TWI770290B - Manufacturing method and manufacturing apparatus of optical member - Google Patents

Abstract

The present invention provides a manufacturing method and a manufacturing apparatus of optical member, by which adhesion of powder such as polishing swarf is less likely to adhere to the optical member.

The manufacturing method of optical member according to the present invention including the steps of: preparing a laminate 100 having an optical film 50 and an adhesive layer 80 disposed on one surface of the optical film 50 and having powders f adhered to its end face E; and colliding dry ice particles d against the end face E of the laminate 100 to remove the powders f from the end face E.

Description

Manufacturing method and manufacturing apparatus of optical member

The present invention relates to a manufacturing method and a manufacturing apparatus of an optical member.

Conventionally, an optical member including an optical film such as a polarizer and an adhesive layer is known.

As a method of obtaining an optical member of a desired size, the method of dicing the raw material laminated body which has an optical film and an adhesive bond layer by a laser or a blade is known (refer patent documents 1 and 2).

[Prior Art Literature] [Patent Literature]

[Patent Document 1] WO2014/189078

[Patent Document 2] Japanese Patent Laid-Open No. 2009-86675

However, in recent years, requirements for the dimensional accuracy of optical members using optical films and adhesive layers have become stricter. Therefore, it is still difficult to obtain the desired dimensional accuracy by simply cutting the raw material laminate. Among them, grinding, polishing, etc. may be performed on the end surface of the layered body after cutting.

However, when grinding or the like is performed on the end surface of the layered body, powder such as grinding dust may adhere to the end surface of the layered body. If the powder remains in the layered product, it is not preferable because it causes contamination of the final product including the layered product.

The present invention has been made in view of the above-mentioned problems, and an object thereof is to provide a method and an apparatus for manufacturing an optical member with less adhesion of powders such as grinding dust.

The manufacturing method of the optical member of the present invention comprises the steps of: preparing a layered body having an optical film and an adhesive layer provided on one side of the optical film and adhering powder to the end surface (preparation step); The step of removing the powder from the end face by colliding the end face of the body with dry ice particles (collision step).

According to the present invention, powders such as cutting chips, cutting chips, and grinding chips are appropriately removed from the end face of the layered body (optical member) with dry ice particles.

Here, the average particle diameter of the aforementioned dry ice particles may be 100 to 1000 μm.

Thereby, powder such as grinding chips can be appropriately removed, and at the same time, the defect of the adhesive on the end face can be suppressed.

Moreover, in the said collision process, the end surface of the laminated structure in which the said laminated body was laminated|stacked in a plurality of layers can be made to collide with the said dry ice particle.

Thereby, the laminated body can be processed in large quantities.

Moreover, at least one selected from the group consisting of cutting, cutting and grinding may be performed on the other part of the end surface of the layered body while causing a part of the end surface to collide with the dry ice particles.

Thereby, a plurality of steps can be performed in parallel at the same time, and the step time can be shortened.

In addition, in the preparation step, the end face may be subjected to at least one treatment selected from the group consisting of cutting, cutting and grinding, and when a part of the end face is collided with the dry ice particles, the end face may not be subjected to a treatment selected from the group consisting of cutting, cutting and grinding. Any of the aforementioned groups.

Thereby, since the environment (space) where the powder is removed by the collision of the dry ice particles and the processing environment (space) where the powder is generated can be distinguished, it is possible to prevent the powder generated by the end face machining from colliding with the dry ice part of it is contaminated.

The aforementioned optical film may be at least one selected from the group consisting of polarizer, protective film, retardation film, brightness enhancement film, window film, and touch sensor, or may include two or more layers selected from the aforementioned group At least one type of laminate film may be a laminate film containing at least two types selected from the aforementioned group.

The relative humidity of the environment in the aforementioned collision step may be 30 to 75%.

The manufacturing apparatus of the optical member of this invention is equipped with the end surface processing part which cuts, cuts or grinds the end surface of the laminated body which has the optical film and the adhesive layer provided on one side of the said optical film, and makes the said laminated body The dry ice particle supply part where the processed part of the end surface processing part collides with the dry ice particles.

The manufacturing apparatus of the said optical member may further comprise the conveyance part which moves the said laminated body between the said end surface processing part and the said dry ice particle supply part.

ADVANTAGE OF THE INVENTION By this invention, the manufacturing method and manufacturing apparatus of an optical member with little adhesion|attachment of powder, such as grinding dust, can be provided.

2‧‧‧Protective film

3‧‧‧Polarizer

50‧‧‧Optical Film

70‧‧‧Protective film

80‧‧‧Adhesive layer

90‧‧‧Isolation film

100‧‧‧Laminate

120‧‧‧Laminated structure

200‧‧‧End face processing department

210‧‧‧Rotating shaft

220‧‧‧Disc

230‧‧‧Cutter

240‧‧‧Cylinder

250‧‧‧Long Blade

300‧‧‧Dry Ice Particle Supply Department

310‧‧‧Liquid carbon dioxide source

320‧‧‧Nozzle

330‧‧‧Transport gas source

340, 360‧‧‧valve

350‧‧‧ orifice

400‧‧‧Conveying Department

410‧‧‧Rotating mechanism

420‧‧‧Upper aids

420a‧‧‧Dry ice particle supply port

422‧‧‧Lowering aids

422b‧‧‧Dry ice particle recovery port

430‧‧‧Cylinder

440‧‧‧Mobile Mechanisms

1000‧‧‧Manufacturing equipment of optical components

d‧‧‧Dry ice particles

E‧‧‧End face

f‧‧‧Powder

L1, L2‧‧‧Pipeline

Fig. 1(a) and Fig. 1(b) are cross-sectional views of a layered body 100 according to an embodiment of the present invention.

Fig. 2(a) and Fig. 2(b) are sectional views of another example of the laminated body, respectively.

FIG. 3 is a schematic configuration diagram of a dry ice particle supply unit.

FIG. 4 is a conceptual diagram showing a state in which the end face of the laminated structure 120 including the plural laminated structure 100 collides with dry ice particles.

Fig. 5 is a perspective view of an optical member manufacturing apparatus according to an embodiment of the present invention.

Fig. 6 is a perspective view showing another example of the end surface processing portion shown in Fig. 5 .

Fig. 7 is a conceptual diagram showing a state in which the inner end face of the laminated structure 120 provided with the through hole H' collides with dry ice particles.

The manufacturing method and manufacturing apparatus of the optical member which concerns on embodiment of this invention are demonstrated simultaneously with reference to drawings.

(Preparation of a layered product with powder attached to the end surface)

First, as shown in FIG. 1( a ), a laminate 100 having the optical film 50 and the adhesive layer 80 provided on one surface of the optical film 50 and having the powder f adhered to the end surface E thereof is prepared. In addition, the end surface E is not limited to the end surface of the outer side of the laminated body 100 . For example, as shown in FIG. 1(b), when the layered body 100 has a hole H penetrating in the direction of the layering, powder such as pore-cutting chips adheres to the inner wall of the hole H, that is, the end surface E inside the layered body 100. f.

(optical film)

The so-called optical film 50 refers to a thin film that transmits at least a part of visible light.

Examples of the optical film 50 are polarizers, protective films, retardation films, brightness enhancement films, window films, and touch sensors. The optical film 50 may have a single type of laminate structure with a plurality of these films, or may It has a laminated structure having plural kinds of these thin films.

(Polarizer)

The so-called polarizer refers to a film in which the transmittance of linearly polarized light is different from each other in two vertical directions within the surface. As the material of the polarizer, known materials used in the production of polarizers can be used, for example, polyvinyl alcohol-based resins, polyvinyl acetate resins, ethylene/vinyl acetate (EVA) resins, polyamide resins, polyvinyl Ester resin, etc. Among them, polyvinyl alcohol-based resins are preferred. After these resin films are stretched, dyeing with iodine or a dichroic dye and boric acid treatment are performed, whereby a film-shaped polarizer (film-type polarizer) can be obtained.

