TWI838506B - Method for producing perforated laminate and device for producing perforated laminate - Google Patents

Abstract

Provided is a method for producing a perforated laminate having a hole penetrating in the laminating direction including a step of preparing a laminate with slits and cut-out piece that formed one or more of resin film layers and one or more binding layers, and having slits and cut-out piece penetrating in the laminating direction and a cut-out piece formed by cutting, and a step of forming a hole by removing the cut-out piece from the cut-out laminate while continuously or intermittently conveying the laminate with slits and cut-out piece.

Description

Manufacturing method and manufacturing device of open hole laminated body

The present invention relates to a method and device for manufacturing a hole-opening laminated body which is at least laminated with a resin film layer and a bonding layer and has holes penetrating the laminated layer.

Polarizing plates have been widely used as polarized light supply elements in display devices such as liquid crystal display devices or organic electroluminescent (EL) display devices, or as polarized light detection elements. Traditionally, polarizing plates are used with protective films attached to one or both sides of the polarizer.

Display devices equipped with polarizing plates are also deployed on mobile devices such as laptops and mobile phones. Due to the diversification of display purposes, clear display distinction, and decoration requirements, polarizing plates with different transmittance areas are required. In particular, in small and medium-sized mobile terminals represented by smartphones or tablet terminals, from a decorative point of view, polarizing plates can be fully bonded to create a seamless design. At this time, since the polarizing plate is also overlapped in the area of the photographic lens or the image or logo printing area under the screen, there will be problems such as poor camera sensitivity or poor design.

Therefore, it is usually possible to suppress the decrease in sensitivity or poor design of the camera by processing such as forming holes in the polarizing plate. Japanese Patent Publication No. 2017-226034 describes a processing method or processing device for forming holes in optical components such as polarizing plates, and Japanese Patent Publication No. 2007-307683 describes a processing method and processing device for punching optical components into a predetermined shape.

When forming holes in a polarizing plate or using a punching blade to punch holes, there may be a situation where punching debris is not removed and remains on the polarizing plate and the holes cannot be formed well. The punching debris remaining on the polarizing plate must be removed from the polarizing plate.

The purpose of the present invention is to provide a manufacturing method and a manufacturing device for efficiently manufacturing a laminate having holes that penetrate the laminate.

The present invention provides a method for manufacturing a porous laminate and a device for manufacturing a porous laminate as shown below.

[1] A method for manufacturing a porous laminate, which is to manufacture a porous laminate having holes penetrating the laminate direction, and the manufacturing method comprises the following steps:

The step of preparing a laminate with slits, wherein the laminate with slits has one or more resin film layers and one or more bonding layers, and has slits running through the laminate and excision pieces formed by the slits; and

The step of forming the hole is to continuously or intermittently transport the aforementioned layered body with the cutout and remove the aforementioned excised piece from the aforementioned layered body with the cutout, thereby forming the aforementioned hole.

[2] A method for manufacturing a hole-forming laminate as described in [1], wherein the hole-forming step is performed by applying an external force to the cut piece.

[3] A method for manufacturing a porous laminate as described in [2], wherein the external force is at least one of a force of pressing the cut piece with a pressing member, a force of sucking the cut piece, and a force of spraying a fluid onto the cut piece.

[4] A method for manufacturing a hole-opening laminate as described in any one of items [1] to [3], wherein the aforementioned preparation step includes cutting a punch blade into the lamination direction of the material laminate of the aforementioned one or more resin layers and the aforementioned one or more bonding layers to form the aforementioned cut gap.

[5] A method for manufacturing a hole-carrying laminate as described in any one of items [1] to [3], wherein the diameter of the hole is greater than 1 mm and less than 20 mm.

[6] A method for manufacturing a multilayer structure with holes as described in any one of items [1] to [5], wherein in the step of forming holes, the multilayer structure with cutouts is transported by at least one of a conveyor belt, a conveyor roller and a rotating table.

[7] A method for manufacturing a multilayer structure with holes as described in any one of items [1] to [6], wherein in the step of forming holes, the multilayer structure with cutouts is transported intermittently, and the slices are removed during the stop period of transporting the multilayer structure with cutouts.

[8] A method for manufacturing a porous laminate as described in any one of items [1] to [7], wherein the step of forming holes further includes an operation of transporting the porous laminate obtained by the removal operation after removing the slice from the laminate with the cutout.

[9] A method for manufacturing a multilayer body with holes as described in any one of items [1] to [8], wherein the multilayer body with cutouts is a sheet-like body.

[10] A method for manufacturing a multilayer structure with holes as described in any one of items [1] to [9], wherein the multilayer structure with cutouts comprises a substrate film and a release film as the resin film layer,

The aforementioned base film, the aforementioned bonding layer and the aforementioned peeling film are layered in this order.

[11] A method for manufacturing a multilayer with holes as described in any one of items [1] to [9], wherein the multilayer with cutouts comprises a linear polarizer and a protective film as the resin film,

The aforementioned protective film is laminated on one or both sides of the aforementioned linear polarizer.

[12] A method for manufacturing a porous laminate as described in any one of items [1] to [11], wherein the bonding layer is an adhesive layer or a bonding agent layer.

[13] A manufacturing device for a porous laminate, wherein the porous laminate has holes that penetrate the laminate direction, and the manufacturing device comprises:

A conveying part for continuously or intermittently conveying a laminate with a cutout, wherein the laminate with a cutout has one or more resin film layers and one or more bonding layers, and has a cutout that penetrates the laminate and a cutout formed by the cutout; and

The hole forming section for forming the aforementioned hole removes the aforementioned cut-off piece from the aforementioned layered body with the cut gap continuously or intermittently transported by the aforementioned transport section to form the aforementioned hole.

[14] A manufacturing device for a hole-perforated laminate as described in [13], wherein the hole-forming portion includes at least one of a pressing portion for pressing the cut piece by a pressing member, a suction portion for sucking the cut piece, and a spray portion for spraying a fluid onto the cut piece.

[15] A manufacturing device for a porous laminate as described in [13] or [14], further comprising a mechanism for obtaining the aforementioned laminate with cutouts by laminating a material laminate of one or more resin film layers and one or more bonding layers.

[16] A manufacturing device for a hole-perforated laminate as described in [15], wherein the structure of the laminate with the slit obtained by the material laminate is a punching tool for forming the slit in the lamination direction of the material laminate.

[17] A manufacturing device for a multilayer body with holes as described in any one of [13] to [16], wherein the conveying section is provided with at least one of a conveyor belt, a conveyor roller and a rotating table for conveying the multilayer body with cutouts.

[18] A manufacturing device for a multilayer body with holes as described in any one of [13] to [17], wherein the conveying unit can immediately convey the multilayer body with holes after removing the cut-off piece.

According to the present invention, a hole-opening laminate having holes penetrating the direction of the laminate can be effectively manufactured.

10a: Material layer

10b: Laminated body with cutouts

10c: Open hole layered structure

11a: Resection piece

11b: Cutting gap

11c: Holes

12a,12b,12c: linear polarizer

13a, 13b, 13c: bonding layer

14a,14b,14c: Protective film

31: Transport Department

32: Nail (pressing member, pressing part)

33: Press and fix the part

34: Conveyor belt

34c: with hole

41: Transport Department

42: Suction unit

51: Transport Department

52: Jet Department

61: Transport Department

62a: No. 1 conveyor belt (conveyor belt)

62b: Second conveyor belt (conveyor belt)

63a,63b: Clamping roller

Figure 1 (a) is a schematic plan view schematically showing an example of a material laminate used in the method for manufacturing an open-hole laminate of the present invention, and (b) is an x-x’ cross-sectional view of (a).

Figure 2 (a) is a schematic plan view schematically showing an example of a laminate with cutouts used in the method for manufacturing a laminate with holes of the present invention, and (b) is a y-y’ cross-sectional view of (a).

Figure 3 (a) is a schematic plan view schematically showing an example of the open-hole laminate of the present invention, and (b) is a z-z’ cross-sectional view of (a).

FIG4 is a schematic diagram schematically showing an example of a manufacturing device for the open-hole laminate of the present invention.

FIG5 is a schematic diagram showing another example of a manufacturing device for a porous laminate of the present invention.

FIG6 is a schematic diagram showing another example of a manufacturing device for a porous laminate of the present invention.

FIG. 7 is a schematic diagram showing another example of a manufacturing device for a porous laminate of the present invention.

The following is a preferred embodiment of the method for manufacturing the open-hole laminate of the present invention with reference to the drawings. The embodiments presented below can be combined arbitrarily. In each embodiment, the same components as those described in the previous embodiments are given the same symbols and their descriptions are omitted.

