WO2018016288A1

WO2018016288A1 - Optical film set and production method therefor

Info

Publication number: WO2018016288A1
Application number: PCT/JP2017/023946
Authority: WO
Inventors: 健太郎池嶋; 聡司三田; 友徳上野; 恵美宮井; 菁▲王番▼ 徐; 岸　敦史
Original assignee: 日東電工株式会社
Priority date: 2016-07-22
Filing date: 2017-06-29
Publication date: 2018-01-25
Also published as: CN107924020A; TW201805656A; KR20190032262A; KR102436860B1; JP6792366B2; JP2018013727A; CN107924020B; TWI725209B

Abstract

The purpose of the present invention is to provide an optical film set that enables preferable production of optical display panels of the same configuration even when a roll-to-panel method and a sheet-to-panel method are concurrently used when attaching a thin optically functional film to an optical cell. The present invention pertains to an optical film set having a rolled optical film and a sheet-like optical film, wherein: the rolled optical film 1 is obtained by stacking a release film 11, a pressure-sensitive adhesive layer 12, an optically functional film 13, and a first surface protection film 14 in this order; and the sheet-like optical film 2 is obtained by stacking a release film 21, a pressure-sensitive adhesive film 22, an optically functional film 23, a first surface protection film 24, and a second surface protection film 25 in this order.

Description

Optical film set and manufacturing method thereof

The present invention relates to an optical film set having a roll-shaped optical film and a sheet-shaped optical film and a method for producing the same.

An optical film in which a release film, an adhesive layer, an optical functional film (typically, a polarizing film) and a surface protective film are laminated in this order is formed in a roll shape. An optical film obtained by cutting the optical film fed from the roll-shaped optical film by cutting the adhesive layer, the optical functional film and the surface protective film in the width direction (half cut) while leaving the release film. (Hereinafter also referred to as “roll-to-panel method”) in which the release film is peeled off and the optical film is bonded to the optical cell through the exposed adhesive layer (for example, Patent Documents 1 and 2). reference).

On the other hand, as an optical film bonding method different from the roll-to-panel method, an optical film that has been in a single wafer state is pasted to an optical cell via an adhesive layer that is exposed by peeling the release film. There is a method of matching (hereinafter also referred to as “sheet-to-panel method”) (see, for example, Patent Document 3).

JP 2011-123208 A Japanese Patent Laid-Open No. 2015-049115 JP 2006-039238 A

By the way, at the manufacturing site of optical display panels such as liquid crystal display panels, there is a new case of manufacturing optical display panels with the same configuration using not only the roll-to-panel method but also the sheet-to-panel method. It has occurred. For example, Patent Document 2 discloses that an optical display panel is continuously manufactured using a roll-to-panel method, and a rework process is performed on the optical display panel determined to be defective. When not many defective products are generated, it is conceivable to use a sheet-to-panel method when a new optical functional film is bonded to the optical cell in the rework process. Also, for example, when optical display panels with the same configuration must be produced in large quantities in a short period of time, the roll-to-panel method cannot cover all supply amounts, and the sheet-to-panel method is used together. Is also possible.

In recent years, as the thickness of optical display panels has been reduced, optical functional films (for example, polarizing films having a thickness of 60 μm or less) such as polarizing films are being developed. Such a thin optical functional film has a low waist (elastic modulus) and is likely to be twisted or curled.

According to the roll-to-panel method, a thin optical functional film is transported to a bonding position in a state of being laminated on a carrier film (release film), and the optical function from the carrier film (release film) at the bonding position. Since the film is peeled off and the optical functional film is bonded to the optical cell, a thin optical functional film can be continuously bonded to the optical cell while suppressing the occurrence of twisting and curling. However, in the sheet-to-panel system, handling such as transporting the optical functional film in a single wafer state, peeling of the release film, and laminating processing of the optical functional film to the liquid crystal cell is difficult, resulting in poor bonding. There is concern about a drop in yield.

In the present invention, an optical display panel having the same configuration can be suitably manufactured even when a roll-to-panel method and a sheet-to-panel method are used in combination when a thin optical functional film is bonded to an optical cell. It aims at providing a film set and its manufacturing method.

The present invention is an optical film set having a roll-shaped optical film and a sheet-shaped optical film,
The roll-shaped optical film has a structure in which a release film, an adhesive layer, an optical functional film, and a first surface protective film are laminated in this order,
The sheet-like optical film has a configuration in which the release film, the pressure-sensitive adhesive layer, the optical functional film, the first surface protective film, and the second surface protective film are laminated in this order.

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

In the above invention, the peeling force between the first surface protective film and the optical functional film may be larger than the peeling force between the second surface protective film and the first surface protective film.

According to the relationship of the peeling force, the second surface protective film can be peeled more smoothly.

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

In the above invention, the polarizing film may have a thickness of 60 μm or less.

In the above invention, the polarizing film may have a polarizer having a thickness of 10 μm or less.

In the above invention, the first surface protective film may have a first base film and a first pressure-sensitive adhesive layer, and may be laminated on the optical functional film via the first pressure-sensitive adhesive layer.

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

In the above invention, the second surface protective film may have a second base film and a second pressure-sensitive adhesive layer, and may be laminated on the first surface protective film via the second pressure-sensitive adhesive layer.

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

In the above invention, the roll-shaped optical film has a width corresponding to a pair of opposing sides of the optical cell, and the sheet-like optical film has a pair of opposing sides of the optical cell. It may have a length corresponding to one set of opposing sides, and another set of opposing sides may have a length corresponding to another set of opposing sides of the optical cell.

In the above invention, the roll-shaped optical film and the sheet-shaped optical film are configured such that the pressure-sensitive adhesive layer, the optical functional film, and the first surface protective film are laminated in this order on one surface of the optical cell. It may be used to manufacture an optical display panel.

In the above invention, the roll-shaped optical film is used to manufacture the optical display panel by a roll-to-panel method, and the sheet-like optical film is a sheet-to-panel method. May be used to manufacture.

In the above invention, the sheet-like optical film is determined as a defective product among the optical display panels manufactured by the roll-to-panel method using the roll-shaped optical film, and the pressure-sensitive adhesive is used. The adhesive layer, the optical functional film, and the first surface protective film are laminated in this order on one surface of the optical cell of the optical display panel from which the layer, the optical functional film, and the first surface protective film are peeled off. It may be used to remanufacture the optical display panel.

The “roll-to-panel method” is a method in which a release film is peeled off from an optical film drawn out from a roll-shaped optical film, and the optical film is bonded to an optical cell through an exposed adhesive layer. Here, before the release film is peeled off, it is only necessary to form cuts at a predetermined interval in the width direction in the optical film leaving the release film. The optical film may be formed with cuts in the width direction before being fed out from the roll, and may be formed in the width direction after being fed out and before peeling of the release film.

“Sheet-to-panel method” is a method in which a release film is peeled off from an optical film that has been in a single wafer state, and the optical film is bonded to an optical cell through an exposed adhesive layer.

Another invention is a method for producing the optical film set, wherein the method for producing the roll-shaped optical film comprises:
A step of preparing an optical film raw material having a configuration in which the release film, the pressure-sensitive adhesive layer, the optical functional film, and the first surface protective film are laminated in this order;
Slitting and winding the optical film original fabric to produce the roll-shaped optical film, and
A method for producing the sheet-like optical film,
Bonding the second surface protective film original fabric to the first surface protective film side of the optical film original material, and producing an optical film original material laminated with a second surface protective film;
Cutting the original optical film on which the second surface protective film is laminated to produce a sheet-like optical film.