The thickness of the film-type polarizer can be set to, for example, 1 to 75 μm.

In addition, another example of the aforementioned polarizer may be a liquid crystal coating-type polarizer formed of a liquid crystalline compound. This liquid crystal coating-type polarizer can be produced, for example, by using a suitable substrate and applying a liquid crystal polarizing composition on the substrate. Before the substrate is coated with the liquid crystal polarizing composition, an alignment film can be formed. The liquid crystal polarizing composition may contain a liquid crystal compound and a dichroic dye compound. The aforementioned liquid crystal compound is only required to have the property of exhibiting a liquid crystal state, especially a high-grade liquid crystal state such as nematic liquid crystal, and the resulting liquid crystal coated polarizer can exhibit high polarizing performance, so it is preferable. Moreover, it is also preferable that the said liquid crystalline compound has a polymerizable functional group. The dichroic dye compound is a dye that aligns with the liquid crystal compound and exhibits dichroism, and the dichroic dye itself may have liquid crystallinity or a polymerizable functional group. Any of the compounds contained in the liquid crystal polarizing composition preferably has a polymerizable functional group. The aforementioned liquid crystal polarizing composition may further contain an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a cross-linking agent, a silane coupling agent, and the like.

Here, a typical example of the method is shown, in which an alignment film is formed on a substrate, and a liquid crystal coating-type polarizer is produced by coating a liquid crystal polarizing composition on the substrate on which the alignment film is formed.

The thickness of the liquid crystal-coated light-type polarizer produced by this method can be thinner than that of the aforementioned film-type polarizer. The thickness of the aforementioned liquid crystal-coated optical polarizer is 0.5 to 10 μm, preferably 1 to 5 μm.

For example, the alignment film system can form an alignment film on the substrate by imparting alignment by rubbing, polarized light irradiation, or the like to a coating film formed by applying an alignment film forming composition on a substrate. The aforementioned composition for forming an alignment film contains an alignment agent, and may also contain a solvent, a crosslinking agent, an initiator, a dispersant, a leveling agent, a silane coupling agent, and the like in addition to the alignment agent. As said alignment agent, polyvinyl alcohol, polyacrylic acid, polyamic acid, and polyimide are mentioned, for example. When photo-alignment is applied as a method for imparting the above-mentioned alignment property, an alignment agent containing a cinnamic acid ester group is preferable.

The aforementioned alignment agent may be a polymer. The weight average molecular weight of the polymer alignment agent is about 10,000 to 1,000,000. The thickness of the aforementioned alignment film formed on the aforementioned substrate is preferably 5 nm to 10000 nm, especially when it is 10 to 500 nm, since sufficient alignment restraining force is exhibited, it is preferable.

The liquid crystal polarizing composition is coated on the substrate on which the alignment film is formed, and dried as necessary to form a coating film of the liquid crystal polarizing composition, and a liquid crystal coating type polarizer is produced from the coating film of the liquid crystal polarizing composition.

The aforementioned liquid crystal polarizer produced in this way can be peeled off from the base material. The method of peeling the liquid crystal coating type polarizer from the substrate, for example, after the second substrate is attached to the surface of the unlayered substrate of the liquid crystal coating type polarizer, the substrate is peeled off to obtain a first The laminate composed of 2 substrates, by using this method, the liquid crystal coated polarizer can be transferred to the second substrate, or the liquid crystal coated polarizer can not be transferred to the second substrate, and the laminate can be maintained as described above. The state of the substrate. It is preferable that the said base material or the said 2nd base material also functions as a transparent base material of a protective film, a retardation plate, and a window film.

(protective film)

The protective film is a transparent film that prevents damage such as scratches on other optical films such as polarizers, and/or damages such as scratches on the optical device (liquid crystal cell, etc.) to which the laminated body 100 is to be attached later. The protective film may be various transparent resin films.

Here, the protective film which protects a polarizer is described. Examples of resins forming the protective film are the following: cellulose-based resins represented by cellulose triacetate; polyolefin-based resins represented by polypropylene-based resins; Cyclic olefin resins; acrylic resins represented by polymethyl methacrylate resins; and polyester resins represented by polybutylene terephthalate resins. Among these, cellulose-based resins are representative.

The thickness of the protective film may be, for example, 5 to 90 μm.

The aforementioned protective film can optionally contain plasticizers, ultraviolet absorbers, infrared absorbers, colorants of pigments or dyes, optical brighteners, dispersants, heat stabilizers, light stabilizers, antistatic agents, antioxidants, lubricants agents, solvents, etc.

In order to improve the scratch resistance of the surface of the protective film, a hardened coating can be provided on at least one side of the protective film. The thickness of the hardened coating is usually in the range of 2 to 100 μm. When the thickness of the hard coat layer is less than 2 μm, it is difficult to ensure sufficient scratch resistance, and when it exceeds 100 μm, the buckling resistance decreases, and when the protective film is attached to a polarizer, etc., there may be cases of curing shrinkage. The problem of curling.

The above-mentioned hard coat layer can be formed from a hard coat composition containing a reactive material that forms a cross-linked structure when irradiated with active energy rays or thermal energy rays. Among these, a hardened coating obtained by irradiation with active energy rays is preferable. The so-called active energy ray is defined as an energy ray that can decompose an active species-generating compound to generate an active species. Examples of active energy rays include visible light, ultraviolet rays, infrared rays, X-rays, alpha rays, beta rays, gamma rays, and electron beams. Among them, particularly preferred is ultraviolet rays. It is preferable that the said hardening coating composition contains at least 1 type of a radically polymerizable compound and a cationically polymerizable compound. An oligomer obtained by partial polymerization of these radically polymerizable compounds and cationically polymerizable compounds may be included in the hard coating composition.

First, the radically polymerizable compound will be described.

The aforementioned radically polymerizable compound refers to a compound having a radically polymerizable group. The radically polymerizable group may be a functional group capable of generating a radical polymerization reaction, and examples thereof include a carbon-carbon unsaturated double bond-containing group, and the like, and a vinyl group, a (meth)acryloyl group, and the like are listed side by side. Moreover, when the said radically polymerizable compound has two or more radically polymerizable groups in 1 molecule, these radically polymerizable groups may be the same or different, respectively. When the above-mentioned radically polymerizable compound has two or more radically polymerizable groups in one molecule, the hardness of the obtained cured coating layer tends to increase. Among the above-mentioned radically polymerizable compounds, those having a (meth)acryloyl group are preferable in terms of their high degree of reactivity, and for example, those having 2 to 6 (meth)acryloyl groups in one molecule are mentioned. Compounds called polyfunctional acrylate monomers, or compounds called epoxy (meth)acrylates, urethane (meth)acrylates, and polyester (meth)acrylates that have in the molecule Oligomers with several (meth)acryloyl groups and molecular weights ranging from hundreds to thousands. Among the compounds having a (meth)acryloyl group, at least one selected from epoxy (meth)acrylate, urethane (meth)acrylate and polyester (meth)acrylate is better.

Next, the cationically polymerizable compound will be described.

The aforementioned cationically polymerizable compound refers to a compound having a cationically polymerizable group such as an epoxy group, an oxetanyl group, and a vinyl ether group. The number of the cationically polymerizable groups contained in one molecule of the cationically polymerizable compound is preferably 2 or more, and more preferably 3 or more, from the viewpoint of increasing the hardness of the resulting cured coating. Moreover, it is preferable that the said cationically polymerizable compound is a compound which has at least one cationically polymerizable group of an epoxy group and an oxetanyl group. The epoxy group or the cyclic ether group of the oxetanyl group has the advantage of less shrinkage accompanying the polymerization reaction. In addition, compounds having an epoxy group in a cyclic ether group are easily commercially available with various structures, and are less likely to adversely affect the durability of the resulting hard coat. When the curing coating composition is a combination of a radically polymerizable compound and a cationically polymerizable compound, the compound having an epoxy group has an advantage of being easy to control the compatibility with the radically polymerizable compound. In addition, the oxetanyl group in the cyclic ether group has the following advantages: the degree of polymerization is easily higher than that of the epoxy group, the toxicity is low, and the network formation from the cationically polymerizable compound of the obtained hard coat layer is improved. The speed and the region mixed with the radically polymerizable compound do not leave unreacted monomers in the film to form an independent network, and the like.