[Implementation Type 1]

In this embodiment, the hole-opening laminate and the laminate with cutouts have a linear polarizer (hereinafter also referred to as a "polarizer") as a resin film layer, a protective film, and a bonding layer. Herein, a linear polarizer (hereinafter also referred to as a "polarizer") having a protective film on one side of the linear polarizer through a bonding layer is taken as an example for explanation.

(Manufacturing method of open-cell laminate)

The manufacturing method of the holed laminate 10c (FIG. 3(a) and (b)) of this embodiment includes the steps of preparing the laminate 10b with cutouts (FIG. 2(a) and (b)) (hereinafter also referred to as the "preparation step") and forming holes 11c (FIG. 3(a) and (b)) that penetrate the laminate (hereinafter also referred to as the "hole forming step"). The cutout 11b in FIG. 2(a) and (b) is a dotted line showing that the cutout piece 11a exists on the laminate 10b with cutouts.

The laminate 10b with a slit can be manufactured by forming a slit 11b on the material laminate 10a described later (Figures 1(a) and (b)). The slit 11b is used to form the hole 11c.

The method of forming the cutout 11b is described in the "preparation step" below.

The hole forming step may further include an operation of conveying the hole-opening laminate 10c obtained by the removal operation after removing the cut-off piece 11a formed by the cut-off 11b from the laminate 10b with the cut-off. The conveying of the hole-opening laminate 10c may be performed continuously or intermittently. In the hole forming step, when the cut-off piece 11a is removed while the laminate 10b with the cut-off is continuously conveyed, the hole-opening laminate 10c obtained by the above-mentioned removal operation may also be conveyed continuously. In the hole forming step, when the conveying of the laminate 10b with the cut-off is stopped when the cut-off piece 11a is removed, the hole-opening laminate 10c obtained by the above-mentioned removal operation may be conveyed continuously or intermittently.

(Open hole layer)

As shown in FIG3(a), the open-hole laminate 10c is a rounded quadrilateral with four rounded corners (having an R shape) in the plane view. For example, as shown in FIG3(b), the open-hole laminate 10c is laminated in the order of polarizer 12c (resin film layer), laminating layer 13c and protective film 14c (resin film layer). The open-hole laminate 10c has holes 11c that penetrate the lamination direction, and the polarizer 12c, laminating layer 13c and protective film 14c of each layer of the open-hole laminate 10c also have holes that penetrate the thickness direction.

The planar shape of the open hole laminate 10c is not particularly limited. It is usually a quadrilateral or a rounded quadrilateral with at least one corner of the quadrilateral being rounded. The part may be a U-shaped, V-shaped, U-shaped, semicircular, or other part with a missing corner. Although the open hole laminate 10c shown in FIG3(a) is a sheet-like body, it may also be a long continuous body.

The shape of the hole 11c is not particularly limited, and can be circular; elliptical; elliptical; polygonal such as a triangle or a quadrilateral; a polygon with at least one corner rounded (having an R shape), etc.

The diameter of the hole 11c is preferably 1 mm or more, and can be 3 mm or more, 5 mm or more, or 7 mm or more, and preferably 20 mm or less, and can be 18 mm or less, 15 mm or less, or 12 mm or less.

In this specification, the hole diameter refers to the diameter of the hole when the hole is circular (perfect circle), and refers to the diameter of the circumscribed circle (perfect circle) of the hole when the hole is a shape other than circular (perfect circle). The manufacturing method and manufacturing device of this embodiment are described below and can be applied to the case of manufacturing a hole-opening laminate 10c with a hole 11c having a diameter within the above range.

In the hole-forming laminate 10c shown in Fig. 3 (a) and (b), although the hole 11c is shown as one, it may have more than two holes. When the polarizing plate is a long continuous body, it is usually cut into a product size (sheet body) in a subsequent step, so it is better to provide a plurality of holes on the continuous body in accordance with the shape when cutting. Although the hole-forming laminate 10c shown in Fig. 3 (b) has a protective film 14c on one side of the polarizer 12c, it may also have protective films on both sides of the polarizer 12c through a bonding layer.

(Material layer)

For example, as shown in FIG1(a), the material laminate 10a is a rounded quadrilateral with four rounded corners in the plan view.

There is no particular limitation on the planar shape of the material stack 10a. Like the hole stack 10c, it is preferably a quadrangular or rounded quadrangular shape, and it may also have a missing corner. Although the material stack 10a shown in FIG1(a) is a sheet-like body, it may also be a long continuous body.

As shown in FIG1(b), the material laminate 10a is laminated in the order of polarizer 12a, bonding layer 13a and protective film 14a. The polarizer 12a and protective film 14a are resin film layers.

Although the material laminate 10a shown in FIG1(b) has a protective film 14a on one side of the polarizer 12a, it may also have protective films on both sides of the polarizer via a bonding layer.

The bonding layer 13a can be a bonding agent layer formed using a bonding agent, or can be an adhesive layer formed using an adhesive. In the laminated body 10b with cutouts described later (Fig. 2 (a) and (b)), when the bonding layer is an adhesive layer, there is a tendency for the cut piece 11a to remain on the laminated body 10b with cutouts. The manufacturing method and manufacturing device of this embodiment can also be applied to the case where an adhesive layer is included as the bonding layer.

(Laminar body with cutouts)

As shown in FIG2(a), the laminate 10b with cutouts is a rounded quadrilateral with four rounded corners in the plane view. As shown in FIG2(b), the laminate 10b with cutouts is a laminate of polarizer 12b, laminating layer 13b and protective film 14b in this order, and the cutouts 11b are formed along the outer edge of the hole 11c of the open-hole laminate 10c. The polarizer 12b, laminating layer 13b and protective film 14b each have cutouts that penetrate their thickness directions.

There is no particular restriction on the plane shape of the laminated body 10b with cutouts. Like the laminated body 10c with holes, it is preferably a quadrangular or rounded quadrangular body, and it may also have a missing corner. Although the laminated body 10b with cutouts shown in FIG. 2(a) is a sheet-like body, it may also be a long continuous body.

The laminate 10b with a cutout has a cutout piece 11a. The cutout piece 11a is a segment of the material laminate 10a formed by the cutout 11b. The cutout piece 11a is partially or completely separated from the main body of the laminate 10b with a cutout (the portion other than the cutout piece 11a) due to the cutout 11b. The cutout piece 11a may exist in an area at least partially surrounded by the cutout 11b, or may be in a state where the cutout piece 11a is not completely separated from the main body of the laminate 10b with a cutout, although it does not exist in the area surrounded by the cutout 11b (for example, the cutout piece 11a is suspended from the main body of the laminate 10b with a cutout). The slits 11b of the laminate 10b with slits are formed in the lamination direction of the polarizer 12b, the laminating layer 13b and the protective film 14b, and are continuously formed along the part of the outline (outer edge) of the hole 11c that becomes the open-hole laminate 10c in the plane perpendicular to the lamination direction. Therefore, by removing the cut piece 11a from the laminate 10b with slits, the open-hole laminate 10c with the hole 11c can be obtained.

The shape of the cut-off piece 11a can be set to correspond to the shape of the hole 11c of the hole-opening laminate 10c. The shape of the cut-off piece 11a can be an ellipse; a small ellipse (oval); a polygon such as a triangle or a quadrilateral; a rounded polygon with at least one corner of the polygon rounded, etc.

The diameter of the cut piece 11a is preferably 1 mm or more, 3 mm or more, 5 mm or more, or 7 mm or more, and preferably 20 mm or less, 18 mm or less, 15 mm or less, or 12 mm or less.

In this manual, the diameter of the cut piece refers to the diameter of the cut piece when the plane shape of the cut piece is a circle (a perfect circle); when the plane shape of the cut piece is other than a circle (a perfect circle), it refers to the diameter of the circumscribed circle (a perfect circle) of the cut piece.

When the diameter of the cut piece 11a is within the above range, it is difficult to remove from the laminated body 10b with a cutout, and is easily left in the area surrounding the cut piece 11a, and tends to be unable to be completely separated from the main body of the laminated body 10b with a cutout. When the diameter of the planar shape of the cut piece 11a is within the above range, in other words, when the cut piece 11a of the above diameter is removed from the laminated body 10b with a cutout to manufacture a hole-opening laminated body 10c having a hole 11c of a diameter corresponding to the diameter of the cut piece 11a (Figure 3 (a)), the manufacturing method and manufacturing device of this embodiment can be applied.

