anvil rolls 66 are arranged to face each other instead of the above-mentioned support table 63 .

[4th Embodiment] In the above-mentioned first to third embodiments, the case where the film product 9 having a substantially quadrangular shape in plan view is produced is exemplified, but the shape of the film product 9 (that is, the plan view shape of the cutting blade 61 ) is not limited to this. Appropriate changes can be made within the intended scope of the present invention.

1: Original optical film 2: Knife support sheet 5: seams 5W: width 6: Cutter device 9: Film products 9a: Longitudinal edge 9b: horizontal edge 11: Optical film 12: Adhesive layer 13: Isolation film 14: Surface protection film 15: Adhesive layer 16: Surface protection film 17: Adhesive layer 21: The first end face 21a: 1st end 22: 2nd end face 22a: 2nd end 31: Guide roller 34: Belt Conveyor 35: Belt Conveyor 36: Belt Conveyor 37: Recycling Department 51: Splicing Tape 51T: Thickness 51W: width 61: Cut off knife 61a: The tip of the cutting knife 62: base plate 63: Support table 65: Rotary die 66: Anvil Roll 71: Press Roller 72: Recovery Roller 91: Punching stubs 100: Original optical film 111: The first protective film 112: polarizing element 113: The second protective film 115: retardation film 200: Knife Support Sheet 210: 1st end face 220: 2nd end face 321: Volume Out Department 322: Volume Out Department 332: Coiler 500: seams 510: Splicing Tape 610: Cut off knife 611: Part 1 612: Part 2 A1, A2, A3: Stamping device B: conveying department C: Stamping processing department D: Punching stub removal part E: Product Recycling Department S1: hollow arrow S2: hollow arrow S3: hollow arrow S4: hollow arrow X: cut line Y: intersection α: angle β: angle

1 : is a schematic side view which shows the press apparatus of the optical film concerning 1st Embodiment of this invention. Figure 2 is a top view of the original optical film. FIG. 3 is a schematic side view showing the layer structure of an example of an optical film original sheet. FIG. 4 is a schematic side view showing the layer structure of an optical film original sheet of another example. Figure 5 is a top view of a knife support sheet including seams. FIG. 6 is an enlarged cross-sectional view taken along the line VI-VI of FIG. 5 . "Cross-sectional view" is a figure which shows only the shape of a cut surface, and does not show the shape further back than a cut surface. Figure 7 is a top view showing the seam of the knife support sheet prior to attaching the splicing tape. Fig. 8 is a top view of the cutting blade. FIG. 9 is an enlarged perspective view of the cutting blade. FIG. 10 is a plan view showing the state of the knife support sheet and the like in each step of punching an optical film original sheet. Fig. 11 is a plan view showing a state where a part of the cutting blade intersects the seam of the blade support sheet. FIG. 12 is a cross-sectional view taken along the line XII-XII of FIG. 11 . FIG. 13 is a cross-sectional view taken along the line XIII-XIII of FIG. 11 . FIG. 14 is a schematic side view showing a punching apparatus for an optical film according to a second embodiment. FIG. 15 is a schematic side view showing a punching apparatus for an optical film according to a third embodiment. FIG. 16 is a reference diagram showing the previous problem.

1: Original optical film 2: Knife support sheet 5: seams 51: Splicing Tape 61: Cut off knife 611: Part 1 612: Part 2 Y: intersection

Claims (9)

A punching device for an optical film, which uses a cutting blade to punch an optical film original sheet to manufacture a plurality of thin film products, and comprises: a conveying part for supporting a blade supporting sheet for supporting the edge of the cutting blade, and The above-mentioned optical film original sheets are conveyed in the longitudinal direction, respectively; and a press processing unit that presses the above-mentioned cutting blade against the above-mentioned optical film original sheet from the side opposite to the above-mentioned knife supporting sheet; A seam formed by connecting the first end face and the second end face of the material, the seam extends in a direction intersecting with the extending direction of the cutting blade, and in the punching part, the original optical film sheet is punched. The seam between the cutting blade and the blade supporting sheet does not overlap linearly, but intersects at the intersection. The punching apparatus for an optical film according to claim 1, wherein the seam of the blade supporting sheet extends obliquely with respect to the short side direction of the blade supporting sheet perpendicular to the longitudinal direction. The punching device for an optical film according to claim 1 or 2, wherein a splicing tape covers the seam and is attached to the knife supporting sheet across the first end and the second end of the sheet, and the splicing The thickness of the tape is 50 μm or less. A method of manufacturing a film product, which is a method for obtaining a plurality of film products by punching an optical film original sheet with a cutting knife, and comprising the steps of: a knife supporting sheet supporting the cutting edge of the cutting knife, and the above-mentioned optical film The original films were Conveying in the longitudinal direction; by pressing the cutting blade against the optical film original sheet from the side opposite to the blade supporting sheet, a plurality of film products are punched out from the optical film original sheet; the blade supporting sheet has The seam formed by connecting the first end face and the second end face of the sheet, the seam of the knife supporting sheet extends in a direction intersecting with either edge of the punched film product, and the punching treatment step Among them, the seam between the cutting blade for punching the optical film original sheet and the blade supporting sheet does not overlap linearly but intersects at the intersection. The method for producing a film product according to claim 4, wherein the seam of the above-mentioned blade supporting sheet extends obliquely with respect to the short-side direction of the above-mentioned blade supporting sheet, which is orthogonal to the long-side direction. The method for producing a film product according to claim 4 or 5, wherein the film product is substantially quadrilateral in plan view, and the substantially quadrilateral shape in plan view has a longitudinal side substantially parallel to the longitudinal direction of the optical film original sheet and a distance between the optical film original sheet and the optical film original sheet. A horizontal side that is approximately parallel to the short side direction. The method for producing a film product according to claim 4 or 5, wherein a splicing tape covers the seam and is attached to the knife supporting sheet across the first end and the second end of the sheet, and the splicing The thickness of the tape is 50 μm or less. The method for producing a film product according to claim 4 or 5, wherein the film product comprises a surface protective film laminated via an adhesive layer. The method for producing a film product according to claim 4 or 5, wherein the film product includes a polarizing element.

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