Examples of the compound having an epoxy group include: polyglycidyl ether of a polyol having an alicyclic ring; Alicyclic epoxy resins obtained by oxidation; polyglycidyl ethers of aliphatic polyols or their alkylene oxide adducts; polyglycidyl esters of aliphatic long-chain polyacids; polyglycidyl esters of (meth)acrylates Aliphatic epoxy resins such as homopolymers and copolymers; bisphenols such as bisphenol A, bisphenol F or oxidized bisphenol A, or their alkylene oxide adducts, caprolactone adducts, etc. Glycidyl ethers produced by the reaction of derivatives and epichlorohydrin; and glycidyl ether-type epoxy resins derived from bisphenols such as novolak epoxy resins.

The aforementioned hard coating composition may further contain a polymerization initiator. As the polymerization initiator, an appropriate polymerization initiator (radical polymerization initiator, cationic polymerization initiator) can be selected and used according to the type of the polymerizable compound contained in the hardening coating composition. These polymerization initiators are decomposed by at least one of active energy ray irradiation and heating, and generate radicals or cations for radical polymerization or cationic polymerization.

The radical polymerization initiator may be any substance capable of releasing radical polymerization by at least one of active energy ray irradiation and heating. For example, the thermal radical polymerization initiator includes organic peroxides such as hydrogen peroxide and peroxybenzoic acid, azo compounds such as azobisbutyronitrile, and the like.

Active energy ray radical polymerization initiators include Type 1 radical polymerization initiators that generate radicals due to molecular decomposition, and Type 2 radical polymerization initiators that coexist with tertiary amines to generate radicals in a hydrogen extraction type reaction The initiators can be used alone or in combination.

The cationic polymerization initiator may be any one capable of releasing a substance capable of initiating cationic polymerization by at least one of active energy ray irradiation and heating. As the cationic polymerization initiator, an aromatic iodonium salt, an aromatic periconium salt, a cyclopentadienyl iron (II) complex, or the like can be used. Depending on the configuration, these may be subjected to either or both of active energy ray irradiation or heating to initiate cationic polymerization.

The content of the aforementioned polymerization initiator may be 0.1 to 10 wt % with respect to the entire weight of the aforementioned hard coating composition. If the content of the polymerization initiator is less than 0.1 wt %, curing cannot proceed sufficiently, and the mechanical properties of the finally obtained cured coating layer are likely to decrease, or the adhesion between the cured coating layer and the protective film is likely to be difficult to exhibit. When the content exceeds 10% by weight, poor adhesion, cracking, and curling may occur due to hardening shrinkage during formation of the hardened coating.

The aforementioned hard coating composition may further contain one or more selected from the group consisting of solvents and additives.

The above-mentioned solvent can be used without limitation as long as it can dissolve or disperse the above-mentioned polymerizable compound and polymerization initiator, as long as it is known as a solvent for a hardening coating composition in the technical field.

The aforementioned additives are inorganic particles, leveling agents, stabilizers, surfactants, antistatic agents, lubricants, antifouling agents, and the like.

Next, the method at the time of bonding a protective film to a polarizer is demonstrated.

The protective film of the polarizer is preferably attached to the polarizer via an adhesive. Examples of the adhesive include water-based adhesives using polyvinyl alcohol-based resin aqueous solutions, water-based two-component urethane-based emulsion adhesives, and the like; curable compositions using a polymerizable compound and a photopolymerization initiator; Curable compositions containing photoreactive resins, curable compositions containing binder resins and photoreactive crosslinking agents, and other active energy ray-curable adhesives.

The polyvinyl alcohol-based resin contained in the polyvinyl alcohol-based resin aqueous solution used as an adhesive is not a vinyl alcohol homopolymer obtained by saponifying polyvinyl acetate, which is a homopolymer of vinyl acetate. There are vinyl alcohol-based copolymers obtained by saponifying copolymers of vinyl acetate and other monomers that can be copolymerized with vinyl acetate, and modified polyvinyl alcohol-based polymers obtained by modifying these hydroxyl moieties. things etc. To such a water-based adhesive, a polyaldehyde, a water-soluble epoxy compound, a melamine-based compound, a zirconia compound, a zinc compound, and the like can be further added as additives.

Moreover, the active energy ray hardening type adhesive agent used as an adhesive agent is the same as one of the said hardening coating compositions listed, ie, the thing containing the reactive material which irradiates an active energy ray and forms a crosslinked structure.

Although the method of using a resin film as a protective film (or a protective film with a hard coat layer) and attaching it to a polarizer has been described above, a thinner protective layer can also be directly laminated on the polarizer to serve as a protective film to replace the aforementioned resin film.

In the method of directly laminating a thinner protective layer on a polarizer, for example, a coating film containing an active energy ray curable resin is formed on the surface of the polarizer, and the coating film is irradiated with active energy rays (UV, etc.) By curing, a protective film thinner than a conventional protective film can be directly formed on the surface of the polarizer. The active energy ray-curable resin is listed as one of the above-mentioned cured coating compositions, that is, one containing a reactive material that forms a cross-linked structure by irradiating active energy rays.

(window film)

On the other hand, a transparent protective film that prevents damage such as scratches on an optical device (liquid crystal cell, etc.) to which the laminated body 100 is to be attached later is also referred to as a window film. For example, when the optical film 50 has a laminated structure having a plurality of films, the window film is arranged on the outermost surface on the opposite side to the surface on which the adhesive layer 80 is provided among the plurality of films.

The window film is arranged on the viewing side of the flexible image display device, and plays a role of protecting other components from external shocks and environmental changes such as temperature and humidity. The conventional protective layer uses glass, but the window film in the flexible image display device is not as rigid as glass, but has flexibility. The aforementioned window film is composed of a flexible transparent substrate, and may contain a hard coating on at least one side.

(transparent substrate)

Describes a transparent substrate that can be used as a window film.

The visible light transmittance of the transparent substrate is 70% or more, preferably 80% or more. As long as the said transparent base material is a polymer film which has transparency, any one can be used. Specifically, the transparent base material may be a film formed of the following polymers, or a film formed by using these polymers alone or by mixing two or more of them: Polyolefins such as cycloolefin derivatives of monomeric units of pentene, norbornene or cycloolefin; (modified) celluloses such as cellulose diacetate, cellulose triacetate, and cellulose propionate; methyl methacrylate Acrylics such as methyl acrylate (co)polymers; polystyrenes such as styrene (co)polymers; acrylonitrile-butadiene-styrene copolymers, acrylonitrile-styrene copolymers; ethylene-acetic acid Vinyl ester copolymers; polyvinyl chloride, polyvinylidene chloride; polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyarylate, etc. Polyesters; nylons and other polyamides; polyamides, polyamides, polyetherimides; polyethers, polyethers; polyvinyl alcohols, polyamides Vinyl acetals; polyurethanes; epoxy resins, etc.

In addition, an unstretched, uniaxial or biaxial stretched film may be used for the film. Preferably, among the listed polymer transparent substrates, polyamide films, polyamide imide films or polyimide films, polyester films, olefin films, which are excellent in transparency and heat resistance , acrylic film, cellulose film is appropriate. Moreover, in the said transparent base material, it is also preferable to disperse|distribute inorganic particles, organic fine particles, rubber particles, etc., such as silicon oxide. In addition, it may also contain colorants such as pigments or dyes, optical brighteners, dispersants, plasticizers, heat stabilizers, light stabilizers, infrared absorbers, ultraviolet absorbers, antistatic agents, antioxidants, lubricants agents, solvents, etc. The thickness of the aforementioned transparent substrate is 5 to 200 μm, preferably 20 to 100 μm.