Although the bonding layer 13b can be a bonding agent layer formed by a bonding agent or an adhesive layer formed by an adhesive, when the bonding layer is an adhesive layer, it is difficult to completely separate the cut piece 11a from the main body of the laminated body with cutouts 10b, and there is a tendency for the cut piece 11a to remain on the laminated body with cutouts 10b. The manufacturing method and manufacturing device of this embodiment can also be applied to the case where the laminated body with cutouts 10b including the adhesive layer is made into a bonding layer.

In the laminate 10b with notches shown in FIG. 2 (a) and (b), although the notches 11b are shown, it may have more than two notches. When the laminate with notches is a long continuous body, it is usually cut into a product size (sheet body) in the subsequent steps, and it is better to design multiple continuous notches to match the shape during the cutting. Although the laminate 10b with notches shown in FIG. 2 (b) has a protective film 14b on one side of the polarizer 12b, it may also have protective films on both sides of the polarizer with a bonding layer interposed therebetween.

(Preparation steps)

The preparation step in the manufacturing method of the hole-opening laminate 10c is, for example, a step of preparing a laminate 10b with a cutout having a cutout 11b and a cut-off piece 11a (FIG. 2(a) and (b)). The preparation step may include an operator who manufactures the laminate 10b with a cutout by forming a cutout 11b on the material laminate 10a (FIG. 1(a) and (b)). The method of manufacturing the laminate 10b with a cutout may include, for example, an operation of forming the cutout 11b by cutting the material laminate 10a in the lamination direction by a punch blade. There is no particular limitation on the punch blade, and for example, a Thompson blade and an etching blade (Pinnacle (registered trademark) blade) can be used.

(Hole forming step)

In the step of forming holes in the manufacturing method of the open hole laminate 10c, a manufacturing device for the open hole laminate 10c, such as that shown in FIG. 4, can be used.

The manufacturing device shown in FIG4 includes a conveying section 31 for continuously or intermittently conveying a laminated body 10b with cutouts, and a pin 32 (pressing member, pressing section) for applying a pressing force (external force) to the cutout pieces 11a of the laminated body 10b with cutouts to press and remove the cutout pieces 11a from the laminated body 10b with cutouts. The pin 32 is used to form a hole 11c by removing the cutout pieces 11a from the laminated body 10b with cutouts conveyed by the conveying section 31. The pin 32 is provided above the conveying section 31 so as to face the laminated body 10b with cutouts conveyed by the conveying section 31. The manufacturing device may further have a pressing and fixing portion 33 (fixing portion) for pressing and fixing the laminated body 10b with the cutout when the nail pin 32 presses the cutout piece 11a. The pressing and fixing portion 33 is provided on the same side as the nail pin 32, i.e., above the conveying portion 31.

The conveying section 31 is provided with a conveying belt 34, and the pin 32 is arranged above the conveying surface of the conveying belt 34. The conveying belt 34 is provided with a belt hole 34c through which the cut piece 11a can pass in a manner that can remove the cut piece 11a punched out by the pin 32. Therefore, the laminate 10b with a cut gap is conveyed in a manner such that the cut piece 11a is arranged at the position of the belt hole 34c and placed on the conveying belt 34.

As shown by the two arrows in FIG. 4 , the pin 32 is arranged to be movable relative to the conveying surface of the conveyor belt 34 and to press the cut-off piece 11a of the laminated body 10b with a cut-off gap conveyed by the conveyor belt 34 to punch the cut-off piece 11a. The pin 32 can be made into a rod-shaped component, for example, and the cross-sectional area of the tip portion in contact with the cut-off piece 11a is preferably smaller than the area of the cut-off piece 11a. The tip portion of the side in contact with the cut-off piece 11a of the pin 32 can be formed into a cone, and a soft component such as sponge or rubber can be attached to the tip portion.

The pressing and fixing portion 33 is, for example, a pressing rod that presses the periphery of the slit 11b of the laminated body 10b with slits. By using the pressing and fixing portion 33 to press and fix the position of the laminated body 10b, the problem of the conveying position deviation of the laminated body 10b with slits or the laminated body with holes 10c can be suppressed as the nail pin 32 moves forward and backward when pressing the cut-off piece 11a or releasing the pressing. In the manufacturing device shown in FIG. 4, the case where two pressing rods are provided in a direction perpendicular to the conveying direction is illustrated. The pressing and fixing portion 33 can be made into, for example, a plate-shaped or rod-shaped component, and can also have a length that can press the entire length of the laminated body 10b with slits perpendicular to the conveying direction. The pressing and fixing part 33 is preferably pressed at a position that does not contact the end face of the product extending perpendicular to the conveying direction of the laminated body 10b with a cut. The bonding layer 13b is exposed on the end face of the laminated body 10b with a cut, so that when this end face contacts the pressing and fixing part 33, the adhesive or adhesive forming the bonding layer 13 will adhere to the pressing and fixing part 33, which may become the cause of foreign matter or contamination of the conveying path. For example, the two arrows in Figure 4 show that the pressing and fixing part 33 is synchronized with the advancing and retreating movement of the nail pin 32 of the laminated body with a cut, and the laminated body 10b with a cut can be pressed in conjunction with the timing when the nail pin 32 presses the cut-off piece 11a.

In the hole forming step, the laminated body 10b with cutouts is sequentially conveyed in the direction indicated by an arrow in FIG. 4 by driving the conveyor belt 34. When the cutout piece 11a of the laminated body 10b with cutouts reaches the setting position of the nail pin 32, the pressing and fixing part 33 moves in and out toward the conveyor belt 34. Therefore, the pressing and fixing part 33 presses the periphery of the cutout piece 11b of the laminated body 10b with cutouts to fix the position of the laminated body 10b with cutouts. In this state, the nail pin 32 moves in and out toward the conveyor belt 34 to press the cutout piece 11a, and the cutout piece 11a is punched to obtain the laminated body 10c with a hole (FIG. 4). The punched cut pieces 11a can be discharged from the belt holes 34c of the conveyor belt 34 to the outside of the conveyor portion. Then, the pins 32 and the pressing and fixing parts are moved away from the conveyor belt 34, and the obtained open-hole laminate 10c is continuously or intermittently transported by the conveyor belt 34 (Figure 4).

The pressing of the cut-off piece 11a by the nail pin 32 can be performed while the laminated body 10b with cut-off gaps is continuously conveyed, or can be performed during the stop period of the intermittent conveyance of the laminated body 10b with cut-off gaps. The pressing of the cut-off piece 11a by the nail pin 32 is performed as the laminated body 10b with cut-off gaps on the conveyor belt 34 moves forward and backward (in FIG. 4 , it moves up and down). Therefore, in order to make the nail pin 32 appropriately press the cut-off piece 11a, it is preferable to make the pressing and fixing part 33 press the cut-off piece 10b and make the nail pin 32 press the cut-off piece 11a during the temporary stop period of the intermittent conveyance of the laminated body 10b with cut-offs or the laminated body 10c with holes. At this time, it is preferable to convey the laminated body 10b with cut-offs or the laminated body 10c with holes without pressing the pressing and fixing part 33 and the nail pin 32.

As shown in FIG. 4 , according to this embodiment, the cut-off piece 11a can be removed by pressing while conveying the laminate 10b with the cut-off gap, so the hole forming step can be effectively performed.

In the manufacturing device shown in FIG. 4, although the pin is disposed above the conveyor belt 34, its position is not particularly limited as long as it can press the cut-off piece 11a of the laminate 10b with a cutout on the conveyor belt 34. For example, the pin may also be disposed below the conveyor belt 34. When the pin is disposed below the conveyor belt 34, it is preferred that the pressing and fixing portion is also disposed below the conveyor belt 34.

In the manufacturing device shown in FIG. 4, although a pin that can move forward and backward relative to the conveying surface of the conveyor belt 34 is used as an example for explanation, it is not limited to this, and a roller with a pin having a predetermined interval on the surface may also be used. The roller with a pin may be rotated while conveying the laminate with the cutouts, so that the pin of the roller with a pin may contact the cutouts in the laminate with the cutouts, and the pin of the roller with a pin may contact the cutouts and press them, thereby removing the cutouts from the laminate with the cutouts.

In the manufacturing device shown in FIG. 4, although two pressing rods are used as the pressing and fixing part as an example, as long as the periphery of the slit 11b can be pressed and fixed, there is no particular restriction on the number or shape of the pressing rods used, and one pressing rod may be used, or a pressing and fixing part of a shape surrounding the periphery of the slit 11b may be provided.

