WO2009054519A1

WO2009054519A1 - Process for producing optical display panel

Info

Publication number: WO2009054519A1
Application number: PCT/JP2008/069390
Authority: WO
Inventors: Kiyoshi Muto; Yoshiki Matsuoka; Yuuhei Inokuchi
Original assignee: Sumitomo Chemical Company, Limited
Priority date: 2007-10-25
Filing date: 2008-10-20
Publication date: 2009-04-30

Abstract

A process for producing an optical display panel by laminating an optical laminated sheet to an optical display element without fouling or marring the optical laminated sheet. A process for producing an optical laminated sheet is also provided which comprises: a step in which continuous optical sheets (1 and 3; and 11 and 13) are drawn out respectively of rolls (2 and 4; and 12 and 14); a first laminating step in which the optical sheets drawn are laminated to form a continuous optical laminated sheet; a second laminating step in which the optical laminated sheet is laminated as it is to an optical display element (7); and a cutting step in which the optical laminated sheet is cut. In the cutting step, the optical laminated sheet is cut into a size having an area which is larger than that of the display region of the optical display element and is smaller than that of the optical display element itself. The second laminating step may follow the cutting step.

Description

Specification

Manufacturing method of optical display panel

The present invention relates to a method for manufacturing an optical display panel. Background art

Conventionally, optical member manufacturers have continuously rolled a long optical film having an optical function such as a polarizing plate used in a liquid crystal display device or an optical sheet that is a laminate thereof in a roll shape. Manufactured. For example, a polarizing plate manufactured in this way is delivered to a panel processing manufacturer, and the panel processing manufacturer uses a liquid crystal display element (an optical display element in which liquid crystal is sealed between two glass plates, also called a liquid crystal display). ). In this way, a liquid crystal panel used for a liquid crystal display device is manufactured. Conventionally, when an optical component manufacturer delivers optical components such as the polarizing plate to a panel processing manufacturer, a sheet obtained by punching a long optical sheet into a predetermined size desired by the panel processing manufacturer ( Optical sheets) were packed in several layers.

In this way, when optical parts manufacturers pack several optical sheets that are obtained by punching to a predetermined size, a high working environment is required so that dust and dirt do not occur. It has been. Also, packing materials were specially selected and packing work had to be done carefully so that scratches and cracks would not occur during transportation. Panel processing manufacturers, on the other hand, use optical sheets that are tightly packed for assembly. However, because the packaging is strict, the work of unpacking is difficult, and cracks can occur when unpacking. It had to be done with extreme caution so as not to occur, and the burden on the workers was large.

In order to solve such a problem, a method in which a long optical sheet is directly bonded to an optical display element (see, for example, Japanese Patent Application Laid-Open No. 11-115050) or a long optical sheet is used. There has been proposed a method of cutting and bonding to an optical display panel in a continuous production line process (refer to Japanese Patent Laid-Open Publication No. 20 07-140 0 46). In addition, in Japanese Patent Application Laid-Open No. 2 0 2 -1 9 6 1 3 2, a polarizing film and a first protective film are pasted and removed, and then the first protective film is pasted. It is disclosed that a polarizing plate is produced by laminating a second protective film on the surface of a non-polarizing film.

Also, in the case of a large optical display device for TV use (for example, a liquid crystal display device), the size varies from about 20 inches to about 100 inches. Therefore, an optical function adapted to the size of this optical display device is provided. There is also a problem that it is necessary to use an optical sheet having the same.

For example, a polarizing plate usually has a structure in which protective films are laminated on both sides of a polarizing film, and an adhesive layer is formed on the outer surface of one protective film. In many cases, the protective film is provided with an optical function. For example, the protective film disposed on the viewing side of the optical display device has a surface treatment (nod coat treatment, antiglare treatment, antireflection treatment, antifouling treatment). The protective film positioned between the polarizing plate and the optical display element is provided with a phase difference function that adjusts the viewing angle, contrast, and hue of the optical display device. May be.

Since a polarizing film has a characteristic that it is easily torn along its stretching direction, a protective film is generally laminated to form a polarizing plate immediately after the production of the polarizing film. At that time, the roll width of the long optical sheet of the polarizing plate needs to be fixed to some extent from the viewpoint of production efficiency. When the roll width of the long optical sheet is fixed, the size of the optical display device varies as described above. Therefore, the polarizing plate must be taken out by cutting according to the size of the optical display device.

As a result, more parts were discarded, and the proportion of products used (recovery efficiency) could be significantly reduced.

The present invention has been made to solve the above-mentioned problems, and the purpose thereof is to provide a method for producing an optical display panel using an optical film that is cleaner than conventional and has fewer defects. It is. The present invention also provides an optical film or its Another object of the present invention is to provide a method for manufacturing an optical display panel, which improves the use efficiency of the optical sheet as a laminate. Disclosure of the invention

The present invention relates to a method for producing an optical display panel by bonding an optical sheet laminate having an optical function to an optical display element, and comprising at least two long optical films having an optical function or a laminate thereof. A drawing process for drawing out a long optical film or a long optical sheet from a plurality of mouthpieces from which a long optical sheet has been scraped, and a plurality of long optical films or long optical sheets drawn out, First, the first bonding step for bonding and forming the long optical sheet laminate, the second bonding step for directly bonding the long optical sheet laminate to the optical display element, and the long optical An optical sheet obtained by cutting a long optical sheet laminate from a bonded body of a sheet laminate and an optical display element in an area that is not less than the display area of the optical display panel and not more than the entire surface of the optical display panel. With stacked bodies A method for manufacturing an optical display panel comprising a cutting step that (hereinafter, referred to this method as "first production method".).

The present invention is also a method for producing an optical display panel by laminating an optical sheet laminate having an optical function to an optical display element, comprising at least two long optical films having an optical function or a laminate thereof. A drawing process for drawing out a long optical film or a long optical sheet from a plurality of rolls from which a long optical sheet is scraped, and a plurality of long optical films or a long optical sheet drawn out, respectively. 1st bonding process which bonds and forms a long optical sheet laminated body, The cutting process which cuts a long optical sheet laminated body, and makes it an optical sheet laminated body, The optical display of the said optical sheet laminated body An optical display panel manufacturing method including a second bonding step for bonding to an element is also provided (hereinafter, this method is referred to as “second manufacturing method”).

As described above, in the present specification, a resin film having one optical function is referred to as an “optical film” in principle, and a laminate of a plurality of types of optical films is generally referred to as an “optical sheet”. The power to call It should be understood that there is no strict distinction between rum and seat. For example, if the base film is coated with an optical layer by surface treatment, it is recognized as one sheet, and as a rule is classified as “optical film”. In addition, as described below, a resin film having a polarizing function itself (for example, a film made of a polybulualcohol resin film in which a dichroic dye is adsorbed and oriented corresponds to this) is called a “polarizing film”. A polarizing film in which another optical film such as a protective film is laminated on at least one side of the polarizing film is called a “polarizing plate”. “Polarizing film” is a kind of “optical film”, and “polarizing plate” is a kind of “optical sheet”. In the first manufacturing method of the present invention or the second manufacturing method of the present invention (hereinafter collectively referred to as “the manufacturing method of the present invention”), it is used for the extraction process. One of the long optical films or the long optical sheets to be used preferably includes a polarizing film made of a polybutyl alcohol resin film.

In the production method of the present invention, one of the long optical sheets subjected to the bow I projecting step is a polarizing film made of a poly (vinyl alcohol) resin film, and heat adhered to at least one surface of the polarizing film. It can be a polarizing plate having a protective film made of a plastic resin.

Further, in the production method of the present invention, one of the long optical sheets subjected to the drawing step is a polarizing film made of a polyvinyl alcohol resin film, an adhesive layer formed on at least one surface of the polarizing film, It may be a polarizing plate having a release film for protecting the adhesive layer. In this case, in the first bonding step or the second bonding step, the release film is peeled off and the exposed adhesive layer is used for bonding to another optical film, optical sheet, or optical display element. Provided.

In the production method of the present invention, one of the long optical sheets used in the drawing step is a polarizing film made of a polybulal alcohol resin film, and a thermoplastic film stuck to one surface of the polarizing film. A polarizing plate having a protective film made of a resin, an adhesive layer formed on the other surface of the polarizing film, and a release film for protecting the adhesive layer may be used. Also in this case, in the first bonding step or the second bonding step, the release film is peeled off, and the exposed adhesive layer is bonded to another optical film, optical sheet, or optical display element. To be served.

Furthermore, in the manufacturing method of the present invention, one of the long optical sheets used in the bow I projecting step was attached to a polarizing film made of a polybulal alcohol resin film and one surface of the polarizing film. A polarizing plate having a protective film made of a thermoplastic resin, an adhesive layer formed on the outer surface of the protective film, and a release film for protecting the adhesive layer may be used. Also in this case, in the first bonding step or the second bonding step, the release film is peeled off, and the exposed adhesive layer is bonded to another optical film, an optical sheet, or an optical display element. To be served.

In the production method of the present invention, it is preferable that one of the long optical film or the long optical sheet subjected to the drawing step includes at least one selected from the following ( _a ) to ( _e ).

(a) a cycloolefin resin film,

(b) Cellulose ester resin film,

(c) polyethylene terephthalate resin film,

(d) (meth) acrylic resin film,

(e) Polypropylene resin film.

In the production method of the present invention, an ultraviolet curable resin adhesive may be used for bonding the long optical film or the long optical sheet and the other long optical film or the long optical sheet in the first bonding step. It is mentioned as one of the preferable forms.

Moreover, a liquid crystal panel can be mentioned as a typical example of the optical display panel manufactured by the manufacturing method of this invention, In this case, an optical display element is a liquid crystal display element. Furthermore, when the optical display element is a liquid crystal display element, it is customary to have different film configurations on the front and back sides (viewing side and backlight side), but some of them, for example, polarizing films, There is also an advantage that it can be shared. Specifically, the polarizing plate on the viewing side of the liquid crystal display element is subjected to surface treatment such as anti-glare treatment or anti-reflection treatment. In many cases, the pack light side polarizing plate is given a unique function such as a light diffusion function or a brightness enhancement function. Conventionally, the required optical film or sheet is used as an optical member to meet these requirements. When we were laminating and delivering to panel processing, we used one type of polarizing film to make up the front and back polarizing plates, and different opticals required for the front and back of the liquid crystal display element. It is also possible to take a form in which a film or an optical sheet is bonded and further bonded to a liquid crystal display element. Brief Description of Drawings

FIG. 1 is a diagram schematically showing a preferred example of the first manufacturing method among the methods for manufacturing an optical display panel according to the present invention.

Fig. 2 Fig. 2 (a) is a diagram showing a schematic cross-section of the long optical sheet i drawn from the drawing roll 2 in the example shown in Fig. 1, and Fig. 2 (b) is drawn from the drawing roll 4. 3 is a diagram showing a schematic cross section of a long optical sheet 3. FIG.

FIG. 3 is a diagram schematically showing another preferred example of the first production method according to the present invention.

FIG. 4 is a diagram schematically showing still another preferred example of the first production method according to the present invention.

FIG. 5 is a diagram schematically showing the first half of a preferred example of the second manufacturing method among the methods for manufacturing an optical display panel according to the present invention.

FIG. 6 is a diagram schematically showing the latter half of a preferred example of the second manufacturing method among the methods for manufacturing an optical display panel according to the present invention.