(hardening coating)

At least one side of the transparent substrate can be provided with a hard coat layer as a window film. As the hard coat layer, the same ones as those of the above-mentioned protective film can be used.

(retardation film)

The retardation film is a transparent film in which the refractive index is different from each other in the two vertical directions in the surface, and which imparts a retardation to the transmitted light.

Examples of the material of the retardation film are a polycarbonate-based resin film, a polysilicon-based resin film, a polyether-based resin film, a polyarylate-based resin film, and a norbornene-based resin film.

These resin films can be given a desired retardation by extending.

Moreover, the retardation film which is easily obtained on the market can also be used.

The thickness of the retardation film may be, for example, 0.5 to 80 μm.

(brightness enhancement film)

The brightness enhancement film is a film that transmits polarized light parallel to the first direction in the surface and reflects the polarized light parallel to the second direction perpendicular to the first direction in the surface. When the optical film used in the present invention has a polarizer, it is preferable to make the first direction coincide with the transmission axis of the polarizer.

The brightness enhancement film may be a multilayer laminate in which a layer having birefringence and a layer having substantially no birefringence are alternately laminated. Examples of materials for layers with birefringence are naphthalene dicarboxylic acid polyesters (such as polyethylene naphthalate), polycarbonates, and acrylic resins (such as polymethyl methacrylate), which are substantially free of birefringence. An example of a refracting layer is a copolyester of naphthalene dicarboxylic acid and terephthalic acid.

The thickness of the brightness enhancement film may be, for example, 10 to 50 μm.

Each of the thin films constituting the optical film listed above may have a plurality of functions. For example, the protective film may be a film having both optical functions of a retardation film or a brightness enhancement film.

(Following in Optical Film)

When the optical film 50 has a laminated structure including a plurality of thin films, the thin films can be bonded via an adhesive. The adhesive is not particularly limited, and may be any of the above-mentioned water-based adhesives or active energy ray-curable adhesives.

In addition, an adhesive can also be used as an adhesive. The adhesive will be described later.

The thickness of the adhesive can be set to 1 to 200 μm.

(Thickness of the optical film in the case of a laminate)

When the optical film 50 has a laminated structure including a plurality of thin films, the thickness of the entire optical film 50 can be set to 10 to 1200 μm.

(adhesive layer)

As mentioned above, the lamination system used in the present invention has an optical film and an adhesive layer provided on one side thereof. The adhesive layer refers to what is formed by an adhesive. Here, the adhesive will be described.

The so-called adhesive refers to a pressure-sensitive adhesive, which exhibits a soft solid (viscoelastic) state in a temperature range around room temperature (for example, 25°C), and has the ability to easily adhere to the adherend due to pressure. material of nature. The adhesive referred to here is as defined in "CADahlquist, Adhesion: Fundamentaland Practice", McLaren & Sons, (1966), P.143". Materials with properties of <10 ⁷ dyne/cm ² (typically materials with the above properties at 25°C). The adhesive in the technique disclosed here can also be understood as the solid matter (non-volatile component) of the adhesive composition or the constituent component of the adhesive layer.

Examples of adhesives are composed of acrylic resins, styrene resins, polysiloxane resins, etc. as matrix polymers, and crosslinking agents such as isocyanate compounds, epoxy compounds, and aziridine compounds are added therein. thing. In this specification, the "matrix polymer" of an adhesive means the main component of the rubber-like polymer contained in the adhesive. The above-mentioned rubbery polymer refers to a polymer that exhibits rubber elasticity in a temperature range around room temperature. In addition, in this specification, the "main component" means the component whose content exceeds 50weight%, unless otherwise noted.

The thickness of the adhesive can be set to 1 to 40 μm.

(Thickness of the optical film in the case of a laminate)

When the optical film 50 has a laminated structure including a plurality of thin films, the thickness of the entire optical film 50 can be set to 10 to 1200 μm.

The adhesive layer 80 is provided on at least one surface of the optical film (single-layer structure or multilayer structure) 50 .

As the adhesive, the aforementioned ones can be used.

(isolation film)

The laminated body 100 may have the release film 90 on the surface opposite to the surface of the adhesive layer 80 that is in contact with the optical film 50.

The so-called release film 90 is a film whose adhesiveness with the adhesive layer 80 is weaker than that of the optical film 50 . The separator 90 protects the surface of the adhesive layer 80 during transport or storage of the laminate 100 before the optical film 50 is attached to other members such as an optical device (liquid crystal cell) via the adhesive layer 80 . When the adhesive layer 80 is attached to another member, the release film 90 is easily peeled off from the adhesive layer 80 .

The isolation film does not need to be transparent, but is preferably transparent. An example of the material of the separator is polyethylene terephthalate. The thickness of the separator can be set to 1 to 40 μm.

(protective film)

Moreover, the laminated body 100 may have the pellicle film 70 arrange|positioned at the outer surface opposite to the surface in which the adhesive layer 80 was provided in the optical film 50.

The pellicle 70 has the function of suppressing the optical device during processing of the layered body 100, when the layered body 100 is attached to an optical device (liquid crystal cell, etc.), or when the optical device to which the layered body 100 is attached is conveyed. And/or the scratching function of the optical film 50 .

Examples of the material of such a pellicle are polyethylene terephthalate, polyethylene, polypropylene, and the like. The protective film 70 does not need to be transparent, but is preferably transparent. The thickness of the pellicle film may be set to 1 to 40 μm.

The protective film 70 may also have a film for protecting the optical film 50 before the product using the optical film 50 is used. At this time, after the optical film 50 is attached to the optical device (liquid crystal cell, etc.) via the adhesive layer 80 , the pellicle film 70 is not peeled off from the optical film 50 .

The protective film 70 can be attached to the optical film 50 through an adhesive layer or by self-adhesion caused by electrostatic adsorption.

A specific example of the laminated structure of the laminated body 100 is shown in Fig. 2(a) and Fig. 2(b).

In the laminated body 100 of FIG. 2(a), a protective film 70, a protective film 2, a polarizer 3, a protective film 2, an adhesive layer 80, and a separator 90 are laminated in this order. The protective film 2 , the polarizer 3 , and the protective film 2 constitute the optical film 50 .

In the laminated body 100 of FIG. 2(b), the protective film 70, the protective film 2, the polarizer 3, the adhesive layer 80, and the separator 90 are laminated in this order. The protective film 2 and the polarizer 3 constitute the optical film 50 . In addition, although not shown, in all the examples, the films in each optical film 50 can be bonded by an adhesive or an adhesive.

(Laminated product for flexible image display device)

The optical film 50 used in the present invention may be a laminate for a flexible image display device used in a flexible image display device such as a bendable device.

A typical example of this flexible image display device is an image display device including a laminate for a flexible image display device and an organic EL display panel. In this typical example, the laminated body for a flexible image display device is usually arranged on the viewing side with respect to the organic EL display panel, and the flexible image display device constitutes a bendable one. The laminate for a flexible image display device may include a window film, a circular polarizer, and a touch sensor, and the order of lamination of these may be arbitrary, but the order from the viewing side is a window film, a circular polarizer Preferably, the stacking sequence of the touch sensor or the stacking sequence of the window film, the touch sensor and the circular polarizer is preferably formed. When there is a circular polarizer on the viewing side of the touch sensor, the pattern of the touch sensor is difficult to observe, and the visibility of the displayed image becomes better, which is preferable. Each member can be laminated using an adhesive, an adhesive, or the like. In addition, a light shielding pattern formed on at least one side of any one of the above-mentioned window film, circular polarizer, and touch sensor may be provided.