A fixing portion that can fix the position of the laminated body 10b with cutouts can be used instead of the pressing fixing portion 33. For example, a suction fixing portion (fixing portion) for fixing the position of the laminated body 10b with cutouts by suction can be provided instead of the pressing fixing portion 33. In addition, if the position of the laminated body 10b with cutouts can be sufficiently fixed, the fixing portion may not be provided.

The manufacturing device of the above-mentioned hole-opening laminate 10c (Figure 4) can be equipped with a punching blade on the upstream side of the conveying direction of the laminate 10b with cutouts to form cutouts 11b in the lamination direction of the material laminate 10a. In this way, the laminate 10b with cutouts can be obtained from the material laminate 1a, and the obtained laminate 10b with cutouts can be conveyed continuously or intermittently to perform the hole forming step.

The manufacturing device shown in FIG. 4 may also be provided with a gathering section for gathering the excised pieces 11a removed from the conveying section 31, and may also be provided with an excised piece discharge section for discharging the excised pieces 11a to the outside of the manufacturing device.

[Implementation Type 2]

In this embodiment, the case of a polarizing plate having an open hole laminate, an open hole laminate, and a material laminate is also cited as an example, similar to the open hole laminate, the open hole laminate, and the material laminate described in the previous embodiment. In this embodiment, the manufacturing device of the open hole laminate shown in FIG. 5 is used to replace the manufacturing device of the open hole laminate shown in FIG. 4. The following mainly describes the differences from the previous embodiment, and omits the same points as the previous embodiment.

FIG5 is a schematic diagram schematically showing another example of the manufacturing device for the open-hole laminated body of the present embodiment. In the manufacturing device for the open-hole laminated body of the present embodiment, a manufacturing device with a suction portion 42 (FIG5) is used to replace the nail pin 32 (FIG4) used in the previous embodiment, which is different from the previous embodiment in the point where the hole forming step is performed.

The manufacturing device shown in FIG5 has a conveying section 41 for continuously or intermittently conveying the laminated body 10b with cutouts, and a suction section 42 for applying a suction force (external force) to the cutout piece 11a of the laminated body 10b with cutouts to remove the cutout piece 11a from the laminated body 10b with cutouts by suction. The suction section 42 is used to form a hole 11c by removing the cutout piece 11a from the laminated body 10b with cutouts conveyed by the conveying section 41. The suction section 42 is provided below the conveying section 41 in a manner that it can be opposite to the laminated body 10b with cutouts conveyed by the conveying section 41.

The conveying part 41 has a conveying belt 34, and the suction part 42 is arranged below the conveying surface of the conveying belt 34. The suctioned part 42, the conveying belt 34 is provided with a belt hole 34c through which the cut piece 11a can pass at the position of the cut piece 11a of the laminated body 10b with a cut-out gap, so that the cut piece 11a sucked by the suction part 42 can be removed by suction. Therefore, the laminated body 10b with a cut-out gap is carried on the conveying belt 34 and conveyed in a manner that the cut piece 11a is arranged at the position of the belt hole 34c.

The suction part 42 is, for example, a suction box, and is located below the conveyor belt 34, and can provide suction force to the laminate 10b with the cut gap from the belt hole 34c of the conveyor belt 34. The suction part 42 is, for example, a rectangular box shape as a whole, has an opening on the surface facing the conveyor belt 34, and has an exhaust port on the other surface for exhausting the gas sucked into the suction box.

In the hole forming step, the laminate 10b with cutouts is sequentially conveyed by the conveyor belt 34 in the direction indicated by an arrow in FIG. 5. When the cutout piece 11a of the laminate 10b with cutouts reaches the setting position of the suction part 42 on the conveyor part 41, it can be removed from the belt hole 34c of the conveyor belt 34 to the outside of the conveyor part 41 by suction of the suction part 42, thereby obtaining the open-hole laminate 10c. The obtained open-hole laminate 10c (FIG. 5) is continuously or intermittently conveyed by the conveyor belt 34.

The suction of the excised piece 11a by the suction unit 42 can be performed while the laminated body 10b with the cutouts is continuously conveyed, or can be performed while the laminated body 10b with the cutouts is intermittently conveyed and during the stop period of the laminated body 10b with the cutouts. In order to effectively perform the suction of the excised piece 11a by the suction unit 42, it is preferable to continuously convey the laminated body 10b with the cutouts by continuously driving the conveyor belt 34 during the suction operation of the suction unit 42, and to make the excised piece 11a pass through the position of the suction unit 42 and be removed by suction.

According to this embodiment, as shown in FIG5 , since the cut piece 11a can be removed by external force such as suction force while conveying the laminate 10b with the cut gap, the hole forming step can be performed effectively.

In the manufacturing device shown in FIG. 5 , although the suction part is disposed below the conveyor belt 34, its position is not particularly limited as long as the cut piece 11a of the laminate 10b with the cutout on the conveyor belt 34 can be sucked. For example, the suction part 42 may also be disposed above the conveyor belt 34.

In the manufacturing device shown in FIG. 5, although a suction box is used as the suction part 42 as an example, it is not limited to this example, and a suction roller having a suction area of a predetermined length in the circumferential direction may also be used. When using the suction roller, the suction roller can be rotated while driving the conveyor belt, and the suction area of the suction roller and the belt hole of the conveyor belt are positioned facing each other, and the excised pieces are removed from the laminated body with the cut gap of the conveyor belt by suction in the suction area of the suction roller.

As described in the previous embodiment, the manufacturing device shown in FIG. 5 may be provided with a punching blade for forming a slit 11b in the lamination direction of the material lamination 10a on the upstream side of the conveying direction of the slit-attached laminate 10b. Therefore, the slit-attached laminate 10b may be obtained from the material lamination 10a, and the obtained slit-attached laminate 10b may be conveyed continuously or intermittently to perform the hole forming step.

In the manufacturing device shown in FIG. 5, a gathering section for gathering the excised pieces 11a removed by the conveying section may be provided, and an excised piece discharge section for discharging the excised pieces 11a outside the manufacturing device may also be provided.

[Implementation Type 3]

In this embodiment, the same open hole laminate, laminate with cutouts, and material laminate as described in the previous embodiment are listed as an example of the case where the open hole laminate, laminate with cutouts, and material laminate are polarizing plates. In this embodiment, the manufacturing device of the open hole laminate shown in FIG. 6 is used to replace the manufacturing device of the open hole laminate described above. The following mainly describes the differences from the previous embodiment, and omits the same points as described in the previous embodiment.

FIG6 is a schematic diagram schematically showing another example of the manufacturing device of the hole-forming laminated body of the present embodiment. In the manufacturing device of the hole-forming laminated body of the present embodiment, a manufacturing device (FIG6) having a spraying part for spraying fluid is used to replace the nail 32 (FIG4) or the suction part 42 used in the previous embodiment, and the point in the hole forming step is different from the previous embodiment.

The manufacturing apparatus shown in FIG6 includes a conveying section 51 for continuously or intermittently conveying a laminated body 10b with cutouts, and a spraying section 52 for applying (external force) to the cutout pieces 11a of the laminated body 10b with cutouts to spray a fluid and remove the cutout pieces 11a from the laminated body 10b with cutouts by spraying. The spraying section 52 is used to form a hole 11c by removing the cutout pieces 11a from the laminated body 10b with cutouts conveyed from the conveying section 51. The spraying section 52 is provided on the upper part of the conveying section 51 so as to face the laminated body 10b with cutouts conveyed from the conveying section 51. The manufacturing device shown in FIG6 may further have a pressing and fixing portion 33 (fixing portion) to press and fix the position of the laminated body 10b with the cut gap when the ejection portion 52 ejects the cut piece 11a. The pressing and fixing portion 33 is on the same side as the ejection portion 52, that is, it is arranged on the upper part of the conveying portion.

The conveying part 51 has a conveying belt 34, and the spraying part 52 is disposed on the upper part of the conveying surface of the conveying belt 34. The position of the cut-off piece 11a of the laminated body 10b with a cut-off gap is provided with a belt hole 34c through which the cut-off piece 11a can pass, so that the cut-off piece 11a can be removed by the spraying part 52. Therefore, the laminated body 10b with a cut-off gap is carried on the conveying belt 34 and conveyed in such a manner that the cut-off piece 11a is arranged at the position of the belt hole 34c.

The spraying part 52 is disposed on the upper part of the conveyor belt 34, and can spray fluids such as air, nitrogen, rare gas, or liquids such as water on the cut piece 11a, preferably one that can spray compressed air. The spraying part 52 can have, for example, a nozzle, and the fluid can be sprayed only on the cut piece 11a or only on the cut piece 11a and its surroundings by adjusting the size of the nozzle.