In the above invention, the “cutting process” is not limited as long as the optical film original is processed into a sheet-like optical film through a cutting process, and the end face is cut into pieces and cut into pieces. It refers to processing including processing, slitting the optical film original to a predetermined width and then cutting in the width direction (however, the end face is not processed).

Another invention is a double-sided optical film set having a first optical film set and a second optical film set,
The first optical film set includes a roll-shaped first optical film and a sheet-shaped first optical film,
The roll-shaped first optical film has a configuration in which a first release film, a first pressure-sensitive adhesive layer, a first optical functional film, and a first surface protective film are laminated in this order,
The sheet-like first optical film has the first release film, the first pressure-sensitive adhesive layer, the first optical functional film, the first surface protective film, and the second surface protective film laminated in this order. Configuration,
The second optical film set includes a roll-shaped second optical film and a sheet-shaped second optical film,
The roll-shaped second optical film has a configuration in which a second release film, a second pressure-sensitive adhesive layer, a second optical function film, and a third surface protective film are laminated in this order,
In the sheet-like second optical film, the second release film, the second pressure-sensitive adhesive layer, the second optical functional film, the third surface protective film, and the fourth surface protective film are laminated in this order. It is a configuration.

In the above invention, the roll-shaped first optical film and the single-wafer-shaped first optical film, and the roll-shaped second optical film and the single-wafer-shaped second optical film are provided on one surface of the optical cell. The first pressure-sensitive adhesive layer, the first optical function film, and the first surface protective film are laminated in this order, and the second pressure-sensitive adhesive layer, the second optical function film, and the second surface of the optical cell. You may use for manufacturing the optical display panel of the structure by which the 3rd surface protection film was laminated | stacked in this order.

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

A method for producing the both-side optical film set,
The method for producing the roll-shaped first optical film comprises:
Preparing a first optical film original fabric having a configuration in which the first release film, the first pressure-sensitive adhesive layer, the first optical functional film, and the first surface protective film are laminated in this order;
Slitting the first optical film raw material, and winding it to produce the roll-shaped first optical film, and may include,
The method for producing the sheet-like first optical film comprises:
Bonding the second surface protective film original to the first surface protective film side of the first optical film original, and producing a second optical film original laminated with a second surface protective film;
Cutting the second optical film raw material on which the second surface protective film is laminated to produce a sheet-shaped first optical film,
A method for producing the roll-shaped second optical film,
Preparing a second optical film original fabric having a configuration in which the second release film, the second pressure-sensitive adhesive layer, the second optical functional film, and the third surface protective film are laminated in this order;
And slitting the second optical film original fabric and winding it to produce the roll-shaped second optical film,
A method for producing the sheet-like second optical film comprises:
Bonding the fourth surface protective film original fabric to the third surface protective film side of the second optical film raw material, and producing a fourth optical film original material laminated with the fourth surface protective film;
Cutting the fourth optical film raw material on which the fourth surface protective film is laminated to produce a sheet-like second optical film.

In the above invention, when a polarizing film is used as the optical functional film (the first optical functional film, the second optical functional film), or when a polarizing film is included as one member of the configuration of the optical functional film, In roll-shaped and single-wafer-shaped optical films (first optical film, second optical film) and optical film originals (first optical film original, second optical film original), the absorption axis direction of the polarizing film is There is no particular limitation as long as the achievement of the object of the invention is not hindered. That is, as long as the combination is such that an optical display panel having the same configuration can be manufactured even if the roll-to-panel method and the sheet-to-panel method are used together, a roll-shaped optical film (first In the optical film, the second optical film) and the optical film original fabric (first optical film original fabric, second optical film original fabric), the polarizing film may have an absorption axis direction parallel to the longitudinal direction and orthogonal. Alternatively, it may be oblique (for example, a direction that forms an angle of 45 ° with respect to the longitudinal direction). Further, the absorption axis direction of the rectangular sheet-like polarizing film may be parallel to the longitudinal direction, may be orthogonal, or may be oblique (for example, a direction that forms an angle of 45 ° with respect to the longitudinal direction). Further, the absorption axis direction of the square sheet-like polarizing film may be parallel to an arbitrary side or may be oblique (for example, a direction that forms an angle of 45 ° with respect to the side).

In the present invention, the roll-shaped optical film is such that the pressure-sensitive adhesive layer, the optical functional film, and the surface protective film are opposed to the optical cell in the direction (width direction) perpendicular to the longitudinal direction of the optical film while leaving the release film. Cuts may be formed at intervals corresponding to another set of sides. According to this configuration, it is not necessary to cut (half-cut) the optical film in the roll-to-panel method.

In the above invention, the optical cell may be a VA mode or IPS mode liquid crystal cell or an organic EL cell.

The shape of the optical cell is not particularly limited as long as it has a pair of opposing sides and another pair of opposing sides, and may be square or rectangular. In general, one set of opposing sides of the optical cell and another set of opposing sides are orthogonal to each other.

The optical film set of the present invention is used to manufacture an optical display panel having the same configuration. A roll-shaped optical film is used in a roll-to-panel system. A sheet-like optical film is used in a sheet-to-panel system. The sheet-like optical film has the same laminated structure as the roll-like optical film except that the second surface protective film is provided. A roll-shaped optical film uses a roll-to-panel method to produce an optical display panel having a structure in which an adhesive layer, an optical functional film, and a first surface protective film are laminated in this order on one surface of an optical cell. Used to do. In addition, since the sheet-like optical film provided with the second surface protective film has improved handling properties, the sheet-to-panel method is used while suppressing the occurrence of twisting and curling. It can be suitably bonded to the optical cell. And by removing (for example, peeling) the second surface protective film from the sheet-like optical film bonded to the optical display panel, as a result, the same as the optical display panel manufactured by the roll-to-panel method A laminated optical display panel can be manufactured. That is, according to the optical film set of the present invention, the optical display panel having the same configuration can be used even when the roll-to-panel method and the sheet-to-panel method are used together when the optical film is bonded to the optical cell. Can be suitably manufactured.

The schematic diagram which shows the optical film set of Embodiment 1. The schematic diagram which shows the both-sides optical film set of Embodiment 2. Schematic diagram showing a method for producing a roll-shaped first optical film The schematic diagram which shows the method of manufacturing a sheet-like 1st optical film Schematic of the continuous manufacturing system of the optical display panel of Embodiment 4. Diagram showing remanufacturing process Schematic of the continuous manufacturing system of the optical display panel of Embodiment 5.

(Embodiment 1: Optical film set)
FIG. 1 is a schematic diagram showing an optical film set. The side surface, plane, and partial cross-sectional enlarged view of the roll-shaped first optical film 1 are shown in the upper part of FIG. The side surface, plane, and partial cross-sectional enlarged view of the sheet-like first optical film 2 are shown in the lower part of FIG. In the roll-shaped first optical film 1, a first release film 11, a first pressure-sensitive adhesive layer 12, a first optical functional film 13, and a first surface protective film 14 are laminated in this order.

The roll-shaped first optical film 1 is used for manufacturing an optical display panel by a roll-to-panel method. In such a case, the strip-shaped first optical film 10 having a width a that is fed out from the roll-shaped first optical film 1 is cut by the cutting means C at a predetermined interval b, leaving the release film 11. Reference numeral s denotes a cut formed in the first optical film 30 by the above cutting.

Further, the sheet-like first optical film 2 includes a first release film 21, a first pressure-sensitive adhesive layer 22, a first optical functional film 23, a first surface protective film 24, and a second surface protective film 25 laminated in this order. Has been. The size of the sheet-like first optical film 2 is vertical a and horizontal b. The sheet-like first optical film 2 is used for manufacturing an optical display panel by a sheet-to-panel method.

In the present embodiment, the first release film 11 and the first release film 21 have the same configuration. The 1st adhesive layer 12 and the 1st adhesive layer 22 are the same structures. The first optical functional film 13 and the first optical functional film 23 have the same configuration. The 1st surface protection film 14, the 1st surface protection film 24, and the 2nd surface protection film 25 are the same structures. The “same configuration” is not limited as long as the materials, thicknesses, and the like completely match, but may be substantially the same (for example, the same in terms of manufacturing quality).

In the present embodiment, the first surface protective film 14 (or 24) has a first base film and a first pressure-sensitive adhesive layer, and the first optical functional film 13 (or 23) via the first pressure-sensitive adhesive layer. ). As another embodiment, the first surface protective film 14 (or 24) may be a self-adhesive film.

In the present embodiment, the second surface protective film 25 has a second base film and a second pressure-sensitive adhesive layer, and is laminated on the first surface protective film 24 via the second pressure-sensitive adhesive layer. As another embodiment, the second surface protective film 25 may be a self-adhesive film.

(Relationship between phase peeling forces)
Further, the peeling force between the first surface protective film 24 and the first optical functional film 23 is larger than the peeling force between the second surface protective film 25 and the first surface protective film 24. According to this, the 2nd surface protection film 25 can be peeled more smoothly. As the measurement of the peeling force, for example, a tensile tester can be used. The peeling condition is measured by 180 ° peeling at 0.3 m / min. The peeling force is controlled by the composition and thickness of the pressure-sensitive adhesive.

The magnitude relationship of the peeling force between each layer in the sheet-like 1st optical film 2 is as follows.
Delamination force A between the first release film 21 and the first pressure-sensitive adhesive layer 22;
Delamination force B between the first pressure-sensitive adhesive layer 22 and the first optical functional film 23,
Delamination force C between the first optical functional film 23 and the first surface protective film 24;
In the case of the delamination force D between the first surface protective film 24 and the second surface protective film 25,
A <B, A <C, A <D.
Preferably, A <D <C ≦ B or A <D <B ≦ C.
More preferably, A <D <C <B.
According to the relationship between the interphase peeling forces, the second surface protective film can be prevented from peeling off when the first release film is peeled off.

<Optical function film>
The first optical

functional films

13 and 23 are not particularly limited as long as they are films having optical functions, and examples thereof include a polarizing film, a retardation film, a brightness enhancement film, and a diffusion film, but are typically polarizing films. .

(Polarizing film)
In the present embodiment, from the viewpoint of thinning, it is preferable to use a polarizing film having a thickness (total thickness) of 60 μm or less, more preferably 55 μm or less, and further preferably 50 μm or less. As a polarizing film, for example, (1) a configuration in which protective films (sometimes referred to as “polarizer protective films”) are laminated on both sides of a polarizer (sometimes referred to as “both protective polarizing films”). (2) A structure in which a protective film is laminated only on one side of a polarizer (sometimes referred to as a “single protective polarizing film”).

(Polarizer)
A polarizer using a polyvinyl alcohol-based resin is used. Examples of polarizers include dichroic iodine and dichroic dyes on hydrophilic polymer films such as polyvinyl alcohol films, partially formalized polyvinyl alcohol films, and ethylene / vinyl acetate copolymer partially saponified films. Examples thereof include polyene-based oriented films such as those obtained by adsorbing substances and uniaxially stretched, polyvinyl alcohol dehydrated products and polyvinyl chloride dehydrochlorinated products. Among these, a polarizer composed of a polyvinyl alcohol film and a dichroic material such as iodine is preferable.

A polarizer obtained by dyeing a polyvinyl alcohol film with iodine and uniaxially stretching it can be produced, for example, by dyeing polyvinyl alcohol in an aqueous iodine solution and stretching it 3 to 7 times the original length. If necessary, it may contain boric acid, zinc sulfate, zinc chloride, or the like, or may be immersed in an aqueous solution such as potassium iodide. Further, if necessary, the polyvinyl alcohol film may be immersed in water and washed before dyeing. In addition to washing the polyvinyl alcohol film surface with dirt and anti-blocking agents by washing the polyvinyl alcohol film with water, it also has the effect of preventing unevenness such as uneven coloring by swelling the polyvinyl alcohol film. is there. Stretching may be performed after dyeing with iodine, may be performed while dyeing, or may be dyed with iodine after stretching. The film can be stretched even in an aqueous solution such as boric acid or potassium iodide or in a water bath.

The thickness of the polarizer is preferably 10 μm or less from the viewpoint of thinning, more preferably 8 μm or less, further 7 μm or less, and further preferably 6 μm or less. On the other hand, the thickness of the polarizer is preferably 2 μm or more, and more preferably 3 μm or more. Such a thin polarizer has less thickness unevenness, excellent visibility, and less dimensional change, and therefore excellent durability against thermal shock. On the other hand, a polarizing film including a polarizer having a thickness of 10 μm or less has a significantly low waist (elastic modulus), and therefore, there is a high possibility of twisting and curling in the sheet-to-panel system. Therefore, the present invention is particularly suitable for the polarizing film.

As a thin polarizer, typically,
Patent No. 4751486,
Japanese Patent No. 4751481,
Patent No. 4815544,
Patent No. 5048120,
International Publication No. 2014/077599 pamphlet,
International Publication No. 2014/077636 Pamphlet,
And the thin polarizers obtained from the production methods described therein.

The polarizer has an optical characteristic expressed by a single transmittance T and a polarization degree P of the following formula: P> − (10 ^0.929T-42.4 −1) × 100 (where T <42.3), Or
P ≧ 99.9 (however, T ≧ 42.3)
It is preferable to be configured to satisfy the above condition. A polarizer configured so as to satisfy the above-described conditions uniquely has performance required as a display for a liquid crystal television using a large display element. Specifically, the contrast ratio is 1000: 1 or more and the maximum luminance is 500 cd / m ² or more. As other uses, for example, it is bonded to the viewing side of the organic EL cell.

As the thin polarizer, among the production methods including the step of stretching in the state of a laminate and the step of dyeing, Patent No. 4751486, Patent, in that it can be stretched at a high magnification and the polarization performance can be improved. What is obtained by the manufacturing method including the process of extending | stretching in a boric-acid aqueous solution as described in the 4751481 specification and the patent 4815544 specification is preferable, and it describes especially in the patent 4751481 specification and the patent 4815544 specification. What is obtained by the manufacturing method including the process of extending | stretching in the air auxiliary before extending | stretching in the boric-acid aqueous solution which has this is preferable. These thin polarizers can be obtained by a production method including a step of stretching a polyvinyl alcohol-based resin (hereinafter also referred to as PVA-based resin) layer and a stretching resin base material in a laminated state and a step of dyeing. With this manufacturing method, even if the PVA-based resin layer is thin, it can be stretched without problems such as breakage due to stretching by being supported by the stretching resin substrate.

(Protective film (polarizer protective film))
As a material constituting the protective film, a material excellent in transparency, mechanical strength, thermal stability, moisture barrier property, isotropy and the like is preferable. For example, polyester polymers such as polyethylene terephthalate and polyethylene naphthalate, cellulose polymers such as diacetyl cellulose and triacetyl cellulose, acrylic polymers such as polymethyl methacrylate, styrene such as polystyrene and acrylonitrile / styrene copolymer (AS resin) And polymers based on polycarbonate and polycarbonate. In addition, polyethylene, polypropylene, polyolefins having a cyclo or norbornene structure, polyolefin polymers such as ethylene / propylene copolymers, vinyl chloride polymers, amide polymers such as nylon and aromatic polyamide, imide polymers, sulfone polymers , Polyether sulfone polymer, polyether ether ketone polymer, polyphenylene sulfide polymer, vinyl alcohol polymer, vinylidene chloride polymer, vinyl butyral polymer, arylate polymer, polyoxymethylene polymer, epoxy polymer, or the above Polymer blends and the like can also be mentioned as examples of the polymer forming the protective film.

In addition, 1 or more types of arbitrary appropriate additives may be contained in the protective film. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a release agent, a coloring inhibitor, a flame retardant, a nucleating agent, an antistatic agent, a pigment, and a coloring agent. The content of the thermoplastic resin in the transparent protective film is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, still more preferably 60 to 98% by weight, and particularly preferably 70 to 97% by weight. . When content of the said thermoplastic resin in a transparent protective film is 50 weight% or less, there exists a possibility that the high transparency etc. which a thermoplastic resin originally has cannot fully be expressed.

As the protective film, a retardation film, a brightness enhancement film, a diffusion film, and the like can also be used.

A functional layer such as a hard coat layer, an antireflection layer, an antisticking layer, a diffusion layer or an antiglare layer can be provided on the surface of the protective film where the polarizer is not adhered. The functional layers such as the hard coat layer, antireflection layer, antisticking layer, diffusion layer and antiglare layer can be provided on the transparent protective film itself, and separately provided separately from the transparent protective film. You can also

(Intervening layer)
The protective film and the polarizer are laminated via an intervening layer such as an adhesive layer, an adhesive layer, and an undercoat layer (primer layer). At this time, it is desirable that the both are laminated without an air gap by an intervening layer.
The adhesive layer is formed of an adhesive. The type of the adhesive is not particularly limited, and various types can be used. The adhesive layer is not particularly limited as long as it is optically transparent. Examples of the adhesive include water-based, solvent-based, hot-melt-based, active energy ray-curable types, and the like. Or an active energy ray hardening-type adhesive agent is suitable.
Examples of the water-based adhesive include an isocyanate-based adhesive, a polyvinyl alcohol-based adhesive, a gelatin-based adhesive, a vinyl-based latex, and a water-based polyester. The water-based adhesive is usually used as an adhesive composed of an aqueous solution, and usually contains 0.5 to 60% by weight of solid content.
The active energy ray curable adhesive is an adhesive that cures by an active energy ray such as an electron beam or ultraviolet rays (radical curable type, cationic curable type), for example, in an electron beam curable type or an ultraviolet curable type. Can be used. As the active energy ray curable adhesive, for example, a photo radical curable adhesive can be used. When the photo radical curable active energy ray curable adhesive is used as an ultraviolet curable adhesive, the adhesive contains a radical polymerizable compound and a photo polymerization initiator.

In addition, in laminating | stacking a polarizer and a protective film, an easily bonding layer can be provided between a transparent protective film and an adhesive bond layer. The easy adhesion layer can be formed of, for example, various resins having a polyester skeleton, a polyether skeleton, a polycarbonate skeleton, a polyurethane skeleton, a silicone-based, a polyamide skeleton, a polyimide skeleton, a polyvinyl alcohol skeleton, and the like. These polymer resins can be used alone or in combination of two or more. Moreover, you may add another additive for formation of an easily bonding layer. Specifically, a stabilizer such as a tackifier, an ultraviolet absorber, an antioxidant, and a heat resistance stabilizer may be used.

The pressure-sensitive adhesive layer is formed from a pressure-sensitive adhesive. Various pressure-sensitive adhesives can be used as the pressure-sensitive adhesive, such as rubber-based pressure-sensitive adhesives, acrylic pressure-sensitive adhesives, silicone-based pressure-sensitive adhesives, urethane-based pressure-sensitive adhesives, vinyl alkyl ether-based pressure-sensitive adhesives, polyvinylpyrrolidone-based pressure-sensitive adhesives, Examples include acrylamide-based adhesives and cellulose-based adhesives. An adhesive base polymer is selected according to the type of the adhesive. Among the pressure-sensitive adhesives, acrylic pressure-sensitive adhesives are preferably used because they are excellent in optical transparency, exhibit appropriate wettability, cohesiveness, and adhesive pressure-sensitive adhesive properties, and are excellent in weather resistance and heat resistance. The

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

(Surface protection film)
A 1st, 2nd surface protection film is provided in the single side | surface (surface which has not laminated | stacked the adhesive layer) in a polarizing film in an optical film, and protects optical function films, such as a polarizing film.
As the base film of the first and second surface protective films, a film material having isotropic property or close to isotropic property is selected from the viewpoints of inspection property and manageability. Examples of film materials include polyester resins such as polyethylene terephthalate film, cellulose resins, acetate resins, polyether sulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, acrylic resins, and the like. Examples thereof include transparent polymers such as resins. Of these, polyester resins are preferred. The base film can be used as a laminate of one kind or two or more kinds of film materials, and a stretched product of the film can also be used. The thickness of the base film is preferably 10 μm to 150 μm, more preferably 20 to 100 μm.

As the first and second surface protective films, the base film can be used as a self-adhesive film, and a film having the base film and an adhesive layer can be used. As the first and second surface protective films, those having an adhesive layer are preferably used from the viewpoint of protecting an optical functional film such as a polarizing film.

Examples of the pressure-sensitive adhesive layer used for laminating the first and second surface protective films include (meth) acrylic polymers, silicone polymers, polyesters, polyurethanes, polyamides, polyethers, fluorine-based and rubber-based polymers. A pressure-sensitive adhesive as a base polymer can be appropriately selected and used. From the viewpoints of transparency, weather resistance, heat resistance and the like, an acrylic pressure-sensitive adhesive having an acrylic polymer as a base polymer is preferable. The thickness (dry film thickness) of the pressure-sensitive adhesive layer is determined according to the required adhesive force. Usually, it is about 1 to 100 μm, preferably 5 to 50 μm.

The first and second surface protective films may be provided with a release treatment layer on the surface opposite to the surface on which the pressure-sensitive adhesive layer is provided with a low adhesive material such as silicone treatment, long-chain alkyl treatment, or fluorine treatment. it can.

<Adhesive layer>
An appropriate pressure-sensitive adhesive can be used for forming the first pressure-sensitive adhesive layers 12 and 22, and the type thereof is not particularly limited. Adhesives include rubber adhesives, acrylic adhesives, silicone adhesives, urethane adhesives, vinyl alkyl ether adhesives, polyvinyl alcohol adhesives, polyvinyl pyrrolidone adhesives, polyacrylamide adhesives, Examples thereof include cellulose-based pressure-sensitive adhesives.

Among these pressure-sensitive adhesives, those having excellent optical transparency, suitable wettability, cohesiveness, and adhesive pressure characteristics, and excellent weather resistance and heat resistance are preferably used. An acrylic pressure-sensitive adhesive is preferably used as one exhibiting such characteristics.

As a method for forming the first pressure-sensitive adhesive layers 12 and 22, for example, a release film obtained by removing the pressure-sensitive adhesive (applied to a separator and the like, and after removing the polymerization solvent and the like to form a pressure-sensitive adhesive layer, By a method of transferring to a polarizer (or transparent protective film) or a method of applying the adhesive to the polarizer (or transparent protective film) and drying and removing the polymerization solvent to form an adhesive layer on the polarizer. In applying the pressure-sensitive adhesive, one or more solvents other than the polymerization solvent may be added as appropriate.

As the release film after the release treatment, a silicone release liner is preferably used. In the step of forming the pressure-sensitive adhesive layer by applying and drying the pressure-sensitive adhesive of the present invention on such a liner, an appropriate method may be adopted as appropriate according to the purpose. Preferably, a method of heating and drying the coating film is used. The heating and drying temperature is preferably 40 ° C to 200 ° C, more preferably 50 ° C to 180 ° C, and particularly preferably 70 ° C to 170 ° C. By setting the heating temperature within the above range, an adhesive having excellent adhesive properties can be obtained.

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

Various methods are used for forming the first pressure-sensitive adhesive layers 12 and 22. Specifically, for example, roll coat, kiss roll coat, gravure coat, reverse coat, roll brush, spray coat, dip roll coat, bar coat, knife coat, air knife coat, curtain coat, lip coat, die coater, etc. Examples thereof include an extrusion coating method.

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

<Release film>
The

first release films

11 and 21 protect the pressure-sensitive adhesive layer until practical use. Examples of the constituent material of the release film include plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and nonwoven fabric, nets, foam sheets, metal foils, and laminates thereof. However, a plastic film is preferably used from the viewpoint of excellent surface smoothness.

The plastic film is not particularly limited as long as it can protect the pressure-sensitive adhesive layer. For example, a polyethylene film, a polypropylene film, a polybutene film, a polybutadiene film, a polymethylpentene film, a polyvinyl chloride film, and a vinyl chloride co-polymer are used. Examples thereof include a polymer film, a polyethylene terephthalate film, a polybutylene terephthalate film, a polyurethane film, and an ethylene-vinyl acetate copolymer film.

The thickness of the

first release films

11 and 21 is usually about 5 to 200 μm, preferably about 5 to 100 μm. For the separator, if necessary, mold release and antifouling treatment with a silicone type, fluorine type, long chain alkyl type or fatty acid amide type release agent, silica powder, etc., coating type, kneading type, vapor deposition type It is also possible to carry out antistatic treatment such as. In particular, the release property from the pressure-sensitive adhesive layer can be further improved by appropriately performing a release treatment such as silicone treatment, long-chain alkyl treatment, or fluorine treatment on the surface of the release film.

(Embodiment 2: Double-sided optical film set)
The double-sided optical film set of Embodiment 2 includes a first optical film set and a second optical film set. Since the first optical film set is the same as the first optical film set of Embodiment 1, description thereof is omitted. The second optical film set will be described with reference to FIG. The second optical film set includes a roll-shaped second optical film 3 and a sheet-shaped second optical film 4.

FIG. 2 shows an enlarged side view, a plane, and a partial cross-sectional view of the roll-shaped second optical film 3 at the top. The side surface, plane, and partial cross-sectional enlarged view of the sheet-like second optical film 4 are shown in the lower part of FIG. In the roll-shaped second optical film 3, a second release film 31, a second pressure-sensitive adhesive layer 32, a second optical function film 33, and a third surface protective film 34 are laminated in this order. The strip-shaped optical film 30 having a width b fed out from the roll-shaped second optical film 3 is cut by the cutting means C at a predetermined interval a while leaving the second release film 31. The symbol s is a cut formed in the optical film 30 by the above cutting.

In addition, the sheet-like second optical film 4 includes a second release film 41, a second pressure-sensitive adhesive layer 42, a second optical function film 43, a third surface protective film 44, and a fourth surface protective film 45 laminated in this order. Has been. The size of the second optical film 4 in a single wafer state is a horizontal a and a vertical b.

In the present embodiment, the second release film 31 and the second release film 41 have the same configuration. The 2nd adhesive layer 32 and the 2nd adhesive layer 42 are the same structures. The second optical functional film 33 and the second optical functional film 43 have the same configuration. The third surface protective film 34, the third surface protective film 44, and the fourth surface protective film 45 have the same configuration. The “same configuration” is not limited as long as the materials, thicknesses, and the like completely match, but may be substantially the same (for example, the same in terms of manufacturing quality).

In the present embodiment, the third surface protective film 34 (or 44) has a third base film and a third pressure-sensitive adhesive layer, and the second optical function film 33 (or 43) via the third pressure-sensitive adhesive layer. ). As another embodiment, the third surface protective film 34 (or 44) may be a self-adhesive film.

In the present embodiment, the fourth surface protective film 45 has a fourth base film and a fourth pressure-sensitive adhesive layer, and is laminated on the third surface protective film 34 via the fourth pressure-sensitive adhesive layer. As another embodiment, the fourth surface protective film 45 may be a self-adhesive film.

(Relationship between phase peeling forces)
In addition, the peeling force between the third surface protective film 34 and the second optical functional film 33 is larger than the peeling force between the fourth surface protective film 45 and the third surface protective film 44. According to this, the 4th surface protection film 45 can be peeled more smoothly.

The magnitude relationship of the peeling force between each layer in the sheet-like second optical film 4 is as follows.
Delamination force A1 between the second release film 41 and the second pressure-sensitive adhesive layer 42,
Delamination force B1 between the second pressure-sensitive adhesive layer 42 and the second optical functional film 43,
Delamination force C1 between the second optical functional film 43 and the third surface protective film 44,
In the case of the delamination force D1 between the third surface protective film 44 and the fourth surface protective film 45,
A1 <B1, A1 <C1, and A <D1.
Preferably, A1 <D1 <C1 ≦ B1 or A1 <D1 <B1 ≦ C1.
More preferably, A1 <D1 <C1 <B1.
According to the relationship between the interphase peeling forces, it is possible to suppress the fourth surface protective film from peeling off when the second release film is peeled off.

The members constituting the roll-shaped second optical film and the sheet-shaped second optical film in the second optical film set are the optical functional film, release film, pressure-sensitive adhesive layer, and surface protective film described in the first embodiment. The same configuration may be used.

(Embodiment 3: Production of optical film set)
Subsequently, the manufacturing method of a 1st optical film set and a 2nd optical film set is demonstrated. FIG. 3A is a schematic diagram showing a method for producing a roll-shaped first optical film 1. FIG. 3B is a schematic view showing a method for producing the sheet-like first optical film 2.

3A, a roll-shaped first optical film original 5 having a configuration in which a first release film, a first pressure-sensitive adhesive layer, a first optical functional film, and a first surface protective film are laminated in this order is prepared. Next, the first optical film is unwound from the first optical film 5 and slit into three strip-shaped optical films with a predetermined width a using the slit cut part sc. The three strip-shaped optical films that have been slit are each wound to produce a roll-shaped first optical film.

In this embodiment, slit processing is performed on three strip-shaped optical films, but the present invention is not limited to this. In the present embodiment, both ends e1 and e2 are trimmed (end trimming). However, either one of the ends may be trimmed or both ends may not be trimmed.

In FIG. 3B, the 2nd surface protection film 25 extended | stretched from 2nd surface protection film original fabric S25 to the 1st surface protection film 14 side of the roll-shaped 1st optical film 1 (equivalent to 1st optical film original fabric). Are bonded by a bonding means (a pair of bonding rolls R1 and R2) to produce an optical film original fabric S2 on which the second surface protective film 25 is laminated. Next, the optical film original fabric S2 on which the second surface protective film 25 is laminated is fully cut at a predetermined interval b by using the cutting means FC, and the sheet-like first optical film 2 is manufactured. The sheet-like first optical film 2 may be stored in a predetermined storage unit or may be laminated on a carrier film. The first optical film set can be manufactured by the above method.

As another embodiment, a step of winding the optical film original fabric S2 and a belt-shaped first optical film from the optical film original fabric S2 may be fed and cut at a predetermined interval b using the cutting means FC.

The second optical film set may be manufactured in the same process as in FIGS. 3A and 3B.

As another embodiment, after the slit processing, the adhesive layer 12, the first optical function film, and the first surface protective film are cut (half cut) at a predetermined interval, leaving the strip-shaped first release film 11. A step of forming a plurality of cuts may be further included.

(Liquid crystal cell, liquid crystal display panel)
The liquid crystal cell has a structure in which a liquid crystal layer is sealed between a pair of substrates (a first substrate (viewing side surface) Pa and a second substrate (back surface) Pb) disposed to face each other. Although any type of liquid crystal cell can be used, it is preferable to use a vertical alignment (VA) mode or in-plane switching (IPS) mode liquid crystal cell in order to achieve high contrast. A liquid crystal display panel has a polarizing film bonded to one or both sides of a liquid crystal cell, and a drive circuit is incorporated as necessary.

(Organic EL cell, organic EL display panel)
The organic EL cell has a configuration in which an electroluminescent layer is sandwiched between a pair of electrodes. As the organic EL cell, for example, an arbitrary type such as a top emission method, a bottom emission method, a double emission method, or the like can be used. The organic EL display panel has a polarizing film bonded to one or both sides of an organic EL cell, and a drive circuit is incorporated as necessary.

(Embodiment 4: Remanufacturing using the first optical film set)
FIG. 4 is a schematic diagram of a continuous manufacturing system of an optical display panel. In the present embodiment, the roll-shaped first optical film 1 is used to manufacture an optical display panel by a roll-to-panel method. The sheet-shaped first optical film 2 is determined as a defective product among the optical display panels manufactured using the roll-shaped first optical film 1, and the first pressure-sensitive adhesive layer, the first optical functional film, and the first Remanufacturing an optical display panel having a structure in which a first pressure-sensitive adhesive layer, a first optical functional film, and a first surface protective film are laminated in this order on one surface of an optical cell of the optical display panel from which the surface protective film has been peeled off. Used to do. Specifically, a sheet-like first optical element is formed on one surface of the optical cell from which the first pressure-sensitive adhesive layer 22, the first optical functional film 23, and the first surface protective film 24 have been peeled by a sheet-to-panel method. After the first release film 21 is peeled from the film 2 and the first pressure-sensitive adhesive layer 22, the first optical function film 23, the first surface protective film 24, and the second surface protective film 25 are bonded together in this order, The surface protective film 25 is peeled off. In this embodiment, a liquid crystal cell will be described as an example of an optical cell, and a liquid crystal display panel will be described as an example of an optical display panel.

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

As shown in FIG. 4, the liquid crystal display panel manufacturing system according to the present embodiment has a first transport unit 81 that transports the liquid crystal cell P to the first pasting unit 64, and a roll-shaped first surface P1 of the liquid crystal cell P. It has the 2nd conveyance part 82 which conveys liquid crystal cell P after sticking an optical film using the 1st optical film 1. FIG. Each transport unit includes a plurality of transport rollers R for transporting the liquid crystal cell P by rotating around a rotation axis parallel to a direction orthogonal to the transport direction. In addition to the conveying roller, a suction plate or the like may be included.

(Liquid crystal cell transport process)
The liquid crystal cell P is disposed in the first transport unit 81 from the storage unit 91 that stores the liquid crystal cell P so that the first surface P1 is the top surface, and is transported to the first pasting unit 64 by the rotation of the transport roller R. The

(First optical film feeding step, first optical film cutting step)
The strip-shaped first optical film 10 drawn out from the roll-shaped first optical film 1 is left without cutting the first release film 11 at the cutting portion 61 while adsorbing and fixing the first release film 11 side. The strip-shaped pressure-sensitive adhesive layer 12, the strip-shaped first optical functional film 13, and the strip-shaped first surface protective film 14 are of a predetermined size (length corresponding to the short side of the liquid crystal cell P (substantially shorter than the short side). )) To form a cut portion s. Examples of the cutting by the cutting unit 61 include cutting using a blade (cutting with a cutting blade) and cutting with a laser device. An example of the cut portion s after being cut is indicated by an arrow in FIG. 4, but the cut is deliberately drawn for easy explanation. A configuration in which a nip roller (not shown) is arranged on the upstream side or the downstream side of the cutting unit 61 and conveys the belt-shaped first optical film 10 may be adopted. Note that nip rollers may be arranged on the upstream side and the downstream side of the cutting portion 61.

(Tension adjustment process)
A first tension adjusting unit for enabling continuous processing so that the processing is not interrupted for a long time in the cutting processing of the strip-shaped first optical film 10 and the subsequent sticking processing and for adjusting the slackness of the film. 62 is provided. The first tension adjusting unit 62 includes a dancer mechanism using a weight, for example. A configuration in which a nip roller (not shown) is disposed on the upstream side or the downstream side of the first tension adjusting unit 62 and conveys the first optical film 10 may be employed. Note that the nip rollers may be arranged on the upstream side and the downstream side of the first tension adjusting unit 62.

(Peeling process)
The first optical film 10 is wound around the first peeling portion 63 and reversed, and the first optical film 10 is peeled from the first release film 11. The first release film 11 is wound on a roll by the first winding unit 65. The 1st winding part 65 has a roll and a rotation drive part, and winds the 1st release film 11 to a roll, when a rotation drive part rotates a roll. Moreover, the structure which a nip roller not shown is arrange | positioned in the upstream or downstream of the peeling part 63, and conveys the 1st optical film 10 or the 1st release film 11 may be sufficient. Note that the nip rollers may be disposed on the upstream side and the downstream side of the peeling portion 63.

(First sticking step)
The first pasting portion 64 conveys the liquid crystal cell P while the first optical film 10 from which the first release film 11 has been peeled off the first surface P1 of the liquid crystal cell P via the first adhesive layer 12. And paste. The 1st sticking part 64 is comprised by a pair of 1st roller 64a and the 2nd roller 64b. Either one may be a driving roller and the other may be a driven roller, and both rollers may be driving rollers. The first optical film 10 is attached to the first surface P1 of the liquid crystal cell P by feeding the first optical film 10 and the liquid crystal cell P to the downstream while sandwiching the first optical film 10 and the liquid crystal cell P by the pair of first roller 64a and second roller 64b. The liquid crystal cell P after the sheet-shaped first optical film 10 is attached to the first surface P1 of the liquid crystal cell P is transported downstream by the second transport unit 82.

(First inspection process)
The first inspection unit 70 optically inspects the liquid crystal cell P. The first inspection unit 70 is disposed on one side of the liquid crystal cell P, and is disposed on the opposite side of the light source with the liquid crystal cell P sandwiched between the light source 71 that transmits light to the liquid crystal cell P, and is transmitted through the liquid crystal cell P. It has the 1st imaging part 72 which images a light image. The first imaging unit 72 may be an area sensor or a line sensor. Moreover, the 1st test | inspection part 70 may have a 2nd imaging part (not shown) which images the reflected light image for test | inspecting the sticking position of the 1st optical film 10. FIG. The image captured by the first inspection unit 70 is subjected to image analysis by the first image analysis unit 51. The control unit 50 controls operation timing of each component of the continuous manufacturing system.

(First determination step)
The first determination unit 52 determines whether the liquid crystal cell P is a good product or a defective product based on the result of analyzing the image by the first image analysis unit 51. Examples of defective products include sticking misalignment and bubble mixing. The liquid crystal cell P determined to be defective is collected by the first non-defective product collecting unit 92. The liquid crystal cell P determined as a defective product is collected by the first defective product collection unit 93.

(First defective film peeling step)
A process for remanufacturing a defective liquid crystal panel into a non-defective liquid crystal panel will be described with reference to FIG. As shown in FIG. 5, the 1st optical film 10 is removed from the liquid crystal cell P by which the 1st determination part 52 determined defective. The removal process may be performed manually or by a peeling device. Next, it will be described that the sheet-shaped first optical film 2 is attached to the first surface P1 of the liquid crystal cell P and remanufactured (sometimes referred to as “rework”) using a sheet-fitting device.

(First reattachment process)
Next, the sheet-like first optical film 2 from which the first release film 21 has been peeled off is peeled off from the first optical film 10 that has been determined to be defective by a sheet-to-panel method (for example, a sheet-fitting device). Affixed to the first surface P1 of the liquid crystal cell P after the heating. A conventional apparatus can be used as the single wafer pasting apparatus. Reference is made to the sheet-like first optical film 2 of FIG.

(Second surface protective film peeling step)
The 2nd surface protection film 25 is peeled from the sheet-like 1st optical film 2 after a 1st resticking process. The peeling treatment may be performed manually or with a peeling device. Through the above steps, a liquid crystal panel having the same stacked structure as that of a liquid crystal panel manufactured by a roll-to-panel method can be manufactured (remanufactured).

(Reproduction using the first and second optical film sets)
Similar to remanufacturing using the first optical film set, remanufacturing using the second optical film set can be performed. The roll-shaped second optical film 3 is used for manufacturing an optical display panel by a roll-to-panel method. The sheet-like second optical film 4 is determined to be defective among the optical display panels manufactured using the roll-shaped second optical film 3, and the second pressure-sensitive adhesive layer, the second optical functional film, and the third Remanufacturing an optical display panel having a structure in which the second pressure-sensitive adhesive layer, the second optical functional film, and the third surface protective film are laminated in this order on one surface of the optical cell of the optical display panel from which the surface protective film has been peeled off. Used to do. Specifically, the sheet-like second optical material is formed on one surface of the optical cell from which the second pressure-sensitive adhesive layer 31, the second optical functional film 32, and the third surface protective film 33 have been peeled by a sheet-to-panel method. After the second release film 41 is peeled from the film 4 and the second pressure-sensitive adhesive layer 42, the second optical function film 43, the third surface protective film 44, and the fourth surface protective film 45 are bonded together in this order, The surface protective film 45 is peeled off.

An optical display panel continuous manufacturing system includes a roll-to-panel manufacturing apparatus using the roll-shaped first optical film 1 and a roll-to-panel system using a roll-shaped second optical film 3. The continuous manufacturing system of the optical display panel which added the manufacturing equipment of this is comprised. The roll-to-panel manufacturing equipment using the roll-shaped second optical film 3 is composed of substantially the same equipment as the roll-to-panel manufacturing equipment using the roll-shaped first optical film 1. May be. The different manufacturing facilities are described below.

The liquid crystal cell P determined to be non-defective by the first inspection unit 70 is sent to the subsequent stage, and the optical cell is attached to the second surface P2 of the liquid crystal cell P using a roll-shaped second optical film. A placement replacement unit (not shown) is installed in the second transport unit 82, and the placement replacement unit reverses the upper and lower surfaces (P1, P2) of the non-defective liquid crystal cell P transported by the second transport unit 82 in the transport direction. In FIG. 5, the short side and the long side of the liquid crystal cell P are switched. A publicly known mechanism can be appropriately employed for the arrangement replacement unit. In this embodiment, the arrangement replacement unit includes a rotating unit that sucks the liquid crystal cell P and horizontally rotates it by 90 °, and an inversion unit that sucks the liquid crystal cell P and reverses the front and back.

The liquid crystal cell P is conveyed to the 2nd sticking part after the process of an arrangement | positioning replacement part. A second cutting part similar to the first cutting part 61, a second tension adjusting part similar to the first tension adjusting part 62, a second peeling part similar to the first peeling part 63, and a first winding part It has the same 2nd winding part.

The second cutting part cuts the second release film 31 while adsorbing and fixing the second release film 31 side of the belt-like second optical film 30 drawn out from the roll-like second optical film 3. The second optical film 30 is left to be cut into a predetermined size (a length corresponding to the long side of the liquid crystal cell P (a length substantially shorter than the long side)). The band-shaped second optical film 30 is conveyed to the second peeling portion via the second tension adjusting portion, wound around the second peeling portion and reversed, and the second optical film 30 is peeled from the second release film 31. The The second release film 31 is wound on a roll by the second winding unit.

The second pasting part has the same configuration as the first pasting part 64. The second affixing unit affixes the second optical film 30 from which the second release film 31 has been peeled off to the second surface P2 of the liquid crystal cell P via the second adhesive layer 32 while conveying the liquid crystal cell P. wear.

The second inspection unit has the same configuration as the first inspection unit 70.
The second inspection unit optically inspects the liquid crystal cell P. The second inspection unit is disposed on one side of the liquid crystal cell P, and is disposed on the opposite side of the light source with the liquid crystal cell P sandwiched between the light source that transmits the light to the liquid crystal cell P, and the transmitted light image of the liquid crystal cell P. And an imaging unit for imaging The second inspection unit may include an imaging unit (not shown) that captures a reflected light image for inspecting the attachment position of the second optical film 30. The image captured by the second inspection unit is subjected to image analysis by the second image analysis unit.

The second determination unit determines whether the liquid crystal cell P is a good product or a defective product based on the result of analyzing the image by the second image analysis unit. Examples of defective products include sticking misalignment and bubble mixing. The liquid crystal cell P determined to be defective is collected by the second defect collection unit. On the other hand, when the non-defective product is determined by the second determination unit, the liquid crystal cell P determined to be non-defective is conveyed and stored in the non-defective storage unit.

The remanufacturing using the sheet-like optical film 4 is the same as the above-described remanufacturing using the sheet-like optical film 2. That is, the second optical film 30 is removed from the liquid crystal cell P determined to be defective. Next, the second optical film 30 determined as a defective product was peeled off from the sheet-like second optical film 4 from which the second release film 31 was peeled off by a sheet-to-panel method (for example, a single-wafer sticking apparatus). Affixed to the second surface P2 of the later liquid crystal cell P. Next, the fourth surface protective film 45 is peeled from the sheet-like second optical film 4.

(Embodiment 5: Production of optical display panel using optical film roll and optical film set of sheet-like optical film)
Embodiment 5 is a continuous manufacturing system of an optical display panel using an optical film set. Hereinafter, the continuous manufacturing system of the optical display panel according to the fifth embodiment will be specifically described with reference to FIG.

The first optical film 10 is attached to the first surface P1 of the liquid crystal cell P using the roll-shaped first optical film 1 by the same roll-to-panel method as in the fourth embodiment (see FIG. 4). 4 and 6 have the same function. The liquid crystal cell P to which the first optical film 10 is attached is reversed by the arrangement replacement unit 821 so that the upper and lower surfaces (P1, P2) are reversed and the short side and the long side of the liquid crystal cell P are switched in the transport direction (y).

Next, the process of attaching the sheet-like second optical film 4 to the second surface P2 of the liquid crystal cell P will be described below. From the container 100 in which the sheet-like second optical film 4 is accommodated, the sheet-like second optical film 4 is adsorbed by the adsorption unit 164a of the sheet-fitting device 164 and supplied to the bonding position. The second release film 41 is peeled off from the sheet-like second optical film 4 by a peeling means. The suction surface of the suction part 164a has a circular arc cross section. For example, the peeling means may peel off the second release film 41 by sticking the adhesive tape to the surface of the second release film 41 using an adhesive tape and moving the adhesive tape with a moving mechanism.

The single wafer pasting device 164 has a fixed surface 164b, and the fixed surface 164b sucks and fixes the first surface P1 side of the liquid crystal cell P. The sheet-like second optical film 4 in a state where the second release film 41 is peeled off and the second pressure-sensitive adhesive layer 42 is exposed is attached to the second surface P2 of the liquid crystal cell P so as to roll the suction portion 164a.

(4th surface protection film peeling process)
After the sheet-like second optical film 4 is attached, the fourth surface protective film 45 is peeled off. The peeling treatment may be performed manually or with a peeling device.

(Another embodiment of Embodiment 5)
In the fifth embodiment, instead of the roll-shaped first optical film 1, the sheet-like first optical film 2 is used to attach the sheet-to-panel method to the liquid crystal cell, and the sheet-like second optical film 4. Instead of this, a roll-like second optical film 3 may be used to attach to the liquid crystal cell by a roll-to-panel method.

(Modification)
In the fourth and fifth embodiments, the use of the roll-shaped optical film and the sheet-like optical film optical film set for the continuous manufacturing method of the liquid crystal display panel has been described. You may use for the continuous manufacturing method of a panel.

In

Embodiments

4 and 5, the optical film is used as a roll-shaped optical film, but the configuration of the roll-shaped optical film is not limited to this. For example, except a release film, you may use what wound the strip | belt-shaped optical film in which the several cut line was formed in the width direction (optical film with a notch).

In

Embodiments

4 and 5, the band-shaped optical film is cut (half cut) at a predetermined interval in the width direction, but from the viewpoint of improving the yield, the band-shaped optical film is avoided so as to avoid the defective portion of the band-shaped optical film. May be cut in the width direction (skip cut), or the optical film including the defective portion may be cut with a size smaller than a predetermined interval (the size of the optical cell) (more preferably with a size as small as possible). Good.

In the fourth and fifth embodiments, the description has been given by taking a horizontally long liquid crystal cell and a liquid crystal display panel as examples. However, the shape of the liquid crystal cell and the liquid crystal display panel is another set of sides facing each other. As long as the shape has the following, there is no particular limitation.

DESCRIPTION OF SYMBOLS 1 Roll-shaped optical film 11 Release film 12 Adhesive layer 13 Optical function film 14 1st surface protection film 2 Sheet-like optical film 21 Release film 22 Adhesive layer 23 Optical function film 24 1st surface protection film 25 1st 2 Surface protective film

Claims

An optical film set having a roll-shaped optical film and a sheet-shaped optical film,
The roll-shaped optical film has a structure in which a release film, an adhesive layer, an optical functional film, and a first surface protective film are laminated in this order,
The sheet-like optical film is an optical film set in which the release film, the pressure-sensitive adhesive layer, the optical functional film, the first surface protective film, and the second surface protective film are laminated in this order.
The optical film set according to claim 1, wherein a peeling force between the first surface protective film and the optical functional film is larger than a peeling force between the second surface protective film and the first surface protective film. .
3. The optical film set according to claim 1, wherein the optical functional film is a polarizing film.
The optical film set according to claim 3, wherein the polarizing film has a thickness of 60 μm or less.
The optical film set according to claim 3 or 4, wherein the polarizing film has a polarizer having a thickness of 10 µm or less.
The first surface protective film has a first base film and a first pressure-sensitive adhesive layer, and is laminated on the optical functional film via the first pressure-sensitive adhesive layer. The optical film set according to any one of 5.
6. The optical film set according to claim 1, wherein the first surface protective film is a self-adhesive film.
The said 2nd surface protection film has a 2nd base film and a 2nd adhesive layer, and is laminated | stacked on the said 1st surface protection film through the said 2nd adhesive layer. 8. The optical film set according to any one of 1 to 7.
The optical film set according to any one of claims 1 to 7, wherein the second surface protective film is a self-adhesive film.
The roll-shaped optical film has a width corresponding to a pair of opposing sides of the optical cell;
The sheet-like optical film has a length in which a pair of opposite sides correspond to a pair of opposite sides of the optical cell, and another pair of opposite sides faces the optical cell. The optical film set according to any one of claims 1 to 9, wherein the optical film set has a length corresponding to another set of sides.
An optical display panel in which the roll-shaped optical film and the sheet-shaped optical film are configured such that the pressure-sensitive adhesive layer, the optical functional film, and the first surface protective film are laminated in this order on one surface of the optical cell. The optical film set according to any one of claims 1 to 10, wherein the optical film set is used to produce
The roll-shaped optical film is used to manufacture the optical display panel in a roll-to-panel system,
12. The optical film set according to claim 11, wherein the sheet-like optical film is used for manufacturing the optical display panel by a sheet-to-panel method.
The sheet-like optical film is determined to be defective among the optical display panels manufactured by the roll-to-panel method using the roll-shaped optical film, and the pressure-sensitive adhesive layer, the optical functional film, and the first 1 Remanufacturing the optical display panel having a configuration in which an adhesive layer, an optical functional film, and a first surface protective film are laminated in this order on one surface of the optical cell of the optical display panel from which the surface protective film has been peeled off. The optical film set according to claim 12, wherein the optical film set is used.
A method for producing an optical film set according to any one of claims 1 to 13,
A manufacturing method of the roll-shaped optical film,
A step of preparing an optical film raw material having a configuration in which the release film, the pressure-sensitive adhesive layer, the optical functional film, and the first surface protective film are laminated in this order;
Slitting and winding the optical film original fabric to produce the roll-shaped optical film, and
A method for producing the sheet-like optical film,
Bonding the second surface protective film original fabric to the first surface protective film side of the optical film original material, and producing an optical film original material laminated with a second surface protective film;
Cutting the optical film raw material on which the second surface protective film is laminated to produce a sheet-like optical film, and a method for producing an optical film set.
A double-sided optical film set having a first optical film set and a second optical film set,
The first optical film set includes a roll-shaped first optical film and a sheet-shaped first optical film,
The roll-shaped first optical film has a configuration in which a first release film, a first pressure-sensitive adhesive layer, a first optical functional film, and a first surface protective film are laminated in this order,
The sheet-like first optical film has the first release film, the first pressure-sensitive adhesive layer, the first optical functional film, the first surface protective film, and the second surface protective film laminated in this order. Configuration,
The second optical film set includes a roll-shaped second optical film and a sheet-shaped second optical film,
The roll-shaped second optical film has a configuration in which a second release film, a second pressure-sensitive adhesive layer, a second optical function film, and a third surface protective film are laminated in this order,
In the sheet-like second optical film, the second release film, the second pressure-sensitive adhesive layer, the second optical functional film, the third surface protective film, and the fourth surface protective film are laminated in this order. This is a double-sided optical film set.
The roll-shaped first optical film and the sheet-shaped first optical film, and the roll-shaped second optical film and the sheet-shaped second optical film are formed on the first surface of the optical cell. The agent layer, the first optical functional film, and the first surface protective film are laminated in this order, and the second pressure-sensitive adhesive layer, the second optical functional film, and the third surface are disposed on the other surface of the optical cell. The double-sided optical film set according to claim 15, which is used to manufacture an optical display panel having a configuration in which protective films are laminated in this order.