(circular polarizer)

The circularly polarizing plate is a functional film having a function to transmit only right or left circularly polarized light components by laminating a λ/4 retardation plate as a retardation film on a linear polarizing plate. When the external light entering the display device passes through the circularly polarizing plate arranged on the viewing side, it is converted into right circularly polarized light and emitted to the organic EL panel side. When the right circularly polarized light is reflected (reflected light) by the metal electrode of the organic EL panel, the reflected light becomes left circularly polarized light. Since the left circularly polarized light cannot penetrate the circular polarizing plate, as a result, the reflected light is not emitted out of the display device. With such a function, only the light-emitting component that is seen in the display panel of the display device becomes the organic EL, and only the light-emitting component is allowed to pass through, so that the influence of reflected light can be prevented, and the image can be easily viewed.

In order to achieve the function of circular polarization, the absorption axis of the linear polarizer and the slow axis of the λ/4 retardation plate must be theoretically 45°, but practically it is 45±10°. The linear polarizer and the λ/4 retardation plate do not need to be stacked adjacent to each other, as long as the relationship between the absorption axis and the slow axis satisfies the aforementioned range. Although it is preferable to achieve complete circular polarization in all wavelengths, it is not necessary in practicality, so the circular polarizing plate of the present invention also includes an elliptical polarizing plate. A λ/4 retardation plate is further laminated on the viewing side of the linear polarizer to make the outgoing light circularly polarized, thereby improving the viewing performance in the state of wearing polarized sunglasses.

The so-called linear polarizer refers to a functional layer having a function of allowing light vibrating in the direction of the transmission axis to pass, but blocking the polarized light of the vibration component perpendicular to it. The aforementioned linear polarizing plate is usually composed of a polarizer and a protective film attached to at least one side thereof. The polarizer can be any of the aforementioned film-type polarizers or liquid crystal coating-type polarizers. As the protective film, what has been described can be used. The thickness of the linear polarizing plate constituting the circular polarizing plate is preferably 200 μm or less, and more preferably 0.5 μm to 100 μm. When this thickness exceeds 200 micrometers, the flexibility (flexibility) applicable to the laminated body for flexible image display apparatuses may fall. By adjusting the thickness of the polarizer and the protective film, the appropriate thickness of the linear polarizer can be adjusted.

The aforementioned λ/4 retardation film as a retardation film is also referred to as a quarter wave plate, and is one that imparts a retardation of π/2 (=λ/4) to the polarization plane of incident light. A retardation film with such properties can be selected from the aforementioned retardation films to prepare a λ/4 retardation plate, but as another example, a liquid crystal coating type retardation plate formed by coating a liquid crystal composition can also be used as λ/4 retardation plate. The liquid crystal coating-type retardation plate formed by applying this liquid crystal composition can be described later, and a λ/4 retardation plate having an extremely thin thickness can be obtained. Therefore, this liquid crystal coating-type retardation plate is particularly preferable as a λ/4 retardation plate as a circularly polarizing plate constituting a laminate for a flexible image display device.

Here, the liquid crystal composition forming the aforementioned λ/4 retardation plate will be described.

The liquid crystal composition includes a liquid crystal compound having a property of exhibiting liquid crystal states such as nematic, cholesteric, and smectic. The aforementioned liquid crystal compound has a polymerizable functional group. The liquid crystal composition may contain plural kinds of liquid crystal compounds, and when plural kinds of liquid crystal compounds are contained, at least one of the liquid crystal compounds has a polymerizable functional group. The aforementioned liquid crystal composition may further contain an initiator, a solvent, a dispersant, a leveling agent, a stabilizer, a surfactant, a cross-linking agent, a silane coupling agent, and the like. The aforementioned liquid crystal coating type retardation plate is the same as that described in the aforementioned manufacturing method of the liquid crystal polarizer, by coating the liquid crystal composition on the alignment film of the substrate having the alignment film preliminarily formed and curing it, so as to achieve alignment It is manufactured by forming a liquid crystal retardation layer on the film. The thickness of the liquid crystal coating type retardation plate can be formed thinner than that of the stretched retardation plate. The thickness of the aforementioned liquid crystal polarizing layer is 0.5 to 10 μm, preferably 1 to 5 μm. The liquid crystal coating-type retardation plate may be peeled from the base material, transferred and laminated, or the base material may be directly laminated. The aforementioned base material is also preferably used as a transparent base material for a protective film or a retardation plate.

Among the general materials constituting the retardation film, generally, birefringence increases as the wavelength becomes shorter, and birefringence decreases as the wavelength becomes longer. At this time, since the retardation of λ/4 cannot be achieved in the entire visible light region, the in-plane retardation of λ/4 is usually designed to be 100 to 180 nm, preferably 130 to 150 nm, near 560 nm, which has high visual sensitivity. Generally speaking, it is preferable to use an inversely dispersed λ/4 retardation plate of a material having an inverse birefringence wavelength dispersion characteristic, since visibility can be improved. For such a material, it is preferable to use those described in Japanese Patent Laid-Open No. 2007-232873 etc. in the case of a stretched retardation plate, and it is preferable to use Japanese Patent Laid-Open No. 2010-30979 in the case of a liquid crystal coating type retardation plate. recorded in the bulletin.

In addition, as another method for forming a circularly polarizing plate and forming a better retardation film, a technique for obtaining a broadband λ/4 retardation film by combining with a λ/2 retardation film is known (Japanese Patent Laid-Open No. 10-90521 Bulletin No. ). The λ/2 retardation plate is also manufactured using the same material method as the λ/4 retardation plate. The combination of the stretched retardation plate and the liquid crystal coating type retardation plate is optional, but it is preferable to use the liquid crystal coating type retardation plate for both because the thickness of the film can be reduced.

In order to improve the visibility in the oblique direction of the circularly polarizing plate, a method of laminating a positive C-plate is known (Japanese Patent Laid-Open No. 2014-224837). The positive type C plate can also be a liquid crystal coating type retardation plate or an extension type retardation plate. The retardation in the thickness direction of the positive type C plate is -200 to -20 nm, preferably -140 to -40 nm.

(touch sensor)

The touch sensor is used as an input means. Various types of touch sensors have been proposed, such as resistive film type, surface elastic wave type, infrared type, electromagnetic induction type, and capacitive type, and any type may be used. Among these, the capacitive type is preferred.

Viewed from the display panel, the capacitive touch sensor is divided into an active area and an inactive area located on the outer contour of the active area. The active area is the area corresponding to the area (display part) of the display screen of the display panel, which is the area that senses the user's touch, and the inactive area is the area corresponding to the area (non-display part) of the display screen of the display device.

The touch sensor may include: a substrate with flexibility; a sensing pattern formed on an active area of the substrate; and each sensing line formed on an inactive area of the substrate and used to pass through the sensing pattern It is connected to the pad part and an external drive circuit. As the substrate having flexibility, a substrate formed of the same material as the transparent substrate of the aforementioned window film can be used. The substrate of the touch sensor having a turbidity of 2,000 MPa% or more is preferable in terms of suppressing the breakage of the touch sensor. More preferably, the turbidity may be 2,000 MPa% to 30,000 MPa%.