The pressing and fixing portion 33 is, for example, a pressing rod that presses the periphery of the slit 11b of the laminate 10b with slits. Therefore, when the fluid is ejected from the ejection portion 52, problems such as the displacement of the conveying position of the laminate 10b with slits or the laminate 10c with holes can be suppressed. The manufacturing device shown in FIG6 shows an example of a case where two pressing rods are provided on the periphery of the slit 11b in a direction perpendicular to the conveying direction. As described in the previous embodiment, the pressing and fixing portion 33 is preferably pressed at a position that contacts the end of the product extending in a direction that is not perpendicular to the conveying direction of the laminate 10b with slits. The pressing and fixing part 33 is represented by two arrows in FIG. 6 , for example, and can move forward and backward synchronously with the fluid sprayed by the spray part 52 , and the spray part 52 can press and press the laminate 10b attached to the cut gap when the fluid is sprayed onto the cut piece 11a .

In the hole forming step, the laminate with cutouts 10b is sequentially conveyed in the direction indicated by the single arrow in FIG. 6 by driving the conveyor belt 34. When the cutout piece 11a of the laminate with cutouts 10b reaches the setting position of the spraying portion 52, the pressing and fixing portion 33 moves in and out of the conveyor belt 34. Therefore, the position of the laminate with cutouts 10b is fixed by pressing the surrounding of the cutout 11b of the laminate with cutouts 10b by the pressing and fixing portion 33, and the spraying portion 52 sprays the fluid toward the cutout piece 11a in this state. The cutout piece 11a sprayed with the fluid is removed from the belt hole 34c of the conveyor belt 34 to the outside of the conveyor portion 51, and the laminate with holes 10c can be obtained. The obtained open-cell laminate 10c is continuously or intermittently transported by a conveyor belt 34 (Fig. 6).

The ejection of the piece 11a by the ejection unit 52 may be performed while the laminated body 10b with the cutouts is continuously conveyed, or may be performed during the intermittent conveyance of the laminated body 10b with the cutouts and during the stop period of the conveyance of the laminated body 10b with the cutouts. When the ejection unit 52 ejects fluid to the cut-off piece 11a, if the laminate 10b with cut-off gaps is pressed and fixed intermittently, the laminate 10b with cut-off gaps is appropriately fixed by the pressing and fixing unit 33, and the fluid is appropriately sprayed on the cut-off piece 11a, and the laminate 10b with cut-off gaps is transported intermittently, and preferably, the pressing and fixing by the pressing and fixing unit 33 and the ejection of fluid by the ejection unit 52 are performed during the stop period of temporarily stopping the transport. At this time, the laminate 10b with cut-off gaps or the laminate 10c with holes is preferably transported by pressing by the pressing and fixing unit 33 or ejecting fluid by the ejection unit 52.

As shown in FIG6 , according to this embodiment, the cut piece 11a can be removed by fluid jetting while conveying the laminate 10b with the cut gap, so the hole forming step can be effectively performed.

In the manufacturing device shown in FIG. 6, although the ejection part 52 is disposed on the upper part of the conveyor belt 34, its position is not particularly limited as long as it can press the cut piece 11a of the laminated body 10b with a cutout on the conveyor belt 34. For example, it can be disposed on the lower part of the conveyor belt 34. If the ejection part is disposed on the lower part of the conveyor belt 34, the pressing and fixing part is preferably also disposed on the lower part of the conveyor belt 34.

In the manufacturing device shown in FIG6, although the ejection part 2 capable of ejecting fluid is specially arranged on the cut piece 11a, there is no limitation as long as an external force can be applied to remove the cut piece 11a from the layered body 10b with cut gaps. For example, the ejection part can be arranged along a line perpendicular to the conveying direction of the layered body 10b with cut gaps, and the fluid can be ejected on the cut piece 11a and its surroundings. In the manufacturing device shown in FIG6, although the ejection part is arranged at a specific position on the conveyor belt as an example, the ejection part can also be arranged to move synchronously with the conveying of the layered body 10b with cut gaps.

In the manufacturing device shown in FIG. 6, although two pressing rods are used as the pressing fixing portion 33 as an example, as described in the previous embodiment, as long as the periphery of the cut slit 11b can be pressed, there is no particular restriction on the number or shape of the pressing rods, and one pressing rod may be used, or a pressing fixing portion of a surrounding shape surrounding the cut slit 11b may be provided.

A fixing portion that can fix the position of the laminated body 10b with cutouts can be used instead of the pressing fixing portion 33. For example, a suction fixing portion (fixing portion) for fixing the position of the laminated body 10b with cutouts by suction can be provided instead of the pressing fixing portion 33. In addition, if the position of the laminated body 10b with cutouts can be sufficiently fixed, the fixing portion may not be provided.

As described in the previous embodiment, the manufacturing device shown in FIG6 can be provided with a punching blade for forming the slits 11b in the lamination direction of the material lamination 10a on the upstream side of the conveying direction of the slit-attached laminate 10b. Therefore, the slit-attached laminate 10b can be obtained from the material lamination 10a, and the obtained slit-attached laminate 10b can be conveyed continuously or intermittently to perform the step of forming holes.

The manufacturing device shown in FIG6 may be provided with a collecting section for collecting the excised pieces 11a removed by the conveying section 51, and may be provided with an excised piece discharge section for discharging the excised pieces 11a outside the manufacturing device.

[Implementation Type 4]

In this embodiment, the same hole-opening laminate, slit-attached laminate, and material laminate described in the previous embodiment are also listed as an example of a case where the hole-opening laminate, slit-attached laminate, and material laminate are polarizing plates. The following mainly describes the differences from the previous embodiment, and omits the same points as the previous embodiment.

FIG. 7 is a schematic diagram schematically showing another example of the manufacturing device of the open-hole laminated body of the present embodiment. In the manufacturing device of the open-hole laminated body of the present embodiment, a manufacturing device with a spraying part between a set of rollers (FIG. 6) is used, replacing the manufacturing device with a spraying part 52 (FIG. 6) on the conveyor belt 34 used in the previous embodiment, which is different from the previous embodiment in the hole forming step.

The manufacturing device shown in FIG7 has a conveying section 51 for continuously or intermittently conveying the laminated body 10b with cutouts, and a spraying section 52 for applying a force (external force) of spraying fluid to the cutout pieces 11a on the laminated body 10b with cutouts to spray and remove the cutout pieces 11a from the laminated body 10b with cutouts. The spraying section 52 is used to remove the cutout pieces 11a from the laminated body 10b with cutouts conveyed by the conveying section 61 to form holes 11c. The spraying section 52 is provided on the upper part of the conveying section 61 in a manner facing the laminated body 10b with cutouts conveyed by the conveying section 61.

The conveying section 61 has a first conveying belt 62a (conveyor belt), a set of clamping rollers 63a, 63b (conveyor rollers), and a second conveying belt 62b (conveyor belt) in order from the upstream side of the conveying direction of the laminated body 10b with cutouts. The first conveying belt 62a conveys the laminated body 10b with cutouts, and the second conveying belt 62b conveys the laminated body 10b with cutouts passing through the set of clamping rollers 63a, 63b or conveys the open-hole laminated body 10c from which the cutout piece 11a has been removed from the laminated body 10b with cutouts (Fig. 7).

A set of clamping rollers 63a, 63b each has a pair of rollers, and can function as a fixing part to fix the position of the laminated body with cut-off gaps 10b when the ejection part 52 ejects fluid on the cut-off piece 11a while the laminated body with cut-off gaps 10b is transported in a state of being sandwiched between the pair of rollers. A set of clamping rollers 63a, 63b is arranged side by side in the axial direction of the clamping rollers 63a, 63b (in a direction perpendicular to the transport direction of the laminated body with cut-off gaps 10b) at a certain interval in a manner that does not press the cut-off gaps 11b of the laminated body with cut-off gaps 10b that can be transported (Figure 7). It is preferred that at least one of the pair of rollers on the clamping rollers 63a, 63b is provided with a driving force.

The spraying part 52 is provided at the upper part between a set of rollers 63a and 63b, for example, as shown in FIG. 7, so as to spray a fluid to the cut piece 11a of the laminate 10b passing through the cut gap between the set of rollers 63a and 63b. The spraying part 52 is capable of spraying a fluid such as air, nitrogen, rare gas, or liquid such as water to the cut piece 11a, preferably capable of spraying compressed air. The spraying part 52 may have, for example, a spray nozzle, and the fluid may be sprayed only to the cut piece 11a or the cut piece 11a and its surroundings by adjusting the size of the spray nozzle.