Fig. 7 After laminating the optical sheet laminate on one surface of the optical display element, the optical display element is turned upside down and the conveyance direction is rotated 90 degrees to the other surface of the optical display element. It is a perspective view showing typically an example in the case of pasting another optical sheet laminated body. Explanation of symbols 1, 1 1, 3, 13, 21, 23, 31, 41 Long optical sheet, 2, 4, 1 2, 14, 22, 24, 26, 32, 34, 42 Draw roll, 25, 33 Long optical Film, 5, 15, 27, 28, 35, 43 First bonding roller, 6, 1 6, 55, 56 Second bonding roller, 7 Optical display element, 8 Polarizing film, 9 Protective film, 10 Adhesive Layer, 1 7 surface treatment film, 18 adhesive layer, 51, 52 optical sheet laminate, 53, 54, 74, 75 cutting means, 57, 58 release roll, 59, 60 release film after peeling, 61, 62 Collection roll, 71 1st transport section, 72 2nd transport section, 77 Reverse section. BEST MODE FOR CARRYING OUT THE INVENTION

The present invention is a method for producing an optical display panel by bonding an optical sheet laminate having an optical function to an optical display element, the first production method of the present invention and the second production method of the present invention. It can be roughly divided into manufacturing methods. The optical display panel manufactured in the present invention includes a liquid crystal panel, an organic EL panel, and the like. Such an optical display panel is used for manufacturing an optical display device such as a liquid crystal display device or an organic EL display device. . Hereinafter, the force S described by taking as an example the case of manufacturing a preferred liquid crystal panel among optical display panels, the optical display panel manufactured according to the present invention is of course not limited to this.

FIG. 1 is a diagram schematically showing a preferred example of the first manufacturing method among the manufacturing methods of the optical display panel according to the present invention. The first production method of the present invention includes a long optical film or a long film from a plurality of rolls from which at least two long optical films having an optical function or a long optical sheet as a laminate thereof are scraped off. A drawing process for drawing out the optical sheet, a first bonding process for bonding a plurality of drawn long optical films or long optical sheets, respectively, to form a long optical sheet laminate, and a long length The optical sheet laminate is directly bonded to the optical display element, from the second bonding step, and from the bonded body of the long optical sheet laminate and the optical display element, the display area of the optical display panel or more, And a cutting step of cutting the long optical sheet laminate in an area equal to or less than the entire surface of the optical display panel to obtain an optical sheet laminate. See Figure 1 below. The first manufacturing method of the present invention will be described in detail with reference to FIG.

In the drawing process, first, as shown in FIG. 1, from the drawing rolls 2 and 12 where the long optical sheets 1 and 11 which are laminated bodies of at least two long optical films having optical functions are scraped off. The long optical sheets 1 and 11 are drawn out, and the other long optical sheets 3 and 1 3, which are laminates of long optical films having optical functions, are drawn from the drawing rolls 4 and 14, respectively. An example is shown.

Here, FIG. 2 (a) is a diagram showing a schematic cross section of the long optical sheet 1 drawn from the pulling roll 2 in the example shown in FIG. 1, and FIG. 2 (b) is a drawing from the pulling roll 4. 3 is a diagram showing a schematic cross section of a long optical sheet 3 that has been drawn out. FIG. The long optical sheet that is a long optical film or a laminate thereof used in the present invention is not particularly limited, but is a long optical sheet laminate that is bonded to one surface of the optical display element 7. For example, as shown in FIG. 2 (a), a long optical sheet 1 having a laminated structure of a polarizing film 8, a protective film 9, and an adhesive layer 10 is used. As shown in FIG. 2 (b), a case where a long optical sheet 3 having a laminated structure of a surface treatment film 17 and an adhesive layer 18 is used is exemplified. Further, as a long optical film and a long optical sheet that form a long optical sheet laminate bonded to the other surface of the optical display element 7, for example, as in the example shown in FIG. Examples include the case where a long optical sheet 11 having a laminated structure of a film, a protective film and an adhesive layer and a long optical sheet 13 having a laminated structure of a protective film and an adhesive layer are used. The

In the subsequent first bonding step, the long optical sheet 1 drawn out as described above and the long optical sheet 3 are occupied, and the long optical sheet 1 1 and the long optical sheet 1 3 are Bonding to form a long optical sheet laminate. In FIG. 1, the long optical sheet 1 and the long optical sheet 3 are pressure-bonded at the first bonding port 5, and the long optical sheet is bonded at another first bonding roller 15. Examples are shown in which 1 1 and a long optical sheet 1 3 are bonded together by pressure bonding.

When using a long optical sheet having the structure shown in FIG. On the polarizing film 8 side, the pressure-sensitive adhesive layer 18 side of the long optical sheet 3 is arranged, and after the first bonding process, the surface treatment film 17, the pressure-sensitive adhesive layer 18, the polarizing film 8, the protective film 9, A long optical sheet laminate laminated in the order of the pressure-sensitive adhesive layer 10 is formed. On the other hand, in the case of the long optical sheet 11, the pressure-sensitive adhesive layer side of the long optical sheet 13 is arranged on the polarizing film side, and after the first bonding step, the protective film, the pressure-sensitive adhesive layer, and the polarizing film A long optical sheet laminate in which a protective film and an adhesive layer are laminated in this order is formed.

Next, in the second bonding step, the long optical sheet laminate in which the long optical sheet 1 and the long optical sheet 3 are bonded together, and the long optical sheet 11 and the long optical sheet 13 The laminated long optical sheet laminate is bonded to the optical display element 7 respectively. In FIG. 1, the long optical sheet laminate in which the long optical sheet 1 and the long optical sheet 3 are bonded is bonded to one surface of the optical display element 7 by the second bonding roller 6 and bonded. In addition, the long optical sheet laminate in which the long optical sheet 11 and the long optical sheet 13 are bonded by the second bonding roller 16 is pressure-bonded to the other surface of the optical display element 7. An example of being pasted is shown. When the long optical sheet having the structure shown in FIG. 2 is used, the long optical sheet laminate adhered to one surface of the optical display element 7 is a surface treatment film 17, an adhesive layer 18, In the laminated structure in the order of the polarizing film 8, the protective film 9, and the pressure-sensitive adhesive layer 10, bonding is performed such that the pressure-sensitive adhesive layer 10 side is disposed on the optical display element 7 side. Similarly, the long optical sheet laminate adhered to the other surface of the optical display element 7 is an outer pressure-sensitive adhesive in a laminated structure in the order of a protective film, a pressure-sensitive adhesive layer, a polarizing film, a protective film, and a pressure-sensitive adhesive layer. Shells are occupied with the layer placed on the optical display element 7 side.

Although not shown, the long optical film or long optical sheet S used in the first bonding step, the other long optical film or long optical sheet used in the first bonding step. In the case of having an adhesive layer for bonding to the optical display element 7 in the second bonding step or in the second bonding step, for example, the long optical shown in FIG. 2 (a) Adhesive layer in sheet 1 10 and adhesive in long optical sheet 3 shown in FIG. 2 (b) In the case of having layer 18, a release film is usually bonded to the surface of the pressure-sensitive adhesive layer to protect the surface of the pressure-sensitive adhesive layer until it is bonded to another member. . Here, the release film is obtained by applying a release agent made of a silicone resin or the like to the surface of a transparent resin film such as a polyethylene terephthalate film. And this release film is peeled and removed before bonding to another member. A specific example of the method of peeling and removing the release film will be described later with reference to FIG. In the first manufacturing method of the present invention, in the subsequent cutting step, from the bonded body of the long optical sheet laminate and the optical display element 7 obtained in the second bonding step described above, the display area of the optical display panel An optical display panel as a final product can be obtained by cutting the long optical sheet laminate in an area that is equal to or less than the entire surface of the optical display panel to obtain an optical sheet laminate (not shown). )

In the first production method of the present invention, the type of long optical film, the number of long optical films, the laminated structure, the long optical film, or the number of rolls for drawing out the long optical sheet are shown in FIG. It is not limited to the examples.

For example, FIG. 3 is a diagram schematically showing another preferred example of the first manufacturing method according to the present invention. FIG. 3 is the same as the example shown in FIG. 1 except for a part thereof, and portions having the same configuration are denoted by the same reference numerals and description thereof is omitted. In the example shown in FIG. 3, the long optical sheet 3 is drawn from the drawing roll 4 as in the example shown in FIG. 1, and the long optical film 21 is drawn from the drawing roll 2 2, and the drawing roll 2 Another long optical sheet 23 is drawn from 4, and another long optical film 25 is drawn from the drawing roll 26. In this case, for example, a polarizing film (for example, a polarizing film in a state where a self-adhesive peeling film described later) is peeled off as the long optical film 21, and an ultraviolet curable resin adhesive as the long optical sheet 23. A pressure-sensitive adhesive film is used as the laminate of the adhesive layer and the protective film formed in the above, and the long optical film 25. In the example shown in FIG. 3, in the first bonding step, the long optical film 25 drawn from the drawing roll 26 and the long optical sheet 23 drawn from the drawing roll 24 are the first bonding. Crimped by the roller 2 7 The long optical film 2 1 drawn from the drawing roll 2 2 is pressed and bonded by another first laminating roller 2 8, and further, the drawing roll 4 force is pulled out. The long optical sheet 3 thus bonded is pressed and bonded by another first bonding roller 5 to form a long optical sheet laminate.

In this case, the long optical sheet laminate is laminated, for example, in the order of a surface treatment film, an adhesive layer, a polarizing film, an adhesive layer, a protective film, and an adhesive film. In the second bonding step, The adhesive film side is disposed on the optical display element 7 side, and is adhered to one surface of the optical display element 7.

In the example shown in FIG. 3, as in the example shown in FIG. 1, the long optical sheet 1 3 is drawn from the drawing roll 14 and the long optical film 3 1 is drawn from the drawing roll 3 2. Then, another long optical film 33 is drawn from the draw roll 34. In this case, for example, a polarizing film (for example, a polarizing film in a state where a peeling film having self-adhesiveness described later) is peeled off as the long optical film 31, and an adhesive film is used as the other long optical film 33. In the example shown in FIG. 3, in the first bonding step, the long optical film 3 3 drawn from the drawing roll 3 4 and the long optical film 3 1 drawn from the drawing roll 3 2 are the first bonding rollers 3. First, the long optical sheet 1 3 pulled out from the draw roll 14 is pressed and bonded by another first laminating roller 1 5 to the long optical sheet. A laminate is formed. In this case, the long optical sheet laminate is laminated in the order of, for example, a protective film, an adhesive layer, a polarizing film, and an adhesive film, and the adhesive film side is the optical display element 7 in the second bonding step. The optical display element 7 is attached to the other surface of the optical display element 7.

For example, FIG. 4 is a diagram schematically showing still another preferred example of the first production method according to the present invention. FIG. 4 is the same as the example shown in FIGS. 1 and 3 except for a part thereof, and parts having the same configuration are denoted by the same reference numerals and description thereof is omitted. In the example shown in FIG. 4, the long optical sheet laminate adhered to one surface (upper side of the drawing) of the optical display element 7 is formed in the same manner as the example shown in FIG. In forming the long optical sheet laminate to be attached to the other surface (lower side of the figure) of the display element 7, the long optical sheet 41 drawn from the drawing roll 42 is further used. Is different. In this case, as the long optical sheet 41, for example, a laminate of an adhesive layer formed of an ultraviolet ray curable resin adhesive and a protective film is used. In the example shown in FIG. 4, in the first bonding step, the long optical film 3 3 drawn from the drawing roll 3 4 and the long optical sheet 4 1 drawn from the drawing roll 4 2 are the first bonding rollers 4. 3 is first bonded and first bonded, and then the long optical sheet 3 1 drawn from the drawing roll 3 2 is pressed and bonded by another first bonding roller 3 5, and this is the drawing roll 1 The long optical sheet 13 drawn out from 4 is pressed and bonded by another first bonding roller 15 to form a long optical sheet stack. In this case, the long optical sheet laminate is laminated in the order of, for example, a protective film, an adhesive layer, a polarizing film, an adhesive layer, a protective film, and an adhesive film. The adhesive film side is disposed on the optical display element 7 side, and is adhered to the other surface of the optical display element 7.