The sensing pattern may include a first pattern formed in the first direction and a second pattern formed in the second direction. The first pattern and the second pattern are arranged in directions different from each other. The first pattern and the second pattern are formed on the same layer, and in order to sense the touch point, each pattern must be electrically connected. The first pattern is a form in which the unit patterns are connected to each other through a junction, but the second pattern is a structure in which the unit patterns are separated from each other into an island form, so additional bridge electrodes are required to electrically connect the second patterns. The sensing pattern is formed of a well-known transparent electrode material. The transparent electrode material includes, for example, indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium zinc tin oxide (IZTO), cadmium tin oxide (CTO), poly(3,4-ethylenedi) Oxythiophene) (PEDOT), carbon nanotube (CNT), graphene, metal wire (the metal used for the metal wire is not particularly limited, for example, silver, gold, aluminum, copper, iron, nickel, titanium, tellurium, Chromium, etc. These can be used alone or in a mixture of two or more) and the like, and these can be used alone or in a mixture of two or more. Preferably it is ITO. A bridge electrode may be formed on the upper part of the sensing pattern via an insulating layer on the upper part of the insulating layer, or a bridge electrode may be formed on the substrate, and the insulating layer and the sensing pattern may be formed on the upper part. The bridge electrode may be formed of the same material as the sensing pattern, or may be formed of a metal such as molybdenum, silver, aluminum, copper, palladium, gold, platinum, zinc, tin, titanium, or an alloy of two or more of these. The first pattern and the second pattern must be electrically insulating, so an insulating layer is formed between the sensing pattern and the bridge electrode. The insulating layer may be formed only between the junction of the first pattern and the bridge electrode, or may be formed as a layer covering the sensing pattern. In the latter case, the bridge electrode can be connected to the second pattern through a contact hole formed in the insulating layer. The aforementioned touch sensor may further include an optical adjustment layer between the substrate and the electrodes to properly compensate for the difference in transmittance between the patterned area with the pattern and the non-patterned area without the pattern. Specifically, In other words, the difference in light transmittance caused by the difference in refractive index in these regions. The aforementioned optical adjustment layer may contain an inorganic insulating substance or an organic insulating substance. The optical adjustment layer can be formed by coating a photocurable composition containing a photocurable organic binder and a solvent on a substrate. The aforementioned photocurable composition may further contain inorganic particles. The refractive index of the optical adjustment layer can be increased by the aforementioned inorganic particles.

The said photocurable organic binder can contain the copolymer of each monomer, such as an acrylate type monomer, a styrene type monomer, and a carboxylic acid type monomer, for example. The aforementioned photocurable organic binder may be, for example, a copolymer containing repeating units different from each other, such as an epoxy group-containing repeating unit, an acrylate repeating unit, and a carboxylic acid repeating unit.

The aforementioned inorganic particles may include, for example, zirconia particles, titanium oxide particles, alumina particles, and the like.

The aforementioned photocurable composition may further contain various additives such as a photopolymerization initiator, a polymerizable monomer, and a curing aid.

Each layer (window film, circular polarizer, touch sensor) which forms the said laminated body for flexible image display apparatuses can be formed with an adhesive agent. As the adhesive, the water-based adhesive, active energy ray-curable adhesive, and adhesive that have been described are generally used.

(shading pattern)

The aforementioned light-shielding pattern can be applied as at least a part of a frame or a casing of the aforementioned flexible image display device. The visibility of the image can be improved by concealing the wiring arranged at the edge portion of the flexible image display device with a light-shielding pattern to make it difficult to see. The aforementioned light-shielding pattern may be in the form of a single layer or a plurality of layers. The color of the light-shielding pattern is not particularly limited, and may be various colors such as black, white, and metallic. The light-shielding pattern can be formed by pigments for developing colors, and polymers such as acrylic resins, ester resins, epoxy resins, polyurethanes, and polysiloxanes. These can also be used individually or as a mixture of 2 or more types. The aforementioned light-shielding pattern can be formed by various methods such as printing, photolithography, and inkjet. The thickness of the light shielding pattern may be 1 μm to 100 μm, preferably 2 μm to 50 μm. Moreover, shapes, such as an inclination, can be given to the thickness direction of a light-shielding pattern.

The optical film and the adhesive contained in the laminate used in the production method of the present invention have been described above. Next, the manufacturing method of the present invention will be described.

(powder)

Referring again to Fig. 1(a) and Fig. 1(b), the manufacturing method of the present invention will be described.

The powder f adhering to the end surface E of the optical film 50 adheres to the end surface by processing the end surface of the layered body 100 . Generally, in order to obtain the layered body 100 of a desired size from the raw material of the layered body 100 , the end surface of the layered body 100 is processed. Examples of processing are cutting, cutting, and grinding. Here, the so-called cutting is a concept including opening. Therefore, as described above, the so-called end face of the laminated body 100 includes not only the end face E on the outer side of the laminated body 100 as shown in FIG. The inner end face E.

The so-called dicing refers to a step of creating a slit from the front surface to the back surface of the laminate by inserting a blade, removing by a laser, etc., whereby the structure of the laminate can be formulated.

The term "cutting" refers to a step of forming a new end face by cutting a part of the end portion of the laminate by bringing a relatively moving cutting blade (blade) into contact with the end portion of the laminate. In addition, this cutting includes hole drilling as described above. The so-called hole drilling process is, for example, as shown in FIG. 1(b), in which a drill or the like is used for the laminated body 100 to provide a hole H at a desired position. In such drilling, powder f (drilling chips) may adhere to the end surface E on the inner side of the inner wall where the hole H is formed.

The term "grinding" refers to a step of cutting a part of the end face by contacting relatively moving abrasive grains (which may be fixed abrasive grains or free abrasive grains) with the end face of the laminated body. Grinding also includes a step called grinding.

For example, after cutting the raw material of the laminated body 100 into a plane shape slightly larger than the desired size with a blade or a laser, the end face of the cut laminated body can be ground and/or polished, and the plane shape of the laminated body can be set in advance. specified dimensions, and can improve the straightness or flatness of the end face.

The planar shape (shape viewed from the thickness direction) of the laminate is not particularly limited. For example, it can be set as a square, a rectangle, a circle, or the like.

Due to such processing of the end face of the layered body, powder of the material constituting the layered body 100 is generated, and a part of the powder adheres to the end face E of the layered body 100 . Therefore, it is one embodiment of the manufacturing process in the manufacturing method of this invention to carry out these processes to the said laminated body. The so-called end surface E may be a surface connecting the two main surfaces of the laminated body 100 .

The average particle diameter of the powder may be, for example, 10 to 3000 μm. The particle size is the D50 of the particle size distribution on a weight basis measured by laser diffraction.

(collision step (powder removal step by collision of dry ice particles))

Next, dry ice particles are caused to collide with the end face E of the layered body 100 to remove the powder f on the end face from the end face.

Specifically, it is suitable to collide with the end surface E of the layered body 100 by transporting the dry ice particles by gas.

The average particle diameter of the dry ice particles to be collided is not particularly limited, but from the viewpoint of efficiently removing the powder, it is preferably 100 μm or more. In addition, from the viewpoint of preventing the adhesive layer from being damaged due to collision with dry ice, the thickness is preferably 1000 μm or less.

The average particle size of the dry ice particles can be measured by a Laser Doppler Velocimeter.

The velocity of the dry ice particles to be collided can be set from 5 m/sec to 100 m/sec.

The conveying gas for dry ice is not particularly limited, and can be, for example, nitrogen, air, or carbon dioxide gas.

Specifically, a dry ice particle supply unit (device) 300 as shown in Fig. 3 can be used.

The apparatus includes a liquid carbon dioxide source 310 , a nozzle 320 , a transport gas source 330 , a line L1 connecting the liquid carbon dioxide source 310 and the nozzle 320 , and a line L2 connecting the transport gas source 330 and the nozzle 320 .

A valve 340 and an orifice 350 are provided in line L1, and a valve 360 is provided in line L2.

The valve 340 is opened to make the liquid of the liquid carbon dioxide source 310 adiabatic expansion at the orifice 350 to generate dry ice particles (dry ice snow) and deliver it to the nozzle 320 . The valve 360 is opened, the gas is supplied from the conveying gas source 330 to the nozzle 320 , and the dry ice particles d are ejected from the nozzle 320 by the gas and supplied to the end surface E of the layered body 100 .

The particle size of the dry ice particles d can be adjusted by the distance from the adiabatic expansion of the orifice 350 until it is ejected from the nozzle 320 (adiabatic expansion distance), or the distance between the nozzle 320 and the supply target of the dry ice particles (ejection distance). In addition, an appropriate preliminary experiment using a dry ice particle supply unit (device) may be performed to confirm the degree of removal of the powder f to adjust the adiabatic expansion distance or the spray distance.

The distance (spray distance) between the nozzle 320 and the end surface E of the layered body 100 is preferably set to be less than 20 mm. In addition, the adiabatic expansion distance can be set to, for example, 10 to 500 mm.

It is suitable that the position of the layered body 100 and the nozzle 320 is relatively moved by the conveyance unit 400 to sweep the end surface E of the portion where the dry ice particles d collide. For example, as shown in FIG. 3, the conveying unit 400 can be used to sweep the layered body 100 on the surface perpendicular to the ejection direction (lateral direction) of the dry ice particles d to move the collision portion of the dry ice particles d on the end face E.

The sweeping speed of the collision portion of the dry ice particles d on the end face E may be set to 1 to 100 m/sec.

(function)

According to this embodiment, since the dry ice particles d are blown to the end face E of the layered body 100 , powders such as cutting chips, cutting chips, drilling chips, and grinding chips are appropriately removed from the end face. Thereby, it is preferable to reduce the pollution caused by the powder in the subsequent steps. Moreover, compared with methods, such as sticking and peeling of an adhesive tape, the time taken to remove the powder is also shorter.

In addition, when the particle size of the dry ice particles to be collided is set to 100 to 1000 μm, the removal rate of the powder can be improved, and the defect of the adhesive layer on the end face can be suppressed, so it is more preferable, and it is more preferably 200 to 700 μm.

(Removal of powder for a laminated structure having a plurality of laminated bodies in layers)

In the above, the dry ice particles are collided with one layered body 100, but as shown in FIG. Thereby, the laminated body 100 can be processed in a large amount.

(Sequence of end face processing and powder removal)

After the machining (cutting, cutting, and grinding) of a part of the end face of the laminated body 100 is completed, while the other part of the end face of the laminated body 100 is being machined, dry ice particles may be blown simultaneously to the end face of the laminated body 100 to remove the powder. body. Thereby, the step time can be shortened.

Conversely, after all the processes such as cutting, cutting, and grinding of the end face of the laminated body are completed, the end face of the laminated body 100 is collided with dry ice particles to clean the powder on the end face. When the dry ice particles collide with the end face, the laminated body does not need to be processed. Processing of other parts of the end face. At this time, it can be distinguished into the environment (space) where the powder is removed by the collision of dry ice particles, and the environment (space) where the end face is processed, so that the end face contamination by the powder generated by the processing can also be prevented.

(Environment during collision step (powder removal step))

In the step of removing the powder from the end face of the layered body and the layered structure by dry ice particles, the surrounding environment of the layered body and the layered structure can be an air environment, but it can be an environment such as nitrogen and carbon dioxide gas if necessary. Moreover, the temperature of an environment is 20-30 degreeC normally, Preferably it is 20-27 degreeC. The relative humidity of the environment is usually less than 80%, preferably 30 to 75%, more preferably 40 to 70%. When the relative humidity of the environment is 80% or higher, condensation may occur due to the cooling of the laminate or laminate structure, and the laminate may absorb water and swell due to the high water absorption of films (such as polarizers). Defects are caused in the appearance or optical properties of the laminate or laminate structure.

(Manufacturing apparatus of optical member)

Next, with reference to FIG. 5, the manufacturing apparatus 1000 of the optical member suitable for carrying out the said method is demonstrated.

The manufacturing apparatus 1000 includes an end surface processing unit 200 for cutting, cutting, or grinding the end surface of the layered body 100 or the layered structure 120 , and collides with dry ice particles on a portion of the layered body 100 processed by the end surface processing unit 200 . The dry ice particle supply part 300 and the conveying part 400 conveying the laminated body 100 .

In FIG. 5 , a cutting device is drawn as the end face machining portion 200 . This cutting device includes a rotating shaft 210 extending in the horizontal direction, a disk 220 attached to the rotating shaft, and a cutting blade 230 attached to the disk 220 . By the rotation of the cutting blade 230, the end face of the laminated body or the like can be cut.

In the dry ice particle supply unit 300, only the nozzle 320 is described for the sake of convenience.

The conveying unit 400 includes a pair of upper aids 420 and lower aids 422 that sandwich the layered body 100 or the layered structure 120 in the thickness direction and support them, and press the upper aid 420 in the thickness direction (downward direction). The pressed cylinder 430, the rotating mechanism 410 that is connected with the lower auxiliary tool 422 to rotate the upper auxiliary tool 420 and the lower auxiliary tool 422 around the vertical axis (Z axis), and the upper auxiliary tool 420 and the lower auxiliary tool 422 are horizontally rotated. The moving mechanism 440 that moves in the direction (X direction).

Next, the manufacturing method of the optical member using this apparatus is demonstrated. First, the laminate 100 or the laminate structure 120 is sandwiched between the upper aid 420 and the lower aid 422 . Next, the upper auxiliary tool 420 is pressed toward the lower auxiliary tool 422 by the cylinder 430 to fix the layered body 100 or the layered structure 120 . In the present embodiment, the layered body 100 or the layered structure 120 is rectangular when viewed from above, and has four end surfaces. Therefore, the rotation position of the layered body 100 or the layered structure 120 is adjusted by the rotation mechanism 410 so that the two end surfaces E face the X axis in parallel.

Next, the end face processing unit 200 is activated. Specifically, the disk 220 is rotated. Next, the layered body 100 and the layered structure 120 are moved in the X direction by the moving mechanism 440 , so that the cutting blade 230 of the end surface processing portion 200 is brought into contact with the end surface E. Thereby, a pair of end faces E of the layered body 100 and the layered structure 120 facing each other are cut by the cutting blade 230 . At this time, chips adhere to the end face E.

Next, while the layered body 100 and the layered structure 120 are moved in the −X direction by the conveying unit 400 , dry ice particles are supplied from the nozzle 320 of the dry ice particle supply unit 300 . Thereby, dry ice particles are collided with the cut end surfaces E of the layered body 100 and the layered structure 120 , and the powder on the end surfaces E is removed.

Next, the layered body 100 and the layered structure 120 are further moved in one direction by the conveying unit 400 , and the layered body 100 and the layered structure 120 are rotated by the rotating mechanism 410 so that the remaining two end faces are parallel to the X direction. . Then, in the same manner as before, the processing of the remaining two end faces and the subsequent powder removal by dry ice particles may be performed in sequence.

The end surface processing part 200 can be set to various forms according to the form of processing. For example, as shown in FIG. 6, it is possible to cut with a planer-type rotary blade having a cylindrical body 240 that rotates around a vertical axis, and a length provided on the outer peripheral surface of the cylindrical body 240 to extend in the axial direction Blade 250.

In addition, instead of the cutting blade 230, a grinding plate provided with a large number of abrasive grains on the surface of the disc can also be used for grinding.

Moreover, when cutting and grinding are not required, it can also be used as a cutting device.

Finally, an example of a method of removing the powder f (drilling chips) adhering to the end face E of the hole H provided in the layered body 100 will be described with reference to FIG. 7 .

First, the layered bodies 100 are drilled, respectively, to prepare a plurality of layered layers 100 in which powder (drilling chips) f adhered to the end surfaces E inside the holes H. As shown in FIG. 1(b), each layered body 100 has a hole H provided at a predetermined position by drilling. Next, the laminated bodies 100 are laminated so that the positions of the holes H of the laminated bodies 100 are aligned on one axis (the axis extending in the thickness direction) to obtain the laminated structure 120 . In this way, the holes H of the stacked structures 100 are connected to each other, and the through holes H' penetrating in the thickness direction of the stacked structures 120 are formed in the stacked structures 120 .

The laminated structure 120 is extruded in the thickness direction of a pair of upper aids 420 and lower aids 422 , a dry ice particle supply port 420a is pre-set in one of the aids, and a dry ice particle recovery port 422b is pre-set in the other aid . The upper aid 420 and the lower aid 422 are arranged so that the through hole H' communicates with the dry ice particle supply port 420a and the dry ice particle recovery port 422b, and the laminated structure 120 is pressed in the thickness direction. Thereby, the preparation step before the dry ice collision step is completed.

Next, dry ice particles are supplied from the nozzle 320 into the through holes H' through the dry ice particle supply port 420a (collision step). The dry ice particles ejected from the nozzle 320 spread in the width direction as they advance, collide with the end face E of the through hole H' of the laminated structure 120, and are discharged together with the powder f from the dry ice particle recovery port 422b. If such an apparatus is used, the powder f can be efficiently removed from the layered body 100 having the powder f adhered to the end face E of the inner wall of the hole H by the drilling process.

(Example)

(Laminated body raw material)

A raw material laminate having the following layer structure was obtained: protective film (made of PET (polyethylene terephthalate): 53 μm)/protective film (made of TAC (cellulose triacetate): 32 μm)/polarizer (PVA ( Iodine-adsorbed polyvinyl alcohol): 12 μm)/protective film (made of COP (cyclic olefin resin): 23 μm)/adhesive layer (acrylic adhesive: 20 μm)/separator film (PET: 38 μm).

The protective film and the polarizer are bonded by a water-based adhesive. The thickness of the laminate was 178 μm.

(Processing of the end face of the laminate)

The raw material layered body was punched out in a rectangular shape having a size of 140×65 mm with a Thomson blade to obtain a layered body.

Next, 50 laminated bodies were stacked to obtain a laminated structure. Each end surface of the laminated structure was cut by a cutting device. Then, each end surface of the laminated structure was polished by a polishing apparatus.

(Removal of powder on the end face of the laminate)

For each of the Examples and Comparative Examples, the removal of the powder on the end face of the layered body was performed under the following conditions.

(Example 1)

Dry ice particle supply device: carbon dioxide gas type dry ice blasting

CO ₂ pressure: 5MPa (in addition, CO ₂ pressure refers to the supply pressure at the orifice)

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end face: about 50mm

Sweep speed of nozzle: 50mm/5 seconds

Center position of nozzle and nozzle sweep direction: The nozzle is oriented toward the center of the thickness direction of the end surface of the laminated structure, and the nozzle is swept in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle size of dry ice particles: 1 to 100 μm

Ambient temperature: 24°C to 26°C, relative humidity of the environment: 45% to 65%

(Example 2)

Dry ice particle supply device: carbon dioxide gas type dry ice blasting

_CO2 pressure: 7MPa

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end face: about 50mm

Sweep speed of nozzle: 50mm/5 seconds

Center position of nozzle and nozzle sweep direction: The nozzle is oriented toward the center of the thickness direction of the end surface of the laminated structure, and the nozzle is swept in a direction perpendicular to the thickness of the end surface of the laminated structure.

Average particle size of dry ice particles: 200 to 700 μm or less

Ambient temperature: 24°C to 26°C, relative humidity of the environment: 45% to 65%

(Example 3)

Dry Ice Particle Supply Device: Particle Dry Ice Blasting

3mm Particle diameter:

3mm

Air pressure: 0.5MPa

The distance between the front end of the nozzle and the end face: about 50mm

Sweep speed of nozzle: 50mm/5 seconds

Center position of nozzle and nozzle sweep direction: The nozzle is oriented toward the center of the end face of the laminated structure in the thickness direction, and the nozzle is swept in a direction perpendicular to the thickness of the end face of the laminated structure.

Average particle size of dry ice particles: 1000μm or more

Ambient temperature: 24°C to 26°C, relative humidity of the environment: 45% to 65%

(Example 4)

The powder removal of the end face of the layered body was performed under the same conditions as in Example 2, except that the ambient temperature was set to 26° C. and the relative humidity of the environment was set to 80 to 90%.

In addition, the layered body is cooled due to contact with dry ice particles during removal, and dew condensation occurs on the layered body. When the portion where dew condensation occurred was confirmed, there was no abrasive dust or chipping, but swelling occurred at the edge of the layered body.

(Comparative Example 1)

The end surface of the laminated structure was wiped with a clean room wipe (manufactured by KURARAY KURAFLEX) impregnated with ethanol.

(Comparative Example 2)

The cutting blade made of OLFA was moved along the end surface of the laminated structure.

(Comparative Example 3)

After affixing an adhesive tape (Cellotape (registered trademark) manufactured by Nichiban Corporation) to the end surface of the laminated structure, the adhesive tape was peeled off from the end surface.

(Comparative Example 4)

The air flow was blown to the end face of the laminated structure in the same manner as in Example 1 except that the liquid carbon dioxide was not supplied.

(Evaluation)

The end faces were observed with a microscope, and the residual state of powder on the end faces and the presence or absence of defects in the adhesive layer on the end faces were investigated.

The results are shown in Table 1.

In addition, ○ in "Powder residue on end face" means that no powder was observed in the field of view with a length of 30 mm in the direction perpendicular to the thickness (hereinafter simply referred to as length), and △ means that 1 to 1 to 1 was observed in a field of view with a length of 30 mm. 2 powders, and X indicates that 3 or more powders were observed in a field of view with a length of 30 mm.

In addition, ○ in "Defects in the adhesive layer on the end face" means that no defects were observed in the visual field with a length of 30 mm in the direction perpendicular to the thickness (hereinafter simply referred to as the length), and △ means that 1 to 1 to 1 were observed in a visual field of 30 mm length. 2 defects, and X indicates that defects at 3 or more positions were observed in a field of view with a length of 30 mm.

50‧‧‧Optical Film

70‧‧‧Protective film

80‧‧‧Adhesive layer

90‧‧‧Isolation film

100‧‧‧Laminate

300‧‧‧Dry Ice Particle Supply Department

310‧‧‧Liquid carbon dioxide source

320‧‧‧Nozzle

330‧‧‧Transport gas source

340, 360‧‧‧valve

350‧‧‧ orifice

400‧‧‧Conveying Department

d‧‧‧Dry ice particles

E‧‧‧End face

f‧‧‧Powder

L1, L2‧‧‧Pipeline

Claims (8)

A method of manufacturing an optical member, comprising the steps of: preparing a layered body having an optical film and an adhesive layer provided on one side of the optical film and having powder attached to the end surface thereof; and making the end surface of the layered body The step of removing the powder from the end face by colliding with dry ice particles; wherein the average particle size of the dry ice particles is 200 to 700 μm. The production method according to claim 1, wherein, in the step of colliding, the dry ice particles are collided with an end surface of a laminated structure in which a plurality of layers of the laminated body are laminated. The production method according to claim 1 or 2, wherein a part of the end surface of the layered body is collided with the dry ice particles, and the other part of the end surface of the layered body is subjected to a method selected from cutting, cutting and polishing. At least one of the groups formed. The manufacturing method according to claim 1 or 2, wherein in the step of preparing the end face, at least one selected from the group consisting of cutting, cutting and grinding is performed, and in the step of making the end face When a part collides with the dry ice particles, the end face is not subjected to any one selected from the group. The manufacturing method according to claim 1 or 2, wherein the optical film is selected from the group consisting of a polarizer, a protective film, a retardation film, a brightness enhancement film, a window film and a touch sensor At least one of them is either a laminate film containing two or more layers of at least one type selected from the aforementioned group, or a laminate film containing at least two types selected from the aforementioned group. The manufacturing method according to claim 1 or 2, wherein the relative humidity of the environment in the step of colliding the end face with the dry ice particles is 30 to 75%. An apparatus for manufacturing an optical member, comprising: an end surface processing portion for cutting, cutting or grinding an end surface of a laminate having an optical film and an adhesive layer provided on one side of the optical film; A dry ice particle supply part where the processed part of the end face processing part collides with the dry ice particles; wherein the average particle diameter of the dry ice particles is 200 to 700 μm. The manufacturing apparatus of the optical member as described in Claim 7 of the Claims further provided with the conveyance part which moves the said laminated body between the said end surface processing part and the said dry ice particle supply part.

Images