In the hole forming step, the laminate 10b with cutouts can be sequentially conveyed in the direction indicated by an arrow in FIG. 7 by driving the first conveyor belt 62a. When the laminate 10b with cutouts reaches the position of a set of clamping rollers 63a and 63b, it is conveyed by the first conveyor belt 62a and the set of clamping rollers 63a and 63b. When the cutout pieces 11a of the laminate 10b with cutouts reach the position of the set of clamping rollers 63a and 63b by the conveying, the cutout pieces 11a are removed from between the set of clamping rollers 63a and 63b to the outside of the conveying portion 61 by the force of the spray fluid from the spraying portion 52, thereby obtaining a laminate 10c with holes. The resulting open-cell laminate 10c (Fig. 7) can be continuously or intermittently conveyed by a set of rollers 63a, 63b or the second conveyor belt 62b.

The fluid spraying of the excised piece 11a by the spraying unit 52 can be performed while the laminated body 10b with cutouts is continuously conveyed, or can be performed during the period of stopping the intermittent conveyance of the laminated body 10b with cutouts. In the manufacturing apparatus shown in FIG7, since a set of clamping rollers 63a, 63b can be used to clamp the laminated body 10b with cutouts and fix the position while conveying, the fluid spraying by the spraying unit 52 can be performed while the laminated body 10b with cutouts is continuously conveyed. In this way, in the hole forming step, a set of clamping rollers 63a, 63b can be used to continuously or intermittently transport the laminate 10b with the cut gap and remove the cut piece 11a at the same time.

As shown in FIG. 7, according to this embodiment, the hole forming step can be effectively performed because the cut piece 11a can be removed by fluid jetting while the laminate 10b with the cut gap is being transported.

In the manufacturing device shown in FIG. 7, although the spraying part 52 is disposed above a set of clamping rollers 63a and 63b, the spraying part may also be disposed below a set of clamping rollers 63a and 63b.

As described in the previous embodiment, the manufacturing device shown in FIG. 7 can be provided with a punching blade for forming the slits 11b in the lamination direction of the material lamination 10a on the upstream side of the conveying direction of the slit-attached laminate 10b. Therefore, the slit-attached laminate 10b can be obtained from the material lamination 10a, and the obtained slit-attached laminate 10b can be conveyed continuously or intermittently to perform the hole forming step.

As described in the previous embodiment, the manufacturing device shown in FIG. 7 can be provided as a collecting section for collecting the excised pieces 11a removed by the conveying section 51, and can be provided as an excised piece discharge section for discharging the excised pieces 11a to the outside of the manufacturing device. The collecting section and the excised piece discharge section can be provided, for example, between a set of rollers 63a and 63b.

Although the above is an explanation of the implementation of the present invention, the present invention is not limited to these implementations, and the structures and steps of the above implementations can also be implemented in combination. The following details the common matters in all implementations or the variations of the above implementations.

(Manufacturing method of open-cell laminate)

As described above, the manufacturing method of the present invention includes the steps of preparing a laminate with cutouts and forming holes.

The aforementioned preparation steps may include an operation of forming a slit in the lamination direction of the material laminate by punching with a punching blade as an operation for obtaining a laminate with a slit.

The hole is usually formed by applying an external force to the cut piece. The external force is at least one of a force of pressing the cut piece by a pressing member, a suction force of sucking the cut piece, and a force of spraying a fluid on the cut piece.

In the step of forming the aforementioned hole, the aforementioned layered body with the cutout is typically transported by at least one of a conveyor belt, a conveyor roller, and a rotating table.

In the step of forming the aforementioned hole, the aforementioned laminate with the cutout gap may be transported intermittently, and the aforementioned excised piece may be removed during the period of stopping the transport of the aforementioned laminate with the cutout gap.

The step of forming the aforementioned hole may further include the operation of transporting the hole-opening laminate obtained by the removal operation after removing the cut piece from the laminate with the cut gap.

(Device for manufacturing porous laminated bodies)

The manufacturing device of the hole-opening laminate of the present invention has a conveying part for continuously or intermittently conveying the laminate 10b with cutouts, and a hole forming part for forming holes 11c by removing the cutout pieces 11a formed by the cutouts 11b from the laminate 10b with cutouts conveyed by the conveying part.

As described in the previous embodiment, the manufacturing device of the present invention can be provided with a mechanism for forming a layered body 10b with a cutout from a material layered body 10a on the upstream side of the conveying direction of the layered body 10b with a cutout. The mechanism can be a punching blade for forming a cutout 11b in the lamination direction of the material layered body 10a.

The conveying section may typically be provided with at least one of a conveying belt, a conveying roller, and a rotating table for conveying the laminate 10b with cutouts.

In the manufacturing device of the open hole laminate (open hole laminate) of the above-mentioned embodiment, although the case where a conveyor belt is provided in the conveying part (Figures 4 to 6) and the case where a conveyor belt and a conveyor roller are provided (Figure 7) are cited as examples for explanation, it is not limited to this. A conveyor roller or a rotating table may be used instead of a conveyor belt, and these may be combined arbitrarily.

In addition, a fixed table and a conveying arm can also be provided on the conveying section, and the conveying arm can be used to lift the laminated body with cutouts or the laminated body with holes carried on the fixed table and convey it to another fixed table.

The conveying unit can convey the laminated body with cutouts or the laminated body with holes, either individually or in a state where two or more layers are laminated. When the laminated body with two or more layers or the laminated body with holes is conveyed, the above-mentioned hole forming step can also be performed in this laminated state.

The hole forming part includes at least one of a pressing part for pressing by a pressing member such as a nail, a suction part for sucking the cut piece, and a spraying part for spraying a fluid on the cut piece.

The manufacturing device of the above-mentioned embodiment can be provided with a cutting tool such as a milling cutter for grinding the hole of the holed laminated body on the downstream side of the conveying direction of the holed laminated body after the cut-off piece is removed from the cut-off laminated body. At this time, after the hole forming step, the processing quality or dimensional accuracy of the hole can be improved by grinding the hole of the holed laminated body after the cut-off portion is removed from the cut-off laminated body with the cut-off portion using the cutting tool.

The manufacturing device of the above-mentioned embodiment may also be provided with an inspection unit for checking whether the cut pieces have been removed on the downstream side of the conveying direction of the holed laminated body after the cut pieces have been removed from the laminated body with the cutout. The inspection unit is configured to inspect the removal state of the cut pieces by, for example, photographing the hole state of the holed laminated body with a camera. The inspection unit may be performed before grinding with the above-mentioned cutting tool or after grinding.

The manufacturing device of the above-mentioned embodiment may also be provided with a device (such as an adhesive roller) for removing foreign matter attached to the surface of the holed laminate after the cut piece is removed from the laminate with the cutout. The device may be provided on the downstream side of the holed laminate in the conveying direction of the inspection unit, or on the upstream side of the conveying direction.

(Material layer)

In the above-mentioned implementation form, although the case where the material laminate is a linear polarizer is cited as an example for explanation, it is not limited to this. Although the material laminate has no particular restrictions on its structure or number of layers as long as it has one or more resin film layers and one or more bonding layers, it is preferred that the resin film layers are provided on both sides of the bonding layer. For example, the material laminate may be a laminate having an optical layer (resin film layer) and a bonding layer, a laminate having a resin film layer other than an optical layer and a bonding layer, or a laminate having a resin film layer other than an optical layer, an optical layer, and a bonding layer.

Optical layers used on the material laminate include, for example, linear polarizers (polarizers), phase difference films, brightness enhancement films, anti-glare films, anti-reflection films, diffusion films, and focusing films. Such optical layers may be used alone or in combination of two or more. A material laminate having an optical layer includes a linear polarizer having a protective film on one or both sides of the linear polarizer with a bonding layer interposed therebetween. The material laminate containing the optical layer may further include a bonding layer for bonding to other components such as a display panel or a display element, and a release film (resin film layer) for coating and protecting the bonding layer.

Examples of material laminates without optical layers include protective films (surface protective films) laminated on the outside of optical films such as polarizing plates. Protective films are laminated in order, for example, with a base film (resin film layer), a bonding layer, and a release film (resin film layer).