Although illustration is abbreviate | omitted here, in order for the elongate optical film or elongate optical sheet provided to a 1st bonding process to bond to another elongate optical film or an elongate optical sheet in a 1st bonding process. Or having a pressure-sensitive adhesive layer for bonding to the optical display element 7 in the second bonding step, or forming a single long optical film with the pressure-sensitive adhesive film itself. On the surface of these pressure-sensitive adhesive layers or pressure-sensitive adhesive films, in order to protect the surface of the pressure-sensitive adhesive layer or pressure-sensitive adhesive film until bonding to other members, a release film similar to that shown above is used. It is customary that they are pasted together. For example, in FIG. 3 and FIG. 4, it is provided on the long optical sheet 3 and is provided on the adhesive layer for bonding to the long optical film 21 (polarizing film), and also on the long optical sheet 13 The adhesive layer for bonding to the long optical film 3 1 (polarizing film), and in FIGS. 3 and 4, the adhesive films that are the long optical films 2 5 and 3 3 themselves are Corresponds to adhesive layer or adhesive film. And the release film provided on the surface of the adhesive layer or adhesive film It is peeled and removed before bonding to the member. A specific example of the method of peeling and removing the release film will be described later with reference to FIG.

The UV curable resin adhesive layer is usually applied immediately before the adhesion treatment.

FIG. 5 is a diagram schematically showing the first half of a preferable example of the second manufacturing method of the optical display panel manufacturing method of the present invention, and FIG. 6 is a preferable example of the second manufacturing method. It is a figure which shows typically about the latter half part of an example. The second production method of the present invention includes a long optical film or a long optical sheet from a plurality of rolls from which a long optical film having an optical function or a long optical sheet as a laminate thereof is scraped off. A first drawing step for laminating the drawn long optical film or long optical sheet to form a long optical sheet laminate, and a long optical sheet laminate The cutting process which makes the optical sheet laminated body, and the 2nd bonding process of bonding the said optical sheet laminated body to an optical display element are included. Hereinafter, the second manufacturing method of the present invention will be described in detail with reference to FIG. 5 and FIG.

The drawing process oppi first bonding process in the second production method of the present invention is the same as the drawing process oppi first bonding process in the first manufacturing method described above. In FIG. 5, as in the example shown in FIG. 1, the long optical sheet 1 is pulled out from the pulling roll 2, the optical long sheet 3 is pulled out from the pulling roll 4, and the first laminating roller 5 At the same time, the long optical sheet 1 1 is pulled out from the drawing roll 1 2, the long optical sheet 1 3 is pulled out from the drawing roll 1 4, and is pressed by the first bonding roller 15. An example in which a long optical sheet laminate is formed is shown. As the long optical film or the long optical sheet in the second production method of the present invention, the same long optical film or long optical sheet as described above for the first production method is used. Can be used.

In the second production method of the present invention, the long optical sheet laminate obtained in the first pasting step is cut in the subsequent cutting step to obtain an optical sheet laminate. In FIG. 5, the long optical sheet laminate of the long optical sheet 1 and the long optical sheet 3 is cut by the cutting means 5 3 to form the optical sheet laminate 51, and the long optical sheet 1 1 And long optical sheet An example is shown in which the optical sheet laminate 52 is formed by cutting the long optical sheet laminate with G 13 by the cutting means 54.

In the second bonding step in the second manufacturing method, the optical sheet stack obtained in the cutting step is bonded to the optical display element, and the optical display panel as the final product is obtained. In FIG. 6, the optical sheet laminate 51 obtained in the cutting step shown in FIG. 5 is pressure-bonded to one surface of the optical display element 7 by the second laminating roller 55, and the optical sheet laminate

An example is shown in which 52 is bonded to the other surface of the optical display element 7 by a second bonding roller 56 and bonded. Here, as described above, the surface to be bonded to the optical display element 7 of the optical sheet laminate 51 and the surface to be bonded to the optical display element 7 of the optical sheet laminate 52 Usually, an adhesive layer is provided, and its surface is protected by a release film. FIG. 6 shows an example in which the release film is bonded to the optical display element 7 while being peeled off from the optical sheet laminates 5 1 and 5 2. That is, in this example, after the release film 5 9 is peeled off from the surface to be bonded to the optical display element 7 of the optical sheet laminate 51 by the peeling roll 5 7, the exposed adhesive layer becomes the optical display element 7. From one surface of the optical sheet laminate 52 to the optical display element 7 of the optical sheet laminate 52, the surface is bonded to the one surface by a peeling roller 5 8. After peeling off the release film 60, the exposed pressure-sensitive adhesive layer is pressure-bonded to the other surface of the optical display element 7 by the second bonding roller 56, and bonded. The peeled release film is scraped off by the collecting rolls 6 1 and 6 2 as necessary. In FIG. 6, white arrows indicate the transport directions of the optical display element 7 and the optical sheet laminates 51 and 52.

Also in the second manufacturing method of the present invention, the type of the long optical film, the number of the long optical films, the laminated structure, the number of rolls for drawing out the long optical film or the long optical sheet, etc. are as shown in FIG. And that is not limited to the example shown in FIG. In both the first manufacturing method and the second manufacturing method of the present invention described above, each step is performed in a continuous manufacturing process. According to the first manufacturing method or the second manufacturing method, conventionally, it has been performed by an optical member manufacturer. The pasting process, cutting process, and packing process of the old film, and the delivery (transport) to the panel cabinet manufacturer are omitted, so the optical film bonded to the optical display panel becomes cleaner and reduces defects. To do. In addition, the yield of the optical sheet which is the optical film or its laminated body is improved, and the product utilization efficiency is improved.

Although not shown in FIG. 1 and FIGS. 3 to 5, the polarizing film included in the optical sheet laminate bonded to one surface of the optical display element and the optical bonded to the other surface The polarizing film included in the sheet laminate needs to be arranged so that the transmission axis directions are orthogonal to each other. For this reason, when performing the first manufacturing method or the second manufacturing method of the present invention described above, for example, polarizing plate attachment as shown in FIG. 6 of Japanese Patent Laid-Open No. 2005-037 17 In the first transport unit, a long optical sheet laminate (in the case of the first manufacturing method) or on one surface of the optical display element that is supplied from the supply unit and transported in the first transport unit is applied. After laminating the optical sheet laminate (in the case of the second production method) and cutting the long optical sheet laminate in the case of the first production method, it is conveyed from the first conveyance unit in the reversing unit. The optical display element that has been inverted is turned upside down so that the end surface on the transport direction side of the inverted optical display element is orthogonal to the transport direction, and sent to the second transport unit. In the second transport unit, Transported in the direction perpendicular to the transport direction of the optical display element transported by the first transport unit Other elongate optical sheet laminate surface or optical sheet one preparative laminate academic display element may be laminated to. An overview of this configuration is shown in Figure 7. That is, FIG. 7 follows the method shown in FIG. 1, but after the optical sheet laminate is bonded to one surface of the optical display element, the optical display element is turned upside down and the transport direction is changed to 9. FIG. 6 is a perspective view schematically showing an example in which another optical sheet laminate is bonded to the other surface of the optical display element after being rotated by 0 °. In FIG. 7, parts having the same configurations as those shown in FIG. 1 are given the same reference numerals, and detailed descriptions thereof are omitted.

In the example shown in FIG. 7, the optical display element 7 is transported in one direction in the first transport unit 71, and the first bonding step according to the present invention is performed on one surface (the upper side in the figure). The 2nd bonding process which bonds the bonded elongate optical sheet laminated body is given. So After that, the laminated long optical sheet laminate is cut into a size suitable for the optical display element 7 by the cutting means 74, and the optical sheet laminate is bonded to one surface of the optical display element 7. It is said. Subsequently, in the reversing unit 7 7, the optical display element 7 is turned upside down without being rotated in-plane, and is sent to the second transport unit 72. Thereby, in the 2nd conveyance part 72, the relationship between the surface where the optical sheet laminated body of the optical display element 7 was bonded, and the surface which is not bonded is the relationship in the 1st conveyance part 71. Is reversed. In the example shown in the figure, the optical sheet laminate is bonded to the upper surface of the optical display element 7 in the first conveyance unit 71, and the optical sheet laminate is bonded in the second conveyance unit 72 by upside down. This surface is the lower surface of the optical display element 7.

In the second transport unit 72, the transport direction of the optical display element 7 is rotated 90 degrees in the plane with respect to the transport direction of the first transport unit 71. That is, the end surface on the transport direction side of the first transport unit 71 of the optical display element 7 is inverted upside down so as to be orthogonal to the transport direction of the second transport unit 72 after the inversion. It is sent to the transport unit 72. In the second transport unit 72, again, the other surface of the optical display element 7 (the surface on which the long optical sheet laminate is not bonded in the first transport unit 71) is again in accordance with the present invention. Another 2nd bonding process of bonding the long optical sheet laminated body bonded by the 1 bonding process is given. Thereafter, the laminated long optical sheet laminate is cut to a size suitable for the optical display element 7 by the cutting means 75, and the optical sheet laminate is bonded to both surfaces of the optical display element 7. .

In the example shown in FIG. 7, in the first transport unit 7 1, the long optical sheet 1 drawn from the drawing roll 2 and the long optical sheet 3 drawn from the drawing roll 4 are the first laminating roller 5. Are bonded to each other and sent to one surface of the optical display element 7. Up to this point, the state is the same as that shown in FIG. Further, in the second transport unit 7 2, the long optical sheet 1 1 pulled out from the pulling roll 1 2 and the long optical sheet 1 3 pulled out from the pulling roll 1 4 are different first laminating rollers 1. It is pressure-bonded by 5 and sent to the other surface of the optical display element 7. Up to this point, the state is the same as shown in the lower side of FIG. When the optical display element 7 is a liquid crystal display element (liquid crystal cell), the optical sheet laminated body containing a polarizing film is bonded on both surfaces, respectively. In FIG. 1, each of the long optical sheet 1 and the long optical sheet 11 1 includes a polarizing film. And the polarizing film arrange | positioned at the front and back of a liquid crystal display element is arrange | positioned so that each absorption axis may become the relationship to orthogonally cross. If the form shown in FIG. 7 is adopted, as can be seen from the above description, the absorption axes of the polarizing films arranged on the front and back of the liquid crystal display element are orthogonal to each other. In Fig. 7, the white arrows indicate the transport direction.

In the above description with reference to FIG. 1 and FIGS. 3 to 7, the optical display element 7 is a liquid crystal display element (liquid crystal cell) as an example, and optical sheet laminates are bonded to both surfaces, respectively. For example, when the optical display element Ί is an EL display element, it is sufficient that the optical sheet laminate is bonded to one side, that is, the viewing side display surface. It will be easily understood.

In the manufacturing method of the present invention described above, it is preferable that the long optical film or the long optical sheet subjected to the drawing step includes a polarizing film made of a polybulu alcohol resin film. The polybule alcohol lunar essence can be obtained by saponifying polyacetate burr. Examples of the polyacetate resin include polyvinyl acetate, which is a homopolymer of vinyl acetate, and copolymers of vinyl acetate and other monomers copolymerizable therewith.

Examples of other monomers copolymerizable with butyl acetate include unsaturated carboxylic acids, olefins such as ethylene and propylene, vinylenoatenoles, unsaturated sulphonic acids, and acrylamides having ammonium groups. .

The saponification degree of the poly Bulle alcohol resin is usually 8 5～1◦ 0 mole ^_0/0, preferably 9 8 mol% or more. These polyvinyl alcohol resins may be modified. For example, polybulformal modified with aldehydes, polyvinyl acetal, and polyvinyl butyl alcohol can be used. The degree of polymerization of the polyvinyl alcohol resin is usually in the range of 10:00 to 10:00, preferably 1500 to Within the range of 5 0 0 0.

A film formed from such a polybulualcohol resin is used as an original film of a polarizing film. The method for forming the polybulualcohol resin is not particularly limited, and can be formed by a conventionally known appropriate method. The film thickness of the raw film made of polyvinyl alcohol resin is not particularly limited, but is, for example, about 10 to 1550 μm.

A polarizing film is usually a process of dyeing a polybullic alcohol resin film with a dichroic dye and adsorbing the dichroic dye (dyeing process), and a polyvinyl alcohol resin film adsorbed with the dichroic dye. It is manufactured through a step of treating with a boric acid aqueous solution (boric acid treatment step) and a step of washing with water after the treatment with the boric acid aqueous solution (water washing treatment step).

In the production of the polarizing film, the polybulal alcohol resin film is usually uniaxially stretched, but this uniaxial stretching may be performed before the dyeing process or during the dyeing process. It may be performed after the dyeing process. When uniaxial stretching is performed after the dyeing treatment step, this uniaxial stretching may be performed before the boric acid treatment step or may be performed during the boric acid treatment step. Of course, it is also possible to perform uniaxial stretching in these plural stages. Uniaxial stretching may be performed uniaxially between rolls having different peripheral speeds, or may be performed uniaxially using a hot roll. Further, it may be dry stretching in which stretching is performed in the air, or may be wet stretching in which stretching is performed in a state swollen with a solvent. The draw ratio is usually about 3 to 8 times. For example, the dyeing of the polybulualcohol resin film with the dichroic dye in the dyeing process is performed by immersing the polybulcoalcohol resin film in an aqueous solution containing the dichroic dye. Examples of dichroic dyes include iodine and dichroic dyes. The dichroic dye includes, for example, a dichroic direct dye composed of a diazo compound such as C.I.DIRECTRED 39, and a dichroic direct dye composed of a compound such as triazoso or tetrakisazo. Polybulal alcohol resin film should be immersed in water before dyeing. It is preferable to keep it.

When iodine is used as the dichroic dye, a method of immersing and dyeing a polyvinyl alcohol resin film in an aqueous solution containing iodine potassium iodide is usually employed. The iodine content in this aqueous solution is usually from 0.01 to 1 part by weight per 100 parts by weight of water, and the potassium iodide content is usually from 0.5 to 2 parts per 100 parts by weight of water. 0 parts by weight. When iodine is used as the dichroic dye, the temperature of the aqueous solution used for dyeing is usually 20 to 40 ° C, and the immersion time (dyeing time) in this aqueous solution is usually 20 to 1 8 0 0 seconds.

On the other hand, when a dichroic dye is used as a dichroic dye, a method of immersing and dyeing a polyvinyl alcohol resin film in an aqueous solution containing an aqueous dichroic dye is usually employed. The content of the dichroic dye in the aqueous solution is usually water 1 0 0 parts by weight per 1 X 1 0- ⁴ ~ 1 0 parts by weight, preferably from 1 X 1 0- ³ ~ 1 parts by weight, particularly good Preferably, 1 X 1 0— ³ to 1 X 1 0— ² parts by weight. This aqueous solution may contain an inorganic salt such as sodium sulfate as a dyeing assistant. When a dichroic dye is used as the dichroic dye, the temperature of the dye aqueous solution used for dyeing is usually 20 to 80 ° C, and the immersion time (dyeing time) in this aqueous solution is usually 1 0 to 1800 seconds. The boric acid treatment step is performed by immersing a polyvinyl alcohol resin film dyed with a dichroic dye in a hydrofluoric acid-containing aqueous solution. The amount of boric acid in the aqueous solution containing oxalic acid is usually 2 to 15 parts by weight, preferably 5 to 12 parts by weight, per 100 parts by weight of water. ·

When iodine is used as the dichroic dye in the dyeing process, the boric acid-containing aqueous solution used in the boric acid treatment process preferably contains potassium iodide. In this case, the amount of potassium oxalate in the boric acid-containing aqueous solution is usually 0.1 to 15 parts by weight, preferably 5 to 12 parts by weight, per 100 parts by weight of water. The immersion time in the boric acid-containing aqueous solution is usually 60 to 120 seconds, preferably 15 hours to 60 seconds, and more preferably 2200 to 400 seconds. The temperature of the hydrofluoric acid-containing aqueous solution is usually 50 ° C or higher, preferably 50 to 85 ° C, more preferably 60 to 80 ° C.

In the subsequent washing process, the polyvinyl alcohol resin film after the fluoric acid treatment is washed with water, for example, by immersing it in water. The temperature of water in the water washing treatment is usually 5 to 40 ° C, and the immersion time is usually 1 to 120 seconds. After the water washing treatment, a drying treatment is usually performed to obtain a polarizing film. The drying process is preferably performed using, for example, a hot air dryer or a far infrared heater. The temperature of the drying treatment is usually 30 to 10 ° (preferably 50 to 80 ° C.) The drying treatment time is usually 60 to 600 seconds, preferably 120 to 6 0 0 seconds.

In the production method of the present invention, the long optical film or the long optical sheet subjected to the drawing step preferably includes the polarizing film as described above, but the long optical sheet (polarizing plate) including the polarizing film. Specific examples include the following.

(A) A polarizing plate comprising a polarizing film made of a polybulal alcohol resin film, and a protective film made of a thermoplastic resin attached to at least one surface of the polarizing film,

(B) A polarizing plate comprising a polarizing film made of a polybulualcohol resin film, an adhesive layer formed on at least one surface of the polarizing film, and a release film protecting the adhesive layer,

(C) a polarizing film made of a polybulualcohol resin film, a protective film made of a thermoplastic resin adhered to one surface of the polarizing film, and an adhesive layer formed on the other surface of the polarizing film, A polarizing plate having a release film for protecting the adhesive layer,

(D) a polarizing film made of a polybulualcohol resin film, a protective film made of a thermoplastic resin attached to one surface of the polarizing film, an adhesive layer formed on the outer surface of the protective film, and A polarizing plate having a release film for protecting the adhesive layer.

Among these, in the polarizing plate having the release film of (B) to (D), the release The film is peeled off in the first bonding step or the second bonding step, and the exposed adhesive layer is used for bonding to another optical film, optical sheet, or optical display element. Provided.

In the polarizing plate as described above, the protective film made of the thermoplastic resin described above is, for example, (a) a cycloolefin resin film, (b) a cellulose ester resin film, (c) a polyethylene terephthalate resin film, (d) (meta) ) Acrylic resin film, (e) polypropylene resin and the like. These thermoplastic resin films are bonded to at least one surface of a polarizing film, and can be used for a drawing process in a state of being a long optical sheet (polarizing plate). The resin film alone may be used as a long optical film for the drawing process, and may be bonded to at least one surface of the polarizing film in the first bonding process. These thermoplastic resin films will be described in more detail below.

(a) Cycloolefin resin film

The cycloolefin resin used in the production method of the present invention is a thermoplastic resin having a monomer unit composed of cyclic olefin (cycloolefin) such as norbornene and polycyclic norbornene monomer (also called thermoplastic olefin resin). ) In the present invention, the cycloolefin resin may be a hydrogenated product of the above-mentioned ring-opening polymer of cycloolefin or a ring-opening copolymer using two or more types of cycloolefin, and has a cycloolefin and a chain-olefin, a bur group, and the like. An addition polymer with an aromatic compound or the like may be used. Those having a polar group introduced are also effective.

In the case of using a copolymer of cycloolefin and a linear olefin or an aromatic compound having z and a vinyl group, examples of the linear olefin include ethylene and propylene, and an aromatic hydrocarbon having a vinyl group. Examples of the compound include styrene, α-methylol styrene, and nuclear alkyl-substituted styrene. In such a copolymer, the monomer unit consisting of cycloolefin is 50 mol% or less. (Preferably 1 5 to 5 0 mole ^_0/0) may be used. In particular, in the case of using a terpolymer of cycloolefin, a chain-shaped polyolefin and an aromatic compound having a vinyl group, the monomer monomer comprising cycloolefin can be used in a relatively small amount as described above. In such terpolymers, units of monomers consisting of linear Orefin usually 5-8 0 mole ^_0/0, the aromatic compound or Ranaru monomer Interview with Bulle group - Tsu DOO is usually 5 8 is 0 mole ^_0/0.

Cycloolefin resins are available on the market, such as Topas (manufactured by Ticona), Arton (manufactured by JSR), ZEONOR (manufactured by Nippon Zeon), ZEONEX (manufactured by Nippon Zeon) ) Manufactured by MITSUBISHI CHEMICAL CO., LTD. When such a cycloolefin resin is formed into a film, a known method such as a solvent casting method or a melt extrusion method is appropriately used. For example, Essina (manufactured by Sekisui Chemical Co., Ltd.)

Commercially available films of cycloolefin finned resin, such as SCA 40 (manufactured by Sekisui Chemical Co., Ltd.) and Xenoah film (manufactured by Optes Co., Ltd.), may be used.

The cycloolefin resin film may be uniaxially stretched or biaxially stretched. By stretching, an arbitrary retardation value can be imparted to the cycloolefin resin film. Stretching is usually carried out continuously while rolling out the film roll, and in the heating furnace, the roll is stretched in the traveling direction, the direction perpendicular to the traveling direction, or both. The temperature of the heating furnace is usually in the range from the vicinity of the glass transition temperature of cycloolefin resin to the glass transition temperature + 10 ° C. The draw ratio is usually 1.1 to 6 times, preferably 1.1 to 3.5 times.

When a cycloolefin resin film is in a roll state, the films tend to adhere to each other and easily cause blocking. Therefore, a protective film is usually attached to roll the film. In addition, since cycloolefin resin films generally have poor surface activity, surface treatment such as plasma treatment, corona treatment, ultraviolet irradiation treatment, flame (flame) treatment, and saponification treatment is performed on the surface to be bonded to the polarizing film. Is preferred. Of these, plasma treatment and corona treatment, which can be carried out relatively easily, are preferred.

When such a cycloolefin resin film is used, the resulting structure is similar to that of a polarizing plate used in an optical display panel such as a conventional liquid crystal panel, but the quality and product utilization efficiency of the obtained optical display panel are improved. The

(b) Cellulose ester resin film

The cellulose ester resin film used in the production method of the present invention is a cellulose partial or fully esterified film, for example, cellulose acetate ester, propionate ester, butyrate ester, mixed ester thereof, etc. The film which consists of can be mentioned. More specifically, examples include triacetyl sesolerose vinylome, dicetinoresenolate mouthpiece suinolem, cenololose acetate mouthpiece pionate film, and cellulose acetate butyretholetofilm. Examples of such cellulose ester resin films include commercially available products such as Fujitac TD 80 (Fuji Film Co., Ltd.), Fujitac TD80UF (Fuji Film Co., Ltd.), Fujitac TD80UZ (Fuji Film Co., Ltd.). ), KC 8UX2M (manufactured by Koriki Minoltaput Co., Ltd.), KC8UY (manufactured by Koni Minol Tabuto Co., Ltd.) and the like can be suitably used.

In the production method of the present invention, a cellulose ester resin film imparted with retardation characteristics is also preferably used. As a commercial product of cellulose ester resin film imparted with retardation characteristics, WV BZ 438 (Fuji Film ( And KC4FR-1 (manufactured by KONiki Minoltaput Co., Ltd.). Furthermore, a cellulose ester resin film having an in-plane or / and thickness direction retardation value that is so small as to be substantially negligible 1 /, a cellulose ester resin film can be suitably used. Examples of commercially available films include KC4UEW (manufactured by Koni Power Minatobuto Co., Ltd.).

When such a cellulose ester resin film is used, a conventional liquid crystal panel As a result, the configuration is the same as that of the polarizing plate used in the optical display panel, but the quality and product utilization efficiency of the obtained optical display panel are improved.

(c) Polyethylene terephthalate resin film

Polyethylene terephthalate is a resin in which 80 mol ⁰ or more of repeating units are composed of ethylene terephthalate. Other copolymer components include, for example, isophthalic acid, p--oxyethoxybenzoic acid, 4.4, dicarboxidiphenyl, 4,4, digi / repoxybenzophenone, bis (4—force / Lepoxyphenol) Dicarboxylic acid components such as ethane, adipic acid, sebacic acid, 5-sodium sulfoisophthalic acid, 1,4-dicarboxysic hexane, such as propylene glycol, butanediol, neopentinoleglycol, diethylene glycol, Examples include diol components such as cyclohexane diol, ethylene oxide adduct of bisphenol A, polyethylene glycolol, polypropylene dalicoranol, and polytetramethylene glycol. These dicarboxylic acid components and glycol components can be used in combination of two or more if necessary. It is also possible to use oxycarboxylic acid such as p-oxybenzoic acid together with the dicarboxylic acid component or glycol component. Such other copolymerization component may contain a compound containing a small amount of a amide bond, a urethane bond, an ether bond, a carbonate bond, or the like.

Polyethylene terephthalate can be produced by any method such as a so-called direct polymerization method in which terephthalic acid and ethylene glycol are directly reacted, or a so-called transesterification reaction in which dimethylesterol of terephthalic acid is transesterified with ethylene dallicol. Can be applied. Moreover, a known additive can be contained as required. For example, a lubricant, an antiblocking agent, a heat stabilizer, an antioxidant, an antistatic agent, a light resistance agent, an impact resistance improvement agent, and the like may be included. However, since transparency is required for optical applications, it is preferable to keep the additive amount to a minimum. The method for producing the polyethylene terephthalate film used in the present invention is not particularly limited. However, the polyethylene terephthalate which is a raw material resin is melted, and the non-oriented film extruded into a sheet shape is subjected to a glass transition. A method of performing heat setting treatment after transverse stretching with a tenter at a temperature higher than the temperature can be mentioned. The stretching temperature is 80 to 130 ° C, preferably 90 to 120 ° C, and the stretching ratio is 2.5 to 6 times, preferably 3 to 5.5 times. Lowering the draw ratio is not preferable because the transparency of the film becomes poor.

From the viewpoint of reducing the distortion of the orientation main axis in the polyethylene terephthalate film, it is preferable that the film is relaxed in the longitudinal direction after the transverse stretching and before the heat setting treatment. The temperature for relaxation treatment is 90 to 200 ° C, and preferably 120 to 180 ° C. The amount of relaxation varies depending on the transverse stretching conditions, but it is preferable to set the relaxation amount and the temperature so that the heat shrinkage rate at 150 ° C. of the film after the relaxation treatment is 2% or less.

The temperature of the heat setting treatment is usually from 180 to 25 ° C, preferably from 20 to 2445 ° C. In the heat setting treatment, first, treatment is performed at a constant length and at the above temperature, and further, the relaxation treatment is performed so that the relaxation rate in the width direction of the film is 1 to 10% (preferably 2 to 5%). It is preferable to do so. In this way, a uniaxially stretched polyethylene terephthalate film with reduced orientation main axis distortion and excellent heat resistance can be obtained. In the present invention, a polyethylene terephthalate film having a maximum value of the distortion of the orientation main axis of 10 degrees or less, more preferably 8 degrees or less, and further preferably 5 degrees or less is suitably used. When a polyethylene terephthalate film having a maximum strain of the orientation main axis exceeding 10 degrees is used, a polarizing plate using such a polyethylene terephthalate film is bonded to the liquid crystal display screen of the liquid crystal display device. , Coloring defects tend to increase. The maximum value of the orientation main axis strain in the above-described polyethylene terephthalate film can be measured, for example, by using a retardation film inspection apparatus R E T S system (manufactured by Otsuka Electronics Co., Ltd.).

The thickness of the polyethylene terephthalate film is about 20 to 60 m. This The film preferably has an in-plane retardation value R0 of 100 O nm or more.

More preferably, it is 0 0 0 nm or more.

The polyethylene terephthalate film may be provided with haze. Examples of the method for applying haze include a method of mixing inorganic fine particles or organic fine particles in a raw material resin, and inorganic fine particles or organic fine particles on the film surface. Examples thereof include, but are not limited to, a method of coating a coating solution in which a resin binder is mixed. Typical examples of the inorganic fine particles include silica, colloidal silica, alumina, alumina sol, aluminosilicate, alumina-silica composite oxide, force orin, talc, mai force, calcium carbonate, and calcium phosphate. be able to. As the organic fine particles, heat-resistant resin particles such as crosslinked polyacrylic acid particles, crosslinked polystyrene particles, crosslinked polymethylmethacrylate particles, silicone resin particles, and polyimide particles can be used.

A polyethylene terephthalate film having the above-mentioned characteristics is comprehensively excellent in mechanical properties, solvent resistance, scratch resistance and cost. When such a polyethylene terephthalate resin film is used, there is an effect that a polarizing plate having a strength equal to or higher than that of a polarizing plate used for an optical display panel such as a conventional liquid crystal panel can be obtained. .

When using poly (ethylene terephthalate) film, the surface of the polyethylene terephthalate film opposite to the surface to be attached to the polarizing film is subjected to surface treatment such as anti-glare treatment, hard coat treatment, and antistatic treatment. May be. In addition, a coating layer made of a liquid crystalline compound or a high molecular weight compound thereof may be formed. In place of the polyethylene terephthalate film, a polyethylene naphthalate film can also be used. (d) (Meth) acrylic resin film

As the (meth) acrylic resin film, acrylic resin or methacrylic resin may be used alone or in combination, and if necessary, acrylic rubber particles And the like, and an acryl resin material obtained by melting and kneading is molded into a film by a melt extrusion method. The (meth) acrylic resin may contain usual additives such as ultraviolet absorbers, organic dyes, pigments, inorganic dyes, antioxidants, antistatic agents, surfactants, and the like.

The (meth) acrylic resin film may have a multilayer structure in combination with a layer having internal scattering or a layer imparting external scattering. In order to impart scattering characteristics, fine particles may be mixed and melt-kneaded. When a (meth) acrylic resin film is installed on the viewing side of the liquid crystal panel, surface treatment (hard coat layer, antiglare layer, antireflection layer, antifouling layer, antistatic layer, etc.) It is preferable to apply.

When such a (meth) acrylic resin film is used, there is an effect that a polarizing plate excellent in surface hardness and rigidity can be obtained as compared with a polarizing plate used in an optical display panel such as a conventional liquid crystal panel.

(e) Polypropylene resin film

The polypropylene resin used in the production method of the present invention is a resin mainly composed of propylene units, and is generally crystalline. In addition to propylene homopolymer, propylene and a comonomer copolymerizable therewith It may be a copolymer of The comonomer copolymerized with propylene can be, for example, ethylene or α-olefin having 4 to 20 carbon atoms.

When a polypropylene resin film is used, the xylene-soluble content at 20 ° C. of the polypropylene resin film is 1% by weight or less, more preferably 0.8% by weight or less, and further preferably 0.5% by weight or less. . If the xylene soluble content of the polypropylene resin film exceeds 1% by weight, when the polarizing plate is exposed to a high temperature environment, the surface of the polypropylene resin film is whitened, and the transmittance of the polarizing plate is significantly reduced. . The whitening of the surface of the polypropylene resin film under such a high temperature environment is presumed to be caused by a bleed-out of low molecular weight components present in the resin film. Typical examples of such low molecular weight components are particularly limited. However, for example, atactic low molecular weight oligomers may be mentioned. Xylene solubles of polypropylene榭脂film (wt ^_0/0) is measured as follows. Specifically, 5 g of propylene resin film is first added to 500 ml of boiling xylene, dissolved completely, then cooled to 20 ° C. and kept at 20 ° C. for 4 hours. Next, the xylene solution is filtered to separate the precipitate and the filtrate, and the solvent is removed from the filtrate, followed by drying at 70 ° C. under reduced pressure to obtain a dried xylene-soluble component. The xylene solubles can be obtained from the following formula. Xylene solubles [wt%] = (Weight of dried xylene solubles [g]) / (5 [g]) X 1 0 0

The polypropylene resin constituting the polypropylene resin film is preferably a polypropylene resin having a xylene soluble content of preferably 1% by weight or less, more preferably 0.8% by weight or less, and even more preferably 0.5% by weight or less. Is used. The method for measuring the xylene-soluble content of the polypropylene resin is the same as that for the polypropylene resin film. The polypropylene resin may be a polypropylene resin made of a propylene homopolymer, or may be a copolymer of propylene and another monomer copolymerizable therewith. These may be used in combination.

Examples of other monomers copolymerizable with propylene include ethylene and α-olefin. As the olefin, olefin having 4 or more carbon atoms is preferably used, and more preferably olefin having 4 to 10 carbon atoms. Specific examples of olefins having 4 to 10 carbon atoms include, for example, linear monoolefins such as 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octaten, 1-decene; Branched monoolefins such as methyl-1-pentene, 3-methyl-1-monopentene, 4-methyl-11-pentene; biel cyclohexane and the like. The copolymer of propylene and another monomer copolymerizable therewith may be a random copolymer or a block copolymer. When the copolymer is used as a polypropylene resin, a polypropylene resin having a xylene-soluble content of 1% by weight or less is relatively easy to obtain. Therefore, the copolymerization ratio of other monomers copolymerized with propylene is 8%. It is preferable that the amount be not more than wt%, and it is more preferable that it be not more than 4 wt%. The content of the structural units derived from other monomers in the copolymer is described in pages 6 and 6 of the “Polymer Analysis Handbook” (published by Kinokuniya, 1995). It can be obtained by performing infrared (IR) spectrum measurement according to the method described.

Among the above, the polypropylene resin constituting the polypropylene resin film includes propylene homopolymer, propylene monoethylene random copolymer, propylene monoethylene 1-butene random copolymer, and propylene monoethylene 1-pentene. Random copolymers are preferably used. These homopolymers and copolymers tend to be relatively easy to obtain a polymer with reduced xylene solubles by selecting an appropriate polymerization catalyst. In particular, by using a homopolymer of propylene, it tends to be easier to obtain a polymer with reduced xylene solubles! /.

The stereoregularity of the propylene resin constituting the polypropylene resin film is preferably substantially isotactic or syndiotactic. Polypropylene resin film made of polypropylene resin having a tactically isotactic or syndiotactic stereoregularity is relatively good in terms of properties and properties, and has excellent mechanical strength in a high temperature environment. Yes. In addition, the polypropylene resin having such stereoregularity has a relatively low generation of atactic low molecular weight component that causes whitening of the polarizing plate in the polymerization stage, and the transmittance decreases under a high temperature environment. A suppressed polarizing plate is easily obtained.

The method for reducing the xylene soluble content of the polypropylene resin to 1% by weight or less is not particularly limited. For example, in the polymerization stage, the degree of polymerization of the polypropylene resin is increased and the ratio of relatively low molecular weight components is decreased. A method known to those skilled in the art, such as a method of washing a polypropylene resin obtained by polymerization with a solvent and extracting and removing a solvent-soluble component such as a low molecular weight component or a combination of these methods. To mention You can. In addition, for example, by appropriately selecting a polymerization catalyst and controlling the stereoregularity of the polypropylene resin to be isotactic or syndiotactic, and polymerizing with Z or propylene alone, the resulting polypropylene is obtained. When the xylene-soluble content of the resin is 1% by weight or less, the treatment for reducing the xylene-soluble content of the propylene resin obtained by polymerization is not necessarily required. The method for forming a polypropylene resin film is not particularly limited, but is an extrusion molding method from molten resin, a solvent casting method in which a resin dissolved in an organic solvent is cast on a flat plate, and the solvent is removed to form a film. However, it is better to use the extrusion method from the viewpoint of productivity. In this case, the polypropylene resin has a melt flow rate (MF R) measured at a temperature of 2 30 ° C and a load of 2 1.1 8 N in accordance with JISK 7 2 10, 0.1 to 20 It is preferably within a range of 0 g Zl 0 minutes, and more preferably within a range of 0.5 to 50 g / 10 minutes. By using a polypropylene resin having an MFR within this range, a uniform polypropylene resin film can be obtained without imposing a heavy load on the extruder.

The polypropylene resin film used in the present invention is preferably excellent in transparency. Specifically, the total haze value measured according to JISK 7 10 5 is 10% or less, preferably 7% or less. . The thickness of the protective film made of a polypropylene resin film is preferably about 5 to 200 μπι. More preferably, it is 10 m or more, and more preferably 15 O wm or less. The polypropylene resin film may be uniaxially stretched or biaxially stretched. By stretching, an arbitrary retardation value can be imparted to the polypropylene resin film. Stretching is usually performed continuously while unwinding the film roll, and in a heating furnace, the film is stretched in the roll traveling direction, the direction perpendicular to the traveling direction, or both. The temperature of the heating furnace is usually in the range from the vicinity of the glass transition temperature of polypropylene resin to the glass transition temperature + 100 ° C. The draw ratio is usually 1.1 to 6 times, preferably 1 .;! To 3.5 times.

When a polypropylene resin film is in a roll state, the films adhere to each other. Therefore, it is usually easy to cause blocking, so a protective film is usually pasted and rolled. In addition, since cycloolefin resin films generally have poor surface activity, surface treatment such as plasma treatment, corona treatment, ultraviolet irradiation treatment, flame (flame) treatment, and saponification treatment is performed on the surface to be bonded to the polarizing film. Is preferred. Among them, plasma treatment and corona treatment that can be carried out relatively easily are preferable.

When such a polypropylene resin film is used, the resulting structure is similar to that of a polarizing plate used in an optical display panel such as a conventional liquid crystal panel, but the quality of the obtained optical display panel and product utilization efficiency are improved. Is done.

The cycloolefin resin film, cellulose ester resin film, polyethylene terephthalate resin film, (meth) acrylic resin film, or polypropylene resin film as described above are preferably used as a protective film for the polarizing film. Also, a polypropylene resin film can be used as a protective film for a polarizing film.

In the production method of the present invention, it is of course possible to previously laminate a self-adhesive release film on at least one surface of the polarizing film, and use the polarizing film by peeling the release film at the time of use. Examples of such a release film include films formed of polyethylene resin, polypropylene resin, and the like. Examples of commercially available products that can be suitably used as such a self-adhesive release film include “Tretec” made of polyethylene resin sold by Toray Industries, Inc., and sold by Sanei Kaken Co., Ltd. For example, “Sanitect”. The release film preferably has few defects such as fish eyes. This is because when a release film having such a defect is used, the shape is transferred to the polarizing film, which may cause a defect of the polarizer.

Further, in the production method of the present invention, an optical film having various functions such as an antiglare function, an antireflection function, a hardness increasing function, and a brightness improving function is provided on the surface opposite to the side facing the optical display element of the polarizing plate. An optical sheet can be bonded. As a long optical film or a long optical sheet having these optical functionalities, for example, a liquid crystal compound is applied to the surface of a base material, an optical compensation film that is oriented, and a certain kind of polarized light is transmitted. A reflective polarizing film that reflects polarized light that exhibits the opposite properties, a retardation film made of polycarbonate resin, a retardation film made of cyclic polyolefin resin, a film with an antiglare function having an uneven shape on the surface, and antireflection on the surface Examples thereof include a film with a function, a reflection film having a reflection function on the surface, and a transflective film having both a reflection function and a transmission function. Commercially available products that correspond to the oriented optical compensation film with a liquid crystal compound applied to the substrate surface include WV film (Fuji Film Co., Ltd.), NH film (Shin Nippon Oil Co., Ltd.) NR film (manufactured by Nippon Oil Corporation). For example, DBEF (manufactured by 3M Corporation, Sumitomo 3EM Co., Ltd. in Japan) is available as a commercial product equivalent to a reflective polarizing film that transmits certain types of polarized light and reflects polarized light that exhibits the opposite properties. APF (available from 3M, available from Sumitomo 3EM Co., Ltd. in Japan). Commercial products corresponding to retardation films made of cyclic polyolefin resin include, for example, Arton Film (manufactured by JSR Corporation), Essina (manufactured by Sekisui Chemical Co., Ltd.), Zeonor Film (manufactured by Optes Co., Ltd.), etc. Is mentioned.

Furthermore, in the production method of the present invention, it is preferable that at least one of the long optical films to be bonded contains an adhesive film and Z or an adhesive film. In addition, before the first bonding step or the second bonding step, the adhesive layer and the Z or adhesive layer are applied to the long optical film, the long optical sheet or the long optical sheet laminate by a coating device. May be formed.

In the production method of the present invention, the pressure-sensitive adhesive (pressure-sensitive adhesive) used for the pressure-sensitive adhesive film or the pressure-sensitive adhesive layer is not particularly limited, and is conventionally known, for example, acrylic resin, urethane resin, natural or synthetic. Mention may be made of rubber resin, butyl ether resin, or a pressure-sensitive adhesive mainly composed of a silicone resin. However, because of its excellent weather resistance, among them, talyl resin or urethane resin is the main component. Those having a main component of attalyl resin are particularly preferable.

In the production method of the present invention, the adhesive used for the adhesive film or adhesive layer is not particularly limited, and is a photocurable resin, an ultraviolet curable resin, a thermosetting resin, and moisture. Examples thereof include an adhesive such as a curable resin. Among these, an ultraviolet curable resin adhesive is preferable because it is excellent in curing speed and can be installed in a relatively simple manner. Examples of the ultraviolet curable resin adhesive that can be particularly suitably used in the production method of the present invention include, for example, a radical polymerization initiator and / or an epoxy resin, an acrylic resin, an oxacene resin, a urethane resin, and a polyvinyl alcohol resin. Or what added the cationic polymerization type initiator is mentioned. Of these, a mixture of an alicyclic epoxy resin and an epoxy resin having no alicyclic structure to which a force thione polymerization type initiator is added is preferable.

The UV curable resin adhesive layer is formed by applying the UV curable resin adhesive in an uncured state to the thermoplastic resin film used in the protective film as described above to form an adhesive coated surface. Or a method in which an ultraviolet curable resin adhesive is dropped between the polarizing film and the protective film in an uncured state, and then uniformly pressed and spread with a tool or the like. There is no particular limitation on the method of applying the UV curable resin adhesive to the protective film. For example, various coating methods such as doctor blade, wire bar, die coater, comma coater, and gravure coater can be used.

In addition, in the method in which the UV curable resin adhesive is dropped between the polarizing film and the protective film and then uniformly spread by pressing with a roll, metal, rubber, or the like is used as the material of the roll. Is possible. In the method of dropping the UV curable resin adhesive between the polarizing film and the protective film, passing it between the roll and the roll, and pressing and spreading it, the two rolls sandwiched from both sides are made of the same material. It may be a different material.

In addition, each step in the first manufacturing method or the second manufacturing method of the present invention described above can be appropriately combined with devices that have been widely used in the art. An apparatus for pulling out the long optical film or the long optical sheet used in the drawing process from the drawing roll is not particularly limited, and any conventionally known appropriate apparatus can be used. From the viewpoint of preventing electrification of the drawn long optical film or the long optical sheet, it is desirable to use one equipped with a slow current device. In the first bonding step of the first manufacturing method or the second manufacturing method of the present invention, two or more long optical sheet laminates having adhesiveness or adhesiveness are bonded with the width direction aligned. It takes a thing. When the optical display element is a liquid crystal display element and the long optical sheet laminate described above is bonded to both sides thereof, at least two first bonding rollers are required for this first bonding process. It becomes. In this case, of course, it is possible to use two or more first bonding rollers only for the formation of a long optical sheet laminate to be bonded to one of the optical display elements. Typically, long optical films and long optical sheets aligned in the width direction are appropriately laminated according to the desired structure, and bonded by pressing when passing between the first bonding rollers. Is done. Usually, the number of long optical films bonded at the same time in the first bonding step is in the range of 2 to 4. The surface of the long optical sheet laminate bonded in the first bonding step may be subjected to a surface treatment using a device that performs surface modification such as corona treatment, plasma treatment, or flame treatment. Good. Among them, it is preferable to perform the corona treatment because of its excellent surface modification effect and easy installation of the apparatus.

Moreover, in the 2nd bonding process in the above-mentioned 1st manufacturing method or 2nd manufacturing method of this invention, it has a roller (2nd bonding roller) currently used for the manufacturing apparatus of a normal liquid crystal panel. A bonding apparatus for a polarizing plate and a liquid crystal display element is used. Examples of the bonding apparatus used in the second bonding step include a mechanism for accurately aligning the long optical sheet laminate or the optical sheet laminate to one side of the optical display element, an adhesive layer or In order to protect the adhesive layer, a mechanism for peeling the release film that is bonded may be provided. The bonding apparatus used in the second bonding step may be a mechanism for bonding a long optical sheet laminate or an optical sheet laminate on one side of the optical display element, and on both sides of the optical display element. At the same time, long optical sheet product It may be a mechanism for laminating a layered body or an optical sheet laminate.

The roller used for bonding in the first bonding step and the second bonding step is preferably a combination of two rubber rollers or a combination of a rubber roller and a metal roller. In the case of a rubber roller, the hardness is preferably in the range of 60 to 80 degrees on the Shore C scale in accordance with JISK 6300. If the hardness is lower than 60 degrees, pressure camber is likely to occur. On the other hand, if the hardness is higher than 80 degrees, the film may be damaged. Examples of rubber materials include urethane rubber, puchinole rubber, -trinole rubber, EP DM rubber, and silicone rubber. From the viewpoint of durability, EP DM rubber is preferably silicone rubber.

Examples of the cutting means used in the cutting process in the first manufacturing method or the second manufacturing method of the present invention described above include a commonly used optical sheet cutting device and an optical sheet punching device. . In addition, the cutting method used in the first manufacturing method was that after cutting the long optical sheet laminate bonded to the optical display element, unnecessary portions remaining on the optical display element were scraped off or scraped off. A device for beautifying the end of the later optical display element and the cut end surface of the laminated optical sheet laminate may be further provided. Further, the cutting means used in the second manufacturing method may further include a device for beautifying the end face of the cut optical sheet laminate before being bonded to the optical display element. The cutting device used in the second manufacturing method may further include a device for taking out the optical sheet laminate cut in the cutting step in order to bond it to the optical display element. As a device for taking out the sheet laminate, a device for bonding a sheet and a liquid crystal display element used in a normal liquid crystal panel manufacturing device can be used. Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

Example 1>

In accordance with the method shown in FIG. 1, a liquid crystal panel is manufactured by the first manufacturing method of the present invention. An example is shown. (Polarized film)

The average degree of polymerization is about 2400, the degree of saponification is 99.9 mol ⁰ /. The polyvinyl alcohol film with a thickness of 75 // πχ is stretched in the longitudinal direction up to a stretching ratio of 1.3 times while immersing and swollen in 30 ° C pure water while keeping the tension state. This polyvinyl alcohol film is kept at the above-mentioned draw ratio, and is an aqueous solution of 30 ° C containing iodine, rhiodide, and rhodium (iodine: potassium iodide: water = 0.05: 2: 100 (weight Ratio))) and dyeing, followed by immersion in a 54 ° C aqueous solution containing potassium iodide and boric acid (potassium iodide: boric acid: water = 12: 5: 100 (weight ratio)) While cross-linking treatment, the dyed fiber is cross-linked in the process so that the total magnification becomes 5.6 times. Then wash with 12 ° C pure water. The washed polybulal alcohol film is dried for 3 minutes in a drying oven maintained at a temperature of 65 ° C. In this way, a polarizing film is obtained in which iodine is adsorbed and oriented on polybulal alcohol.

(Polarizing plate roll)

Separately, 100 parts by weight of water, 3 parts by weight of carboxyl group-modified polybulal alcohol (Kurarepoval KL 318, manufactured by Kuraray Co., Ltd.), water-soluble polyamide epoxy resin (Smiles Resin 650, Sumika Chemtex Co., Ltd.) ) Manufactured) (Aqueous solution with a solid content of 30%) 1. Dissolve 5 parts by weight to prepare a water adhesive mainly composed of polyvinyl alcohol resin. A biaxially stretched film (Zeonor film, manufactured by Optes Co., Ltd., thickness 80 m) made of norbornene resin, which has been previously subjected to corona treatment, is bonded to one surface of the polarizing film produced by the method shown above. Laminate through the agent, dry at 80 ° C for 5 minutes while maintaining the tension, and then slit to a width corresponding to the panel width. Next, Norvo A roll adhesive is formed with a release film on the surface of the pressure-sensitive adhesive layer, while applying an edge treatment to the surface of the runnene resin film and forming an acrylic pressure-sensitive adhesive layer on the corona-treated surface. And In this way, the polarizing plate roll laminated | stacked in order of the polarizing film, the norbornene resin film, and the adhesive layer (with a release film) is obtained.

(Surface treatment finolemeal)

Surface treatment film with an antiglare treatment layer on the surface of triacetyl cellulose with a width corresponding to the panel width 8 3 μπι (Matte Hard Coat TAC Film DS 1 LR 2, manufactured by Dai Nippon Printing Co., Ltd.) ) Acrylic pressure-sensitive adhesive layer is formed on the surface of triacetyl cellulose, and the surface of the pressure-sensitive adhesive layer is roll-rolled with a release film. Thus, a surface-treated film roll with an adhesive layer is obtained.

(Polyethylene terephthalate protective film roll)

After corona treatment is applied to the surface of a uniaxially stretched polyethylene terephthalate film (thickness: 45 ^ m) corresponding to the panel width, an acrylic pressure-sensitive adhesive layer is formed on the surface of the pressure-sensitive adhesive layer. In a state where is provided, a roll is formed. In this way, a protective film mouthpiece with an adhesive layer is obtained.

(LCD panel)

A liquid crystal panel is produced by the first production method of the present invention using the polarizing plate roll, the surface-treated film roll with an adhesive layer and the protective film roll, as shown in FIG. That is, the above-described polarizing plate roll is pulled out as a long optical sheet 1 and the surface-treated film roll with an adhesive layer as a long optical sheet 3, respectively, and is released on the surface of the pressure-sensitive adhesive layer of the surface-treated film mouthpiece. After the film is peeled off, the pressure-sensitive adhesive layer side of the surface-treated film mouth is placed on the polarizing film side of the polarizing plate roll, and bonded by pressing with a nip roll while maintaining the tension. Next, after peeling off the release film provided on the polarizing plate side pressure-sensitive adhesive layer surface, the pressure-sensitive adhesive layer side is liquid crystal Bonded to one surface of the liquid crystal display element so as to be arranged on the display element side On the other hand, the polarizing plate roll described above is a long optical sheet 11, and the protective film roll with an adhesive layer is a long optical sheet 1 Each is pulled out as 3, and after the release film provided on the surface of the adhesive layer of the protective film roll is peeled off, the adhesive layer side of the protective film roll is disposed on the polarizing film side of the polarizing plate While holding the tension, press and bond with a two-ply roll. Next, after peeling off the release film provided on the polarizing plate-side pressure-sensitive adhesive layer surface, the adhesive layer is bonded to the other surface of the liquid crystal display element so that the pressure-sensitive adhesive layer is disposed on the liquid crystal display element side. . In addition, for example, using a push-cut type cutter or a dicing type cutter (cutting means), the excess area film bonded to the liquid crystal display element is cut. Thus, an adhesive layer, a norbornene resin biaxially stretched film, a polarizing film, and a surface treatment film are laminated in this order on one surface of the liquid crystal display element, and an adhesive layer on the other surface of the liquid crystal display element. A liquid crystal panel in which a biaxially stretched film of norbornene resin, a polarizing film, an adhesive layer, and a polyethylene terephthalate protective film are laminated in this order is obtained.

An example in which a liquid crystal panel is manufactured by the second manufacturing method of the present invention according to the method shown in FIGS.

(Polarizing plate roll)

The same polarizing plate roll as shown in the section of (polarizing plate roll) in Example 1 is used.

(Surface treatment film mouth)

Triacetyl cellulose surface with antiglare treatment layer 8 3 μπιι thick surface The treated film (Matsu Hard Coat TAC Film DS—LR 2, manufactured by Dai Nippon Printing Co., Ltd., rolled) is slit to the width corresponding to the panel width, and the surface treated film roll is used as it is. To do. This corresponds to the surface-treated film roll shown in the section of (Surface-treated film roll) in Example 1, in which the pressure-sensitive adhesive layer is not formed.

(Polyethylene terephthalate protective film mouthpiece)

—A roll of an axially stretched polyethylene terephthalate film (thickness: 45 μm) is slit to a width corresponding to the panel width and used as a protective film roll. This corresponds to the protective film roll shown in the section of (Polyethylene terephthalate protective film roll) in Example 1 in which the pressure-sensitive adhesive layer is not formed.

(LCD panel)

In FIG. 5, the polarizing plate roll described above is pulled out as the long optical sheet 1 and the surface treatment film roll as the long optical sheet 3, respectively, and the triacetyl cellulose side of the surface treatment film roll is disposed on the polarizing film side of the polarizing plate roll. In this state, an ultraviolet curable resin adhesive containing an epoxy resin and a force thione polymerization type initiator is interposed between the two and bonded with a nip roll while maintaining the tension. After bonding, the adhesive layer is cured by irradiating ultraviolet rays from the polarizing plate side.

-On the other hand, the polarizing plate roll described above is pulled out as the long optical sheet 11 and the protective film roll as the long optical sheet 13 respectively, and the protective film mouth is arranged on the polarizing film side of the polarizing plate roll. An ultraviolet curable resin adhesive containing an epoxy resin and a cationic polymerization type initiator is interposed between the two, and bonding is performed with a nip roll while maintaining the tension. After bonding, irradiate UV from the protective film side to harden the adhesive layer. Then, a laminate of the polarizing plate and the surface treatment film, and the polarizing plate and protection Using the cutting means as shown in Example 1, each of the bonded products with the film is cut into a size corresponding to the liquid crystal display element to be bonded.

After transporting the optical sheet laminate 51 obtained by cutting the bonded product of the polarizing plate and the surface-treated film and peeling the release film from the pressure-sensitive adhesive layer side of the polarizing plate as shown in FIG. An optical sheet laminate obtained by bonding the adhesive layer to one surface of the liquid crystal display element so that the pressure-sensitive adhesive layer is disposed on the liquid crystal display element side, and cutting the bonded product of the polarizing plate and the protective film. As shown in FIG. 6, after removing the release film from the pressure-sensitive adhesive layer side of the polarizing plate, the pressure-sensitive adhesive layer is arranged on the liquid crystal display element side. Paste it on the other side.

Thus, the pressure-sensitive adhesive layer, the norbornene resin biaxially stretched film, the polarizing film, and the surface treatment film are laminated in this order on one surface of the liquid crystal display element, and the pressure-sensitive adhesive layer is formed on the other surface of the liquid crystal display element. A liquid crystal panel is obtained in which a biaxially stretched film of norbornene resin, a polarizing film, and a polyethylene terephthalate protective film are laminated in this order. Example 3>

An example in which a liquid crystal panel is manufactured by the first manufacturing method of the present invention according to the method shown in FIG. (Polarizing film roll)

A polarizing film made of polyethylene is bonded to both sides of the polarizing film obtained in accordance with the method described in the section of (Polarizing film) in Example 1, and slitted to a width corresponding to the liquid crystal display element. To do. (Surface treatment film roll)

The same surface-treated film roll as shown in the section (Surface-treated film roll) of Example 2 is used. (Norbornene rosin film mouthpiece)

Norbornene resin biaxially stretched film wound in a round shape (Zeono Ryo Film, Optes Co., Ltd., Thickness: 8 0 111) is slit to the width corresponding to the panel width, and then Norbornene A protective film roll is used.

(Polyethylene terephthalate protection Fino Rem Low ^ /)

The same polyethylene terephthalate protective film roll as in Example 2 (Polyethylene terephthalate protective film roll) is used.

(LCD panel)

In FIG. 3, the stripping film is peeled off from the polarizing film film as described above, the long optical film 21, the surface treatment film roll as described above is the long optical sheet 3, and the above norbornene protective film film is long. The optical sheet 23 and the adhesive film formed of the attaryl adhesive are each drawn out as a long optical film 25 with a release film on one side. At this time, the triacetyl cellulose side of the surface-treated film faces the polarizing film, and the epoxy resin and the cationic polymerization type start between the surface-treated film and the polarizing film and between the polarizing film and the protective film, respectively. An ultraviolet curable resin adhesive containing an agent is interposed, and a surface-treated film, an adhesive layer, a polarizing film, an adhesive layer, a protective film, an adhesive film, and a release film are arranged in this order. In this state, stick with a nip roll while maintaining the tension. After bonding, UV light is irradiated from the release film side to cure the adhesive layer between the surface treatment film and the polarizing film and between the polarizing film and the protective film. Subsequently, the release film is peeled off from the adhesive film, and the adhesive film side is disposed on the liquid crystal display element side and bonded to one surface of the liquid crystal display element. On the other hand, a long optical film 31 obtained by peeling a release film from the polarizing film mouth described above, a long optical sheet 13 ₃ comprising the above polyethylene terephthalate protective film roll, and an adhesive film formed of an acrylic adhesive. With the release film provided on one side, each is pulled out as a long optical film 33. At this time, an ultraviolet curable resin adhesive containing an epoxy resin and a cationic polymerization initiator is interposed between the polarizing film and the polyethylene terephthalate protective film, and the protective film, the adhesive layer, the polarizing film, and the adhesive film. Arrange them in the following order. In this state, it is bonded with a roll-up roll while maintaining the tension. After bonding, UV light is irradiated from the protective film side to harden the adhesive layer between the polarizing film and the protective film. Subsequently, the release film is peeled off from the adhesive film, and the adhesive film side is disposed on the liquid crystal display element side, and is bonded to the other surface of the liquid crystal display element. Thus, after laminating the respective optical sheet laminates on both sides of the liquid crystal display element, the excess area film pasted on the liquid crystal display element is cut using the cutting means as shown in Example 1. . Thus, the pressure-sensitive adhesive film, the norbornene resin biaxially stretched film, the polarizing film, and the surface treatment film are laminated in this order on one surface of the liquid crystal display element, and the pressure-sensitive adhesive film and polarizing film are laminated on the other surface of the liquid crystal display element. A liquid crystal panel in which polyethylene terephthalate protective films are laminated in this order is obtained. Example 4>

The same polarizing film roll as shown in the (Polarizing film roll) section of Example 3 is used. (Surface treatment film mouth)

The same surface-treated film roll as shown in the section (Surface-treated film roll) of Example 2 is used.

(Triacetyl cellulose protective film roll)

A roll of stretched film made of triacetyl cellulose with a thickness of 43 μm (KC 4 FR-1, manufactured by Konica Minoltaput Co., Ltd.) is slit to the width corresponding to the panel width A protective film roll is used.

(Polyethylene terephthalate protective film roll)

The same polyethylene terephthalate protective film roll as in Example 2 (Polyethylene terephthalate protective film roll) is used. (LCD panel)

In FIG. 4, the stripped film is peeled off from the polarizing film mouth and the long optical film 21, the surface treatment film roll is the long optical sheet 3, and the triacetyl cellulose protective film is the long optical film. Sheet 2 3, Acrylic Adhesive film formed with adhesive is drawn out as a long optical film 25 with a release film on one side. At this time, the triacetyl cellulose side of the surface treatment film is faced to the polarizing film, and the epoxy resin and the cationic polymerization type start between the surface treatment film and the polarizing film and between the polarizing film and the triacetyl cellulose protective film, respectively. An ultraviolet curable resin adhesive containing an agent is interposed, and a surface treatment film, an adhesive layer, a polarizing film, an adhesive layer, a protective film, an adhesive film, and a release film are arranged in this order. In this state, it is bonded with an ep roll while maintaining the tension. After bonding, UV light is irradiated from the release film side, and between the surface treatment film and the polarizing film, and the polarizing buoy. Cure the adhesive layer between the film and the protective film. Subsequently, the release film is peeled off from the adhesive film, and the adhesive film side is disposed on the liquid crystal display element side and bonded to one surface of the liquid crystal display element. On the other hand, a long optical film 31 obtained by peeling off the release film from the polarizing film roll described above, a long optical sheet 13 as described above for the polyethylene terephthalate protective film roll, and a long optical sheet as described above for the triacetyl cellulose protective film roll. Sheet 41, adhesive film made of acrylic adhesive, is pulled out as long optical film 33 with a release film on one side. At this time, an ultraviolet curable resin adhesive containing an epoxy resin and a force thione polymerization initiator is interposed between the polyethylene terephthalate protective film and the polarizing film and between the polarizing film and the triacetyl cellulose protective film. Polyethylene terephthalate protective film, adhesive layer, polarizing film, adhesive layer, triacetyl cellulose protective film, adhesive film, and release film are arranged in this order. In this state, it is bonded with a nip roll while maintaining the tension. After bonding, ultraviolet rays are irradiated from the polyethylene terephthalate protective film side, and the adhesive layer between the polyethylene terephthalate protective film and the polarizing film and between the polarizing film and the triacetyl cellulose protective film is cured. Subsequently, the release film is peeled off from the adhesive film, and the adhesive film side is disposed on the liquid crystal display element side, and is bonded to the other surface of the liquid crystal display element. Thereafter, using the cutting means as shown in Example 1, the film of the extra region bonded to the liquid crystal display element is cut. Thus, an adhesive film, a triacetyl cellulose protective film, a polarizing film, and a surface treatment film are laminated in this order on one surface of the liquid crystal display element, and an adhesive film, triacetyl cellulose on the other surface of the liquid crystal display element. Protective film, polarizing film, polyethylene terephthalate protective film were laminated in this order LCD panel is obtained

An example in which a liquid crystal panel having a layer structure different from that of Example 1 is manufactured by the first manufacturing method of the present invention in accordance with the method shown in FIG.

(Polarizing plate roll)

One surface of a polarizing film obtained according to the method described in the section of (Polarizing film) in Example 1 is a biaxially stretched film made of norbornene resin (Zeonor film, Optes Co., Ltd.) that has been previously corona-treated. The anti-glare treatment layer is provided on the surface of the methacrylic resin film on the other side of the polarizing film so that its corona treatment surface is the front (non-adhesive surface). A protective film having a thickness of 85 is attached via an ultraviolet curable resin adhesive containing an epoxy resin and a force thione polymerization initiator so that the antiglare layer is a surface (non-adhesive surface). Match. After pasting, the adhesive is cured by irradiating ultraviolet rays from the side of the biaxially stretched film made of norbornene resin, and further rolled into a polarizing plate roll.

(LCD panel)

In FIG. 1, the polarizing plate roll described above is drawn out as a long optical sheet 3 and a pressure-sensitive adhesive film formed of attaryl pressure-sensitive adhesive as a long optical film 1 with a release film provided on one side thereof. At this time, it arrange | positions so that the corona treatment surface of the biaxially-stretched film of norbornene resin in a polarizing plate roll may face an adhesive film, and the release film on an adhesive film may become the outermost side. In this state, press and bond with a nip roll while maintaining the tension. Next, after peeling off the release film on the outer side of the adhesive film, the adhesive film side is placed on the liquid crystal display element side and bonded to one surface of the liquid crystal display element. On the other surface of the liquid crystal display element, as shown in Example 1, a pressure-sensitive adhesive layer, a biaxially stretched film of norbornene resin, a polarizing plate A film, an adhesive layer, and a polyethylene terephthalate protective film are laminated in this order. Thus, an adhesive film, a norbornene resin biaxially stretched film, a polarizing film, and a metataryl resin film having an antiglare layer are laminated in this order on one surface of the liquid crystal display element, and on the other surface of the liquid crystal display element, A liquid crystal panel in which a pressure-sensitive adhesive layer, a norbornene resin biaxially stretched film, a polarizing film, a pressure-sensitive adhesive layer, and a polyethylene terephthalate protective film are laminated in this order is obtained. Industrial applicability

According to the manufacturing method of the present invention, the film bonding process, cutting process, packing process, and delivery (transport) to the panel processing manufacturer in the optical member manufacturer are omitted. This has the effect of making the film cleaner and reducing defects. In addition, the yield of the optical sheet that is the optical film or its laminate is improved, and the product utilization efficiency is improved.

Furthermore, when the optical display element is a liquid crystal display element, it is customary to have different film configurations on the front and back sides (viewing side and backlight side), but some of them, for example, polarizing films, There is also an advantage that it can be shared. Specifically, the viewing-side polarizing plate of the liquid crystal display element is subjected to surface treatment such as anti-glare treatment and anti-reflection treatment, and the pack light-side polarizing plate is given unique functions such as a light diffusion function and a brightness enhancement function. In the past, in response to these requirements, the required optical film or optical sheet was laminated by an optical material manufacturer and delivered to a panel processing manufacturer. One type of film can be used, and a different optical film or optical sheet required for the front and back of the liquid crystal display element can be bonded to the liquid crystal display element. .

Claims

The scope of the claims

1. A method of manufacturing an optical display panel by bonding an optical sheet laminate having an optical function to an optical display element, comprising:

A drawing process for drawing out a long optical film or a long optical sheet from a plurality of rolls wound with a long optical film having an optical function or a long optical sheet as a laminate thereof, and a drawn long length A first laminating step of laminating an optical film or a long optical sheet, respectively, to form a long optical sheet laminate; and

From the second bonding step of bonding the long optical sheet laminate to the optical display element as it is, and from the bonded body of the long optical sheet laminate and the optical display element, the display area of the optical display panel is more than, And a cutting step of cutting the long optical sheet laminate in an area equal to or less than the entire surface of the optical display panel to obtain an optical sheet laminate.

2. A method of manufacturing an optical display panel by bonding an optical sheet laminate having an optical function to an optical display element,

A drawing process for drawing out the long optical film or the long optical sheet from a plurality of rolls wound with the long optical film having an optical function or a long optical sheet as a laminate thereof, and the drawn long optical A first bonding step of bonding a film or a long optical sheet, respectively, to form a long optical sheet laminate; and

A method for manufacturing an optical display panel, comprising: a cutting step of cutting a long optical sheet laminate to form an optical sheet laminate; and a second bonding step of bonding the optical sheet laminate to an optical display element.

3. The method for producing an optical display panel according to claim 1, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes a polarizing film made of a polybutyl alcohol resin film.

4. One force of a long optical sheet used for the drawing process A polarizing film made of a polybulualcohol resin film, and a protective film made of a thermoplastic resin attached to at least one surface of the polarizing film The method for producing an optical display panel according to claim 1, wherein the optical display panel is a polarizing plate.

5. One force of a long optical sheet used in the drawing process, a polarizing film made of a polybulu alcohol resin film, an adhesive layer formed on at least one surface of the polarizing film, and the adhesive layer A release film that protects the adhesive film, and in the first bonding step or the second bonding step, the release film is peeled off and the exposed adhesive layer is exposed to another optical film or optical film. The method for producing an optical display panel according to claim 1, which is used for bonding to a sheet or an optical display element.

6.One of the long optical sheets used in the drawing process is a polarizing film made of a polybulualcohol resin film, a protective film made of a thermoplastic resin attached to one surface of the polarizing film, and A polarizing plate having a pressure-sensitive adhesive layer formed on the other surface of the polarizing film and a release film for protecting the pressure-sensitive adhesive layer. In the first bonding step or the second bonding step, the mold release The method for producing an optical display panel according to claim 1, wherein the film is peeled and the pressure-sensitive adhesive layer exposed is applied to another optical film, or an optical sheet or an optical display element.

7. One force of the long optical sheet used in the drawing process, a polarizing film made of a polybulualcohol resin film, a protective film made of a thermoplastic resin affixed to one surface of the polarizing film, A polarizing plate having a pressure-sensitive adhesive layer formed on the outer surface of a protective film and a release film for protecting the pressure-sensitive adhesive layer. In the first bonding step or the second bonding step, the release film The method for producing an optical display panel according to claim 1, wherein the pressure-sensitive adhesive layer is peeled and exposed to bonding to another optical film or optical sheet or optical display element.

8. The method for producing an optical display panel according to claim 1, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes a cycloolefin resin film.

9. The method for producing an optical display panel according to claim 1 or 2, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes a cellulose ester resin film.

10. The method for producing an optical display panel according to claim 1, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes a polyethylene terephthalate resin film.

1 1. The method for producing an optical display panel according to claim 1, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes (meth) acrylic resin film.

1. The method for producing an optical display panel according to claim 1, wherein one of the long optical film or the long optical sheet subjected to the drawing step includes a polypropylene resin film.

3. The method for producing an optical display panel according to claim 1, wherein the optical display element is a liquid crystal display element, and the optical display panel is a liquid crystal panel.

1 4. The method for producing an optical display panel according to 2, wherein an ultraviolet curable resin adhesive is used for bonding in the first bonding step.