WO2023017716A1

WO2023017716A1 - Long multilayer body

Info

Publication number: WO2023017716A1
Application number: PCT/JP2022/028153
Authority: WO
Inventors: 孝伸矢野; 太郎朝比奈
Original assignee: 日東電工株式会社
Priority date: 2021-08-10
Filing date: 2022-07-20
Publication date: 2023-02-16
Also published as: CN117677494A; KR20240042367A; JP2023025535A

Abstract

This long multilayer body comprises: a long first base material film which has a first main surface and a second main surface that is on the reverse side of the first main surface; a glass member which is superposed on the first main surface side of the first base material film; a long carrier film which is superposed on the second main surface side of the first base material film; a first bonding agent layer which is interposed between the first base material film and the glass member; and a first adhesive layer which is interposed between the first base material film and the carrier film. The first base material film is provided with a plurality of frame-shaped grooves that penetrate the first base material film in the thickness direction. Voids are formed in the grooves.

Description

long laminate

The present disclosure relates to a long laminate including a plurality of laminates used for display panels of flat panel displays (FPDs), for example.

In general, a laminate of a glass member such as a glass film and a resin film is prepared by preparing a roll of a long glass member and a roll of a long resin film, and laminating them together by roll-to-roll. Formed by shaping and cutting the body. For cutting, for example, a knife or a laser beam is used. However, when a knife is used, the smoothness of the cut surface is poor. When a laser beam is used, it is difficult to cleanly cut the glass member and the resin film at the same time because the processing conditions such as the processing temperature suitable for each are different. Therefore, a method has been proposed in which the resin film is first cut and then the glass member is cut.

For example, Patent Document 1 discloses a method for producing a flexible film, which includes cutting a laminate including thin glass having a thickness of 100 μm or less and a resin layer disposed on one side or both sides of the thin glass. proposed a manufacturing method including a step of forming a groove from the outer surface side of the resin layer and a step of cutting the laminate along the groove. The groove is formed using a cutting tool or laser light. In Patent Document 1, the depth of the groove is made smaller than the thickness of the resin layer or the total thickness of the resin layer and the adhesive layer so as not to form the groove in the thin glass.

Patent Document 2 discloses a method for dividing a composite material in which a brittle material layer and a resin layer are laminated, and removes the resin by irradiating the resin layer with a laser beam along a planned dividing line of the composite material. a resin removing step of forming a processed groove along the planned dividing line; and after the resin removing step, irradiating the brittle material layer with a laser beam oscillated from an ultrashort pulse laser light source along the planned dividing line. a brittle material removing step of forming a working trace along the planned dividing line by removing the brittle material by applying an external force along the planned dividing line after the brittle material removing step; and a composite material cutting step of cutting the composite material, wherein the processing marks are perforation-like through-holes along the planned dividing line, and the pitch of the through-holes is 10 μm or less. is proposing. Patent Document 2 also describes a third embodiment in which resin layers 2a and 2b are laminated on both sides of the brittle material layer 1, respectively. In this case, a machined groove is formed in one of the resin layers, and a machined groove is formed in the other resin layer.

JP 2014-159352 A (claim 1, [0036], [0041], FIG. 2) JP 2019-122966 A (claim 1, FIG. 1, [0055], FIG. 3)

If a groove can be formed to the interface with the glass member in the member that holds the glass member (specifically, a resin film, or a laminate of an adhesive layer and a resin film, etc.), only the glass member will be exposed to laser light in the next step. can be cut with However, it is not possible to suppress the formation of scratches on the glass member when forming the grooves. Such scratches cause scattering of laser light when the glass member is cut with laser light, making it difficult to cleanly cut the glass member.

The method of Patent Document 1 suppresses the formation of scratches on the thin glass when forming the grooves. However, since the groove is not formed to the interface between the resin layer or adhesive layer and the thin glass, it becomes necessary to remove the resin layer or adhesive layer. At this time, force is applied to the thin glass, and scratches are formed. Therefore, similarly to the above, it becomes a cause of laser light scattering, and it is difficult to cleanly cut thin glass.

In the method of Patent Document 2, since the laser beam is irradiated from both the resin layer side and the brittle material layer side, the vicinity of the interface between these layers is easily damaged by the laser beam, resulting in deterioration of quality. In the case of the third embodiment of Patent Document 2, the brittle material layer cannot be cut unless both resin layers are removed. Difficult to cut cleanly.