Specific examples of the material laminate include, in addition to the above-mentioned polarizing plate and protective film, a polarizing plate with a protective film having a polarizing plate and a protective film, a circular polarizing plate having a linear polarizing plate and a retardation film, etc. The retardation film used in the circular polarizing plate includes a λ/2 layer, a λ/4 layer, a λ/4 layer with reverse wavelength dispersion, a positive C layer, etc. The layer structure of the circular polarizing plate may include, for example, a linear polarizing plate, a laminating layer, a λ/2 layer, a laminating layer, and a λ/4 layer laminated in sequence, a linear polarizing plate, a laminating layer, a λ/4 layer with reverse wavelength dispersion, a laminating layer, and a positive C layer laminated in sequence, and a linear polarizing plate, a laminating layer, a positive C layer, a laminating layer, and a λ/4 layer with reverse wavelength dispersion laminated in sequence. The phase difference film may be a resin film or a cured film of a polymerizable liquid crystal compound.

(Laminar body with cutouts)

In the above-mentioned embodiment, although the case where the laminate with notches is a linear polarizer is cited as an example for explanation, it is not limited to this. The layer structure of the laminate with notches can be cited as having the same layer structure as the above-mentioned material laminate. On the above-mentioned material laminate, the notches are formed by penetrating the material laminate in the lamination direction, and the laminate with notches can be obtained.

There is no particular limitation on the laminated body with cutouts, and examples thereof include laminated bodies.

As an example of a laminate with a cutout, there can be cited a laminate in which a base film, the aforementioned laminating layer, and the aforementioned peeling film are laminated in sequence, or a laminate in which a polarizing plate having the aforementioned protective film laminated on one or both sides of a linear polarizer is laminated.

(Open hole layer)

In the above-mentioned embodiment, although the case where the hole-opening laminate is a polarizing plate is cited as an example for explanation, it is not limited to this. The layer structure of the hole-opening laminate can be cited as having the same layer structure as the above-mentioned material laminate or the above-mentioned laminate with cutouts. The hole-opening laminate can be obtained by removing the cutout piece from the above-mentioned laminate with cutouts.

The hole diameter is preferably 1mm or more, and can be 3mm or more, 5mm or more, or 7mm or more. It is preferably 20mm or less, and can be 18mm or less, 15mm or less, or 12mm or less.

The hole-forming laminate can be used in display devices such as liquid crystal display devices or organic electroluminescent (EL) display devices when a linear polarizer is used as an optical layer. By arranging holes in the hole-forming laminate in the area where the camera lens of a display device such as a smartphone or tablet terminal can be arranged or in the area where an image or logo can be printed, it is possible to achieve this in a manner where a linear polarizer is not arranged in such an area.

(Linear polarizer)

A linear polarizer is a layer or film that has the function of selectively passing a linear polarization in a certain direction from natural light. Examples of linear polarizers include films on which dichroic pigments are adsorbed and oriented on a polyvinyl alcohol resin film that is uniaxially or biaxially extended. Examples of dichroic pigments include iodine and dichroic organic dyes. In addition, a linear polarizer can be a coating-type polarizing film in which a dichroic dye in a lyotropic liquid crystal state is coated on a substrate film and oriented and fixed.

The thickness of the linear polarizer can be made below 40μm, preferably below 30μm (for example, below 20μm, below 15μm is better, below 10μm or below 8μm is even better). The thickness of the linear polarizer is usually above 2μm.

(Protective film)

The protective film provided on one or both sides of the linear polarizer is not limited as long as it is a light-transmitting resin film. Examples of resin films include cyclic polyolefin resin films, cellulose acetate resin films formed from resins such as triacetyl cellulose and diacetyl cellulose, polyester resin films formed from resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate, polycarbonate resin films, (meth) acrylic resin films, polypropylene resin films, and other films known in the field. From the perspective of thinning, the thickness of the protective film is usually 300 μm or less, preferably 200 μm or less, and more preferably 100 μm or less. In addition, it is usually 5 μm or more, and preferably 20 μm or more. The protective film may or may not have optical functions such as phase difference characteristics or brightness improvement. The protective film having phase difference characteristics can be obtained by extending a transparent resin film formed from the above-mentioned materials (uniaxial extension or biaxial extension, etc.) or forming a liquid crystal layer on the film, etc., to give an arbitrary phase difference value.

The protective film may be formed with a hard coating. The hard coating may be formed on one side of the transparent resin film formed of the above-mentioned material, or may be formed on both sides. By providing a hard coating, a protective film with improved hardness and scratch resistance can be made. The hard coating is, for example, a hardened layer of a UV-curable resin. Examples of UV-curable resins include acrylic resins, organic silicone resins, polyester resins, polyurethane resins, amide resins, and epoxy resins. The hard coating may also contain additives to increase strength. The additives are not limited, and may include inorganic particles, organic particles, or mixtures thereof.

(Protective film)

The protective film has a base film, a laminating layer and a peeling film as described above. The resin constituting the base film is not particularly limited, and can be a thermoplastic resin such as polyethylene resin such as polyethylene, polypropylene resin such as polypropylene, polyester resin such as polyethylene terephthalate or polyethylene naphthalate, polycarbonate resin, etc. It is preferred to use polyester resins such as polyethylene terephthalate.

The release film may be a film formed from polyethylene resins such as polyethylene, polypropylene resins such as polypropylene, polyester resins such as polyethylene terephthalate, etc., and subjected to release treatment using silicone coating or the like.

(bonding layer)

The bonding layer can be an adhesive layer formed by an adhesive or an adhesive layer formed by an adhesive. As mentioned above, when an adhesive layer is included as a bonding layer, there is a tendency that the cut piece 11a is easily left in the laminate 10b with a cut gap. Therefore, the manufacturing method and manufacturing device of each embodiment described above can be applied to the case where a material laminate, a laminate with a cut gap, and a laminate with a hole have an adhesive layer as a bonding layer.

The adhesive used in the adhesive layer may be one using (meth)acrylic resins, organic silicone resins, polyester resins, polyurethane resins, polyether resins, etc. as base polymers. Among them, (meth)acrylic adhesives are preferred from the viewpoints of transparency, adhesion, reliability, weather resistance, heat resistance, and finishing processability. In the (meth)acrylic adhesive, (meth)acrylic alkyl esters having an alkyl group with a carbon number of 20 or less such as methyl, ethyl, n-, iso-, or t-butyl and (meth)acrylic acid or (meth)acrylic monomers containing functional groups such as (meth)acrylic acid hydroxyethyl ester are mixed in a manner such that the glass transition temperature is preferably below 25°C, and more preferably below 0°C, to form a (meth)acrylic resin having a weight average molecular weight of 100,000 or more as the base polymer.

The thickness of the adhesive layer depends on its adhesion, etc., but it is appropriate to be in the range of 1μm to 50μm, and preferably in the range of 2μm to 40μm.

The adhesive layer used in the adhesive layer includes known water-based compositions (including water-based adhesives) in which the curable resin component is dissolved or dispersed in water and known active energy ray-curable compositions (including active energy ray-curable adhesives) containing active energy ray-curable compounds.

The resin component contained in the water-based composition may include polyvinyl alcohol resin or polyurethane resin. The active energy ray-curable composition is a composition that is cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. The composition that is cured by irradiation with active energy rays is preferably an ultraviolet ray-curable composition, and more preferably contains an epoxy compound that is cured by cationic polymerization as a curing component.

There is no particular restriction on the thickness of the adhesive layer. The appropriate range is 1 μm to 50 μm, and the best range is 2 μm to 40 μm.

The above-mentioned open hole laminate can be applied to, for example, a display device. When the open hole laminate is applied to a display device, the open hole laminate alone, or the open hole laminate and the front panel or back panel laminate can be made into an optical laminate and applied to the display device.

When the optical laminate has a front panel or a back panel, and the open-hole laminate contains an optical layer such as a linear polarizer or a phase difference film, the optical laminate may have a front panel, an open-hole laminate, and a back panel in sequence.

(Front panel)

The front panel is the outermost surface of the viewing side of the display device and can protect the front (screen) of the display device. The front panel is preferably a light-transmitting plate. The front panel can be composed of only one layer or more than two layers. The front panel can have the function of cutting off blue light, adjusting the viewing angle, etc.

The front panel may be a glass plate (glass plate, flexible thin glass, etc.), a resin plate (resin plate, resin sheet, resin film (also called window film), etc.), and a plate showing flexibility is preferred. Among the above, a resin plate such as a resin film is preferred.

Examples of the resin plate-like body include resin films formed of thermoplastic resins. Examples of the thermoplastic resins include polyolefin resins such as chain polyolefin resins (polyethylene resins, polypropylene resins, polymethylpentene resins, etc.) and cyclic polyolefin resins (norbornene resins, etc.); cellulose resins such as triacetyl cellulose; polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate; polycarbonate resins; ethylene-vinyl acetate resins; Polystyrene resins; polyamide resins; polyetherimide resins; polymethyl (meth)acrylate resins, etc. (meth)acrylic resins; polyimide resins; polyethersulfone resins; polysulfone resins; polyvinyl chloride resins; polyvinylidene chloride resins; polyvinyl alcohol resins; polyvinyl acetal resins; polyetherketone resins; polyetheretherketone resins; polyethersulfone resins; polyamideimide resins, etc.

Thermoplastic resins can be used alone or as a mixture of two or more.

Among them, from the viewpoints of flexibility, strength and transparency, the thermoplastic resin constituting the front panel can be applied to polyimide resin, polyamide resin, and polyamide imide resin.

The front panel can be provided with a hard coating layer on at least one side of the base film to further improve the hardness of the film. The base film can use the above-mentioned resin film.

The hard coating layer can be formed on one side of the substrate film or on both sides. The hard coating layer can be provided to improve the hardness and scratch resistance. The thickness of the hard coating layer can be, for example, 0.1 μm to 30 μm, preferably 1 μm to 20 μm, and more preferably 5 μm to 15 μm.

The hard coating layer is a hardened layer of, for example, a UV-curable resin. Examples of UV-curable resins include (meth)acrylic resins, organic silicone resins, polyester resins, polyurethane resins, amide resins, and epoxy resins. The hard coating layer may contain additives to increase strength. The additives are not limited, and examples include inorganic microparticles, organic microparticles, and mixtures thereof.

The thickness of the front panel may be, for example, 20 μm to 2000 μm, preferably 25 μm to 1500 μm, more preferably 30 μm to 1000 μm, more preferably 40 μm to 500 μm, more preferably 40 μm to 200 μm, and more preferably 40 μm to 100 μm.

(Back panel)

The back panel is preferably a light-transmitting plate. The back panel can be composed of only one layer or more than two layers.

The back panel may constitute an image display element layer such as a liquid crystal panel or an organic display element of a display device.

Similar to the front panel, the back panel may be a plate-like body made of glass (e.g., a glass plate, a glass film, etc.), or a plate-like body made of resin (e.g., a resin plate, a resin sheet, a resin film, etc.).

Specific examples of thermoplastic resins constituting the resin plate-like body include the thermoplastic resins exemplified in the front panel. Thermoplastic resins are preferably cellulose resins, (meth) acrylic resins, cyclic polyolefin resins, polyester resins, polycarbonate resins, etc.

From the perspective of thinness, the thickness of the back panel is preferably between 15μm and 200μm, more preferably between 20μm and 150μm, and even more preferably between 30μm and 130μm.

(Display device)

When the open-cell laminate contains an optical layer such as a linear polarizer or a phase difference film, it can be applied to a display device. There is no particular limitation on the display device, and examples thereof include a liquid crystal display device, an organic EL display device, etc.

The display device may be a display device having flexibility (flexibility) that can be folded, bent, or repeatedly rolled up.

Claims (19)

A method for manufacturing a porous laminate having a hole penetrating the laminate comprises the following steps: a step of preparing a laminate with a slit, wherein the laminate with a slit has one or more resin film layers and one or more bonding layers, and has a slit penetrating the laminate and a cut-off piece formed by the slit; and a step of forming a hole by continuously or intermittently conveying the laminate with a slit and simultaneously conveying the slit from the laminate to the substrate. The aforementioned hole is formed by removing the aforementioned cut-off piece from the aforementioned laminate with cut-off gaps; in the aforementioned step of forming the hole, a set of clamping rollers are arranged side by side at a certain interval in a direction perpendicular to the conveying direction of the aforementioned laminate with cut-off gaps without pressing the aforementioned cut-off gaps, the aforementioned laminate with cut-off gaps is conveyed by the aforementioned set of clamping rollers, and the aforementioned cut-off piece of the laminate with cut-off gaps passing between the aforementioned set of clamping rollers is subjected to a jetting fluid force, thereby forming the aforementioned hole. The manufacturing method of the hole-opening laminate as described in claim 1, wherein the aforementioned preparation step includes the operation of forming the aforementioned slit by cutting with a punch blade in the lamination direction of the material laminate having the aforementioned one or more resin layers and the aforementioned one or more bonding layers. A method for manufacturing a hole-carrying laminate as described in claim 1 or 2, wherein the diameter of the hole is greater than 1 mm and less than 20 mm. A method for manufacturing a laminate with holes as described in claim 1 or 2, wherein in the step of forming holes, the laminate with cutouts is transported intermittently, and the cutout pieces are removed during the period of stopping the transport of the laminate with cutouts. The manufacturing method of the open-hole laminate as described in claim 1 or 2, wherein the step of forming the hole further includes the operation of transporting the open-hole laminate obtained by the removal operation after removing the cut piece from the laminate with the cut gap. The manufacturing method of the open-hole laminate as described in claim 5, wherein a first conveyor belt, a set of clamping rollers and a second conveyor belt are sequentially provided from the upstream side of the conveying direction of the aforementioned laminate with cutouts, and in the aforementioned step of forming holes, the aforementioned laminate with cutouts is conveyed by the aforementioned first conveyor belt and the aforementioned set of clamping rollers, and the aforementioned open-hole laminate obtained by the aforementioned removal operation is conveyed by the aforementioned second conveyor belt. A method for manufacturing a porous laminate as described in claim 1 or 2, wherein the laminate with cutouts is a sheet-like body. The manufacturing method of the open hole laminate as described in claim 1 or 2, wherein the laminate with cutouts comprises a base film and a release film as the resin film, and the base film, the bonding layer and the release film are laminated in this order. A method for manufacturing a multilayer with holes as described in claim 1 or 2, wherein the multilayer with cutouts comprises a linear polarizer and a protective film as the resin film, and the protective film is laminated on one or both sides of the linear polarizer. A method for manufacturing a porous laminate as described in claim 1 or 2, wherein the bonding layer is an adhesive layer or a bonding agent layer. A method for manufacturing a porous laminate as described in claim 1 or 2, wherein in the step of forming the holes, the fluid is sprayed from a spray nozzle onto the cut piece. A method for manufacturing a porous laminate as described in claim 1 or 2, wherein the fluid is a gas. A manufacturing device for a hole-opening laminate, wherein the hole-opening laminate has holes penetrating the laminate, and the manufacturing device comprises: a conveying unit for continuously or intermittently conveying the laminate with cutouts, wherein the laminate with cutouts has one or more resin film layers and one or more bonding layers, and has cutouts penetrating the laminate and cutouts formed by the cutouts; and a hole forming unit for forming the aforementioned holes, which is a unit for continuously or intermittently conveying the laminate with cutouts by the conveying unit. The aforementioned layered body with cutouts is removed from the aforementioned cutout pieces to form the aforementioned holes; a set of rollers is provided in the aforementioned conveying section, the aforementioned set of rollers is arranged side by side at a certain interval in a direction orthogonal to the conveying direction of the aforementioned layered body with cutouts without pressing the aforementioned cutouts, and is used to roll and convey the aforementioned layered body with cutouts, and the aforementioned hole forming section includes a spraying section to spray a fluid on the aforementioned cutout pieces of the aforementioned layered body with cutouts passing between the aforementioned set of rollers. The manufacturing device of the open hole laminate as described in claim 13 is further provided with: a mechanism for obtaining the aforementioned laminate with cutouts by laminating a material laminate having at least one resin film layer and at least one bonding layer. The manufacturing device of the hole-perforated laminate as described in claim 14, wherein the mechanism for obtaining the laminate with the aforementioned slit by the aforementioned material laminate is provided with a punching blade for forming the aforementioned slit in the lamination direction of the aforementioned material laminate. A manufacturing device for a multilayer body with holes as described in any one of claims 13 to 15, wherein the conveying unit can immediately convey the multilayer body with holes after removing the cut-off piece. A manufacturing device for a layered structure with holes as described in any one of claims 13 to 15, wherein the conveying section is provided with a first conveyor belt, a set of clamping rollers and a second conveyor belt in sequence from the upstream side of the conveying direction of the layered structure with cutouts, the layered structure with cutouts is conveyed by the first conveyor belt and the set of clamping rollers, and the layered structure with holes is conveyed by the second conveyor belt immediately after the cutout pieces are removed. A manufacturing device for a porous laminate as described in any one of claims 13 to 15, wherein the spraying portion is provided with a spray nozzle for spraying the fluid. A manufacturing device for a porous laminate as described in any one of claims 13 to 15, wherein the aforementioned fluid is a gas.

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