One aspect of the present disclosure is
a long first base film having a first principal surface and a second principal surface opposite to the first principal surface;
a glass member laminated on the first main surface side of the first base film;
A long carrier film laminated on the second main surface side of the first base film;
a first adhesive layer interposed between the first base film and the glass member;
and a first adhesive layer interposed between the first base film and the carrier film,
A plurality of frame-shaped grooves penetrating the first base film in the thickness direction are formed in the first base film,
The present invention relates to a long laminated body in which voids are formed in the grooves.

It is possible to provide a long laminate that enables clean cutting of the glass member held by the base film.

1 is a plan view showing a configuration of a long laminate according to a first embodiment of the present disclosure; FIG. FIG. 1B is a schematic cross-sectional view of the long laminate of FIG. 1A taken along line bb, viewed in the direction of the arrow; FIG. 5 is a schematic cross-sectional view of a long laminate according to a second embodiment; FIG. 11 is a schematic cross-sectional view of a long laminate according to a third embodiment; FIG. 11 is a schematic cross-sectional view of a long laminate according to a fourth embodiment; FIG. 4 is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove and its vicinity of the long laminate according to the first embodiment, or the division of the glass member or the long laminate by laser light irradiation. FIG. 10 is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminate and its vicinity, or the division of the glass member or the long laminate by laser light irradiation according to the fifth embodiment. FIG. 10 is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminate and its vicinity, or the division of the glass member or the long laminate by laser light irradiation according to the sixth embodiment. FIG. 10 is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminate and its vicinity, or the division of the glass member or the long laminate by laser light irradiation according to the seventh embodiment. FIG. 12 is a schematic cross-sectional view for explaining the state of the first adhesive layer in the groove of the long laminate and its vicinity, or the division of the glass member or the long laminate by laser light irradiation according to the eighth embodiment. FIG. 4 is an illustration of a previous step in a method for measuring adhesion between a first adhesive layer and a glass member; FIG. 4 is an illustration of a subsequent step in the method of measuring the adhesive force between the first adhesive layer and the glass member; It is explanatory drawing which shows an example of the manufacturing method of a long laminated body. FIG. 3 is a plan view showing an arrangement example of a plurality of frame-shaped grooves G in a substrate laminate. It is explanatory drawing which shows an example of a series of processes by which a laminated body is singulated from a long laminated body. FIG. 7C is a schematic cross-sectional view of the laminated body with the glass member, which has been separated into pieces in FIG. 7C, taken along line VIII-VIII and viewed in the direction of the arrow. It is process drawing which shows an example of a series of process which manufactures the laminated body with a glass member pieced from the long laminated body. FIG. 4 is a process drawing showing another example of a series of steps for manufacturing a laminated body with a glass member that is separated from a long laminated body.

While the novel features of the present invention are set forth in the appended claims, the present invention, both as to construction and content, together with other objects and features of the present invention, will be further developed by the following detailed description in conjunction with the drawings. will be well understood.

Hereinafter, a long laminate according to the present disclosure and a method for manufacturing a laminate with a glass member that is separated into pieces using the long laminate will be sequentially described with reference to embodiments. However, the embodiments are examples, and the method for manufacturing the long laminate and the individualized laminate with a glass member according to the present disclosure is not limited to the following embodiments.

Although the term "parallel" is used from time to time in this specification, it does not necessarily have to be strictly parallel. may deviate from Similarly, although the term "perpendicular" is used from time to time, it does not necessarily have to be strictly perpendicular, and the extent to which one and the other form an angle of, for example, 80° or more and 100° or less (or 85° or more and 95° or less). may deviate from being perpendicular to

When referring to the drawings, the shape or dimensions of each component in each drawing are not shown to the same scale as the actual. The relative relationships of these dimensions are shown schematically and exaggerated to clarify the characteristics of each component.

[Long laminate]
A long laminate according to one aspect of the present disclosure includes a laminate including a glass member, and at least a portion of the laminate is divided to manufacture a plurality of individualized laminates with glass members. is useful for In other words, the long laminated body is an intermediate when manufacturing a plurality of individualized laminated bodies with glass members. A laminated body with a glass member that has been separated into pieces is useful, for example, as an optical laminated body used for a display panel of an FPD. FPD typically refers to a thin image display device such as an organic EL display device. However, the FPD is not limited to such specific examples.

The long laminate may be completed in a rolled state. The length laminate may be unwound from a rolled state and fed to other processes (or stages) in a roll-to-roll fashion. The long laminated body may be unwound from a rolled state and supplied to a step of processing the long laminated body (such as a step including at least a step of singulating the glass member). The intermediate body before being completed as a long laminate may also be handled in a rolled state. The intermediate may be unwound from a rolled state and supplied to a process for obtaining a long laminate by a roll-to-roll method.

The roll-to-roll method is one method for handling a long laminate or an intermediate product before it is completed as a long laminate. The roll-to-roll method includes unwinding the long laminated body or intermediate from a rolled state, and winding the long laminated body or intermediate into a roll. In the roll-to-roll method, an unwinding section for unwinding the long laminate or the intermediate and a winding section for winding the long laminate or the intermediate are used.

The long laminate includes a long first substrate film, a glass member and a long carrier film laminated so as to sandwich the first substrate film, and between the first substrate film and the glass member. An intervening first adhesive layer and a first adhesive layer interposed between the first substrate film and the carrier film. More specifically, the first base film has a first major surface and a second major surface opposite to the first major surface. A glass member is laminated on the first main surface side of the first base film, and a carrier film is laminated on the second main surface side.

The first main surface and the second main surface are a pair of front and back surfaces that occupy most of the entire surface of the long first base film. The first base film has, in addition to the first main surface and the second main surface, side surfaces (or end surfaces) that connect these main surfaces and determine the outer periphery of the first base film.

In the long laminate of the present disclosure, a plurality of frame-shaped grooves that penetrate the first base film in the thickness direction are formed in the first base film. A gap is formed in the groove. Such grooves are formed before laminating the first base film and the glass member. Therefore, unlike the conventional technique in which grooves are formed after lamination, grooves can be formed up to the surface of the glass member. Moreover, it is possible to prevent the glass member from being damaged when forming the groove unlike the conventional technique. The grooves are formed prior to lamination with the glass member. Therefore, the first adhesive is applied to the first main surface of the first base film having the grooves, and the glass member is laminated on the first base film so as to be in contact with the coating film. Therefore, the first adhesive may enter the grooves and form a first adhesive layer upon curing. However, in the present disclosure, voids are formed within the grooves. Therefore, the first adhesive layer may not be formed in the grooves, or the thickness of the first adhesive layer may be small even if it is formed. Therefore, by irradiating the region corresponding to the groove of the long laminate with a laser beam from the glass member side, the glass member can be easily cut, and the first adhesive layer in the groove can be easily removed. . Also, by irradiating the region corresponding to the groove of the long laminate with a laser beam from the side of the first base film, the first adhesive layer in the groove can be easily removed as the laser beam passes through the groove. and the glass member can be easily cut. As a result, the glass member held by the first base film can be cleanly cut.

In this specification, "inside the groove" may include a portion between the end of the groove on the first main surface side and the glass member. In other words, the space between the end of the groove on the first main surface side and the glass member and the inside of the groove may simply be referred to as the inside of the groove. That is, in the present disclosure, a gap is formed at least one of between the end of the groove on the first main surface side and the glass member and inside the groove. A state in which voids are formed in the grooves means that these portions are not completely filled with the first adhesive layer. Such a state can be achieved, for example, by adjusting the position where the first adhesive is applied (for example, applying it only to portions other than the grooves on the first main surface), or by adjusting the viscosity or application amount of the first adhesive. can be obtained by doing

The first base film is held by the carrier film via the first adhesive layer. The first pressure-sensitive adhesive layer is composed of a fluid first pressure-sensitive adhesive, and can be easily removed together with the carrier film, unlike an adhesive layer such as the first adhesive layer. Therefore, when irradiating the first adhesive layer in the groove or the glass member through the groove with laser light from the first base film side (more specifically, from the second main surface side), , after removing the carrier film and the first adhesive layer. In this case, the first adhesive layer in the groove can be removed more easily, and the glass member held by the first base film can be cleanly cut.

A second base film may be laminated on the main surface of the glass member opposite to the first base film side. A second adhesive layer or a second adhesive layer is interposed between the second base film and the glass member. Such a configuration is also included in the long laminate of the present disclosure. In this case, in the region corresponding to the groove of the long laminate, a laser beam is applied from the glass member side (more specifically, the second base film side) to the second base film and the second pressure-sensitive adhesive layer. (or the second adhesive layer) to cut them. At this portion, the glass member and the second pressure-sensitive adhesive layer or the second adhesive layer are in contact with each other, so the same problems as in the prior art tend to occur. However, in the present disclosure, after removing the carrier film and the first pressure-sensitive adhesive layer, the glass member can be irradiated with laser light through the groove from the second main surface side of the first base film. Therefore, formation of scratches on the glass member can be suppressed at the interface between the glass member and the first base film, and the glass member can be cleanly cut. In addition, since the gap is formed in the groove, the first adhesive layer in the groove can be easily removed even when laser light is irradiated through the groove from the second main surface side. . Therefore, even when the long laminated body is a laminated body in which the glass member is sandwiched between the first base film and the second base film, the glass member can be cleanly cut without requiring advanced control of the irradiation conditions of the laser beam. It is possible.

In the present disclosure, grooves are formed in advance in the first base film, and when the second base film is provided, the second base film is cut separately from the glass member. That is, basically, it is sufficient to cut only the glass member with the laser beam. Therefore, compared to the conventional case of cutting a laminate of a base film and a glass film at once with a laser beam, in the present disclosure, it is easier to control the irradiation conditions of the laser beam suitable for the glass member, and the glass The parts can be cut cleanly.

The constituent elements of the long laminate will be described in more detail below.

(First base film)
In the present disclosure, the first base film is formed with a frame-shaped groove penetrating through the first base film in the thickness direction. This groove is formed prior to lamination of the glass member and the first base film. When the laser beam is emitted toward the region corresponding to the groove of the long laminate, the glass member is irradiated with the laser beam without irradiating the first base film, so that the glass member can be cleanly cut.

A plurality of frame-shaped grooves are formed in the first base film. A plurality of grooves may be formed along the length direction of the long first base film. One frame-shaped groove may be formed in the width direction of the first base film, or a plurality of grooves may be formed along the width direction. However, it is not limited to these cases, and for example, a plurality of rows of frame-shaped grooves formed along the length direction of the first base film are formed so as to be shifted from adjacent rows. may The arrangement of the frame-shaped grooves in the first base film is not particularly limited.

The grooves are formed while the first base film is held by the carrier film via the first adhesive layer. When the first base film is viewed from the first main surface side, the shape of the groove is not particularly limited as long as it is frame-like, and can take various shapes. When the first base film is viewed from the first main surface side, the shape of the frame may be rectangular, for example. Rectangular typically means a square or rectangular shape, but need not be strictly square or rectangular. For example, the rectangular corners may be R-chamfered and rounded, or the corners may be C-chamfered. Also, the four sides of the rectangle may not be straight lines, and may be formed by lines having some bends or irregularities. In addition, the frame can have various shapes, such as parallelogram, rhombus, circle, and ellipse, depending on the application.

A first adhesive is applied to the first main surface of the first base film on which the grooves are formed, and the glass member is laminated so as to be in contact with the first adhesive. Therefore, the first adhesive may enter the groove. Even in such a case, the groove preferably has a certain width so that a gap is formed in the groove. The width of the groove is preferably 5 mm or more, and may be 7 mm or more or 10 mm or more. The upper limit of the width of the groove is not particularly limited, and may be determined in consideration of the arrangement of the grooves, cost, and the like. The width of the groove may be, for example, 20 mm or less. The width of the groove is the average value of the minimum widths in each of a plurality of (for example, five) arbitrarily selected grooves.

The first adhesive that has entered the groove forms a first adhesive layer by curing. In the present disclosure, since the first adhesive is applied to the first base film after the grooves are formed, the first adhesive that has entered the grooves covers at least part of the end surface of the first base film in the grooves. Sometimes. In this case, when the first adhesive is cured, in the groove, at least part of the end surface of the first base film is covered with the first adhesive layer. If such a state is observed, it can be understood that the grooves were formed prior to lamination of the first base film and the glass member. In addition, the first adhesive layer formed in the groove is only formed so as to cover the end surface of the first base film, and a frame-shaped space is maintained inside the first adhesive layer. In this case, it is also possible to irradiate laser light from the second principal surface side so as to pass through the grooves by utilizing this space. In this case, there is no need to cut the first adhesive layer with a laser beam to divide the first base film, which is advantageous.

It is preferable that the first adhesive layer not covering at least a part of the glass member along the width direction of the groove is not formed between the edge of the groove on the first main surface side and the glass member. It is preferable that the first adhesive layer that blocks at least a part of the groove in the width direction of the groove is not formed in the groove. This is because such a first adhesive layer reconnects the first base film divided by the grooves. Also, when laser light is irradiated from the second main surface side of the first base film through the grooves, it is difficult to directly irradiate the glass member. Therefore, it is preferable that the thickness of the first adhesive layer is small. The minimum thickness of such a first adhesive layer is preferably 0 μm or more and 3 μm or less, and may be 0 μm or more and 2 μm or less. When the first adhesive layer is continuously formed both between the end of the groove on the first main surface side and the glass member and in the groove, the minimum thickness of the first adhesive layer is is preferably within the above range. When the first adhesive layer formed between the end of the groove on the first main surface side and at least one of the glass member and inside the groove is divided into a plurality of layers, the total thickness is within the above range. is preferably a first adhesive layer formed between the end of the groove on the first main surface side and the glass member along the width direction of the groove so as to cover at least part of the glass member; The minimum thickness of the first adhesive layer formed so as to cover at least part of the groove in the width direction is the minimum length in the direction parallel to the depth direction of the groove. Therefore, it is irrelevant to the thickness of the first adhesive layer covering the end surface of the first base film while maintaining the frame-shaped space in the groove. (minimum length in the direction parallel to the depth direction of the groove) need not be within the above range.

The first base film is, for example, a resin film made of resin. The first base film may be a single layer film or a multilayer film. A multilayer film is a laminate of two or more layers of resin films. The resin films of each layer constituting the multilayer film may be directly bonded, or the resin films of each layer may be bonded with an adhesive layer or pressure-sensitive adhesive layer.

The resin that constitutes the resin film may be a thermoplastic resin or a thermosetting resin. Examples of thermoplastic resins include polyethersulfone-based resins, polycarbonate-based resins, acrylic-based resins, polyester-based resins, polyolefin-based resins, cycloolefin-based resins, polyimide-based resins, polyamide-based resins, polyimide-amide-based resins, and polyarylate-based resins. resin, polysulfone-based resin, and polyetherimide-based resin. Examples of polyester-based resins are aromatic polyester-based resins (such as polyalkylene arylate resins). Examples of polyalkylene arylate resins are polyethylene terephthalate resin, polybutylene terephthalate resin, and polyethylene naphthalate resin. Examples of cycloolefin resins are norbornene resins. Examples of thermosetting resins are epoxy-based resins, urethane-based resins, and silicone-based resins. However, these resins are merely examples, and the resins constituting the resin film are not limited to these. The resin film may contain one type of resin or a combination of two or more types of resin. Each layer constituting the multilayer film may contain one kind of resin or a combination of two or more kinds of resins.

The storage elastic modulus of the first base film at 25° C. is not particularly limited, and is, for example, 1.5 GPa or more and 10 GPa or less, may be 1.8 GPa or more and 9 GPa or less, or 1.8 GPa or more and 8 GPa or less. may When the storage elastic modulus of the first base film is in such a range, the effect of supporting and protecting the glass member is high, and the productivity is further improved when manufacturing the laminated body with the glass member that is separated into pieces. do. The storage modulus can be determined by dynamic viscoelasticity measurement. Polyethylene terephthalate (PET) resin is preferable as the resin constituting the first substrate film because it easily exhibits such a storage elastic modulus. When a multilayer film is used as the first base film, the storage elastic modulus of the layer on the glass member side is preferably within the above range.

The first base film is not limited to the above, and may be, for example, a multilayer film containing an optical film. Such a multilayer film may be a multilayer film containing an optical film and a substrate film (such as the resin film described above), a multilayer film containing two or more optical films, or a multilayer film containing one or more optical films. Alternatively, it may be a multilayer film containing two or more layers of optical films and a separator. Each film constituting the multilayer film may be directly bonded, or may be bonded via a pressure-sensitive adhesive layer or an adhesive layer.

The optical film is not particularly limited, but includes, for example, a polarizing plate, a retardation plate, and an isotropic film. Materials constituting the optical film include, for example, polyvinyl alcohol-based resins, polyolefin-based resins, cyclic olefin-based resins, polycarbonate-based resins, cellulose-based resins, polyester-based resins, polyvinyl alcohol-based resins, polyamide-based resins, polyimide-based resins, Polyether-based resins, polystyrene-based resins, (meth)acrylic-based resins, (meth)acrylic urethane-based resins, polysulfone-based resins, acetate-based resins, epoxy-based resins, and silicone-based resins can be used. The optical film may be a metal oxide film (metal film, ITO film, etc.) or a laminated film of a metal film and a resin film.

As the separator, for example, a release sheet comprising a base sheet and a release agent provided on at least one main surface of the base sheet is used. For the base sheet, for example, the same material as the resin film exemplified as the first base film can be arbitrarily selected and used. Examples of the release agent include known release agents (eg, silicone-based release agents, fluorine-based release agents).

The thickness of the first base film is, for example, 5 μm or more and 300 μm or less. When the first base film is a single layer film, the thickness may be, for example, 5 μm or more and 60 μm or less, may be 5 μm or more and 50 μm or less, or may be 10 μm or more and 40 μm or less. When the first base film is a multilayer film, the thickness is, for example, 10 μm or more and 300 μm or less, and may be 30 μm or more and 200 μm or less. The thickness of each layer constituting the multilayer film is adjusted so that the thickness of the multilayer film falls within this range.

In this specification, unless otherwise specified, the thickness of the constituent elements of each laminate is the average value of thicknesses measured at arbitrary multiple locations (eg, 5 locations).

(glass member)
For example, a glass film is used as the glass member. Glass films are also commonly referred to as thin glass. The glass member preferably has a uniform thickness.

Glass films such as thin glass have high flexibility and are sometimes supplied in roll form. Therefore, a long glass member (such as a glass film) may be used for the long laminate. In this case, the glass member can be laminated on the first base film by a roll-to-roll method, which is convenient. However, not limited to this case, for example, large-sized glass members may be arranged and laminated on the first base film. When a plurality of large-sized glass members are used, they may all be the same glass member, or different glass members may be arranged at different positions depending on the purpose. When using a large-sized glass member, a glass member having one main surface area larger than the size of the frame-shaped groove is used.

The composition of the glass constituting the glass member is not particularly limited. Examples of glasses are soda lime glass, borate glass, aluminosilicate glass, and quartz glass. The glass may be alkali-free glass or low-alkali glass. The total content of alkali metal components (eg, Na ₂ O, K ₂ O, Li ₂ O) in the glass is, for example, 15% by mass or less, and may be 10% by mass or less.

The thickness of the glass member is, for example, 100 μm or less, and may be 10 μm or more and 60 μm or less.

The density of the glass member is, for example, 2.3 g/cm ³ or more and 3.0 g/cm ³ or less, and may be 2.3 g/cm ³ or more and 2.7 g/cm ³ or less.

The glass member is manufactured by any appropriate method. Typically, a glass film is prepared by heating a mixture containing ceramics (silica, alumina, etc.) as a main raw material, an antifoaming agent (mirabilite, antimony oxide, etc.), and a reducing agent (carbon, etc.) at a temperature of 1400° C. It is produced by melting at a temperature of ℃ or below, molding it into a film, and then cooling it. Examples of the method for forming the glass film include a slot down draw method, a fusion method, and a float method. The glass film obtained by these methods may be chemically polished with a solvent such as hydrofluoric acid, if necessary, in order to further thin the plate or improve the smoothness of the surface and edges.

The surface of the glass member may be surface-treated in order to improve adhesion with the adhesive layer or pressure-sensitive adhesive layer in contact with the glass member. The surface treatment is not particularly limited, and includes corona treatment, plasma treatment, coupling treatment, and the like.

Further, if necessary, a surface coat layer having various functions may be provided on at least a part of the surface layer of the glass member opposite to the first base film.

Examples of the surface coat layer include an anti-fingerprint coat layer, a hard coat layer, an antireflection layer, an antiglare layer, an antifouling layer, an antisticking layer, a hue adjusting layer, an antistatic layer, an easy adhesion layer, and an ingredient deposition prevention layer. , a shock absorbing layer, and a scattering prevention layer. The surface coat layer can be composed of various materials, and the anti-fingerprint coat layer includes, for example, fluorine resin, silicone resin, and the like. Other surface coating layers are formed of, for example, acrylic coating agents, melamine coating agents, urethane coating agents, epoxy coating agents, silicone coating agents, inorganic coating agents, and the like. Coating agents include silane coupling agents, colorants, dyes, pigments, fillers, surfactants, plasticizers, antistatic agents, surface lubricants, leveling agents, antioxidants, light stabilizers, UV absorbers, Additives such as polymerization inhibitors and antifouling agents may be included.

The surface coat layer may be formed in the form of a long laminated body, or may be formed after singulating the glass member as necessary. Also, a surface coat layer may be formed on the glass member prior to forming the long laminate.

(Carrier film)
The long carrier film is not particularly limited, and can be composed of, for example, a resin film. The resin constituting the resin film can be arbitrarily selected from, for example, the resins exemplified for the resin film of the first base film. Considering transportability, strength, etc., a PET resin film or the like is preferable.

The thickness of the carrier film is, for example, 10 μm or more and 200 μm or less, may be 30 μm or more and 150 μm or less, or may be 40 μm or more and 100 μm or less.

(Second base film)
The long laminate may further include a long second base film. The second base film is laminated on the main surface of the glass member opposite to the first base film side.

The second base film is not particularly limited, and may be selected according to the use of the individualized laminate with glass member, and may be a protective film for protecting the glass member. The second base film can be selected from resin films, optical films, and the like exemplified for the first base film. The second base film may be a single layer film or a multilayer film. When the second base film is a multilayer film, each layer may be directly bonded, or may be bonded via an adhesive layer or pressure-sensitive adhesive layer. For details other than the grooves, the description of the first base film can be referred to. The elastic modulus of the second base film may be set within the range described for the elastic modulus of the first base film.

At least part of the surface layer of the second base film on the side opposite to the glass member may be provided with a surface coating layer having various functions, if necessary. As for the surface coat layer, the description of the surface coat layer formed on the surface of the glass member can be referred to. In addition to the above, for example, a surface coat layer may be formed on the second base film prior to forming the long laminate.

(adhesive layer)
In the present disclosure, the adhesive layer is formed by curing an adhesive coating. Therefore, the adhesive layer has substantially no fluidity. On the other hand, the pressure-sensitive adhesive layer is composed of a pressure-sensitive adhesive, but is non-curing and has fluidity. Thus, in this disclosure, a distinction is made between an adhesive layer and an adhesive layer.

The storage modulus of the adhesive layer at 25°C is greater than 10 MPa, may be 100 MPa or more, and is usually about 1 GPa. Adhesive layers are also distinguished from adhesive layers by storage modulus.

(First adhesive layer)
The first adhesive layer is interposed between the first base film and the glass member. The first adhesive layer is formed by applying a first adhesive to the first main surface of the first base film in which grooves are formed, stacking the glass member so as to be in contact with the first adhesive, and then applying the first adhesive. formed by curing the The first adhesive is usually applied to the portion of the first main surface of the first base film excluding the grooves.

From the viewpoint of reducing the flow of the first adhesive into the grooves, the first adhesive may be applied so that the thickness of the first adhesive layer is 0.5 μm or more and 5 μm or less. preferable. The thickness of the first adhesive layer is more preferably 0.5 μm or more and 3 μm or less. However, the thickness of the first adhesive layer is the thickness of the first adhesive layer on the first main surface of the first base film excluding the grooves.

The viscosity of the first adhesive is also important for forming voids in the grooves. The viscosity of the first adhesive at 25° C. is preferably 150 mPa·s or less or 100 mPa·s or less. When the viscosity of the first adhesive is within such a range, it is formed between the edge of the groove on the first main surface side and the glass member so as to cover at least a portion of the glass member along the width direction of the groove. The thickness of the first adhesive layer formed in the groove and the first adhesive layer formed in the groove so as to block at least a part of the groove in the width direction of the groove is reduced (preferably such a first adhesion so that the agent layer is not formed). The viscosity of the first adhesive at 25° C. may be 0.1 mPa·s or more.

The viscosity of the first adhesive is measured using a commercially available viscoelasticity measuring device under the conditions of 25°C and a shear rate of 200 (1/s). Specifically, a rheometer MCR302 manufactured by Anton Paar is used as the viscoelasticity measuring device.

The adhesive strength between the first adhesive layer and the first base film and the adhesive strength between the first adhesive layer and the glass member may each be, for example, 0.1 N/mm or more at 25° C., or 1 N /mm or more. Such an adhesive strength can suppress peeling between the first base film and the glass member to a higher degree of hardness. Such adhesion can be adjusted, for example, by selecting the type or composition of the first adhesive.

The first adhesive is not particularly limited, and any appropriate adhesive can be used. Examples of the first adhesive include adhesives containing resins having a cyclic ether group (epoxy group, glycidyl group, oxetanyl group, etc.), adhesives containing acrylic resins, and adhesives containing silicone resins. The first adhesive is preferably UV curable. When the first adhesive is an ultraviolet curing type, it is possible to further increase the productivity of the laminate in the method for producing the laminate.

(Other adhesive layers)
When the long laminate includes a second substrate film, a second adhesive layer may be interposed between the second substrate film and the glass member. Further, when the first substrate film or the second substrate film is a multilayer film, the layers constituting the multilayer film may be adhered with an adhesive layer. These adhesive layers can also be formed by placing a coating of adhesive between the layers to be adhered and curing, as in the case of the first adhesive layer.

Examples of adhesives forming adhesive layers other than the first adhesive layer, including the second adhesive forming the second adhesive layer, include the adhesives exemplified for the first adhesive. For the same reason as the first adhesive, the second adhesive is preferably UV curable. Other adhesives may be thermosetting or photo-curing (ultraviolet-curing, etc.).

The viscosity at 25°C of the adhesive that forms the adhesive layers other than the first adhesive layer is, for example, 0.1 mPa s or more and 1000 mPa s or less, and 0.1 mPa s or more and 300 mPa s or less. good too. The viscosity of the adhesive is measured using the same procedure as for the first adhesive.

The thickness of the adhesive layers other than the first adhesive layer is, for example, 0.5 μm or more and 10 μm or less, and may be 1 μm or more and 5 μm or less.

(Adhesive layer)
The adhesive layer has fluidity as described above. The storage elastic modulus of the pressure-sensitive adhesive layer at 25°C is, for example, 10 MPa or less, and usually 1 MPa or less. The storage modulus of the pressure-sensitive adhesive layer at 25°C may be 0.2 MPa or less or 0.1 MPa or less. When the storage modulus of the pressure-sensitive adhesive layer is within such a range, the pressure-sensitive adhesive layer can be peeled off relatively easily from the layer in contact with the pressure-sensitive adhesive layer. The storage modulus of the pressure-sensitive adhesive layer at 25°C may be 0.001 MPa or more.

(First adhesive layer)
The first pressure-sensitive adhesive layer is interposed between the first substrate film and the carrier film. Therefore, when the long laminated body is irradiated with a laser beam to cut the glass member, if the first pressure-sensitive adhesive layer and the carrier film are peeled off from the first base film, the second main surface of the first base film can be removed. Laser light irradiation can be performed from the side through the groove. For example, when the long laminate includes the second substrate film, it is difficult to directly irradiate the glass member with laser light from the second substrate film side. However, in the present disclosure, grooves are formed in the first base film, and voids exist even though the first adhesive layer is formed in or near the grooves. Therefore, by peeling the first pressure-sensitive adhesive layer and the carrier film from the first base film, it is easy to irradiate the glass member with a laser beam through the grooves of the first base film, and the frame is formed along the shape of the grooves. The glass member can be cleanly cut into the shape enclosed by .

The first adhesive layer is formed, for example, by applying the first adhesive to at least one of the facing surfaces of the carrier film and the first base film and stacking the carrier film and the first base film. . At this stage, since grooves are not formed in the first base film, a length including the carrier film, the first base film, and the first pressure-sensitive adhesive layer interposed therebetween is applied by a roll-to-roll method. It is possible to easily form a base material laminate having a length of approx. A first pressure-sensitive adhesive layer may be formed on the surface of the carrier film, and the first base film may be attached to the carrier film via the first pressure-sensitive adhesive layer.

The first pressure-sensitive adhesive that constitutes the first pressure-sensitive adhesive layer is not particularly limited. Examples include pyrrolidone-based adhesives, polyacrylamide-based adhesives, and cellulose-based adhesives.

For each adhesive, for example, base polymer, cross-linking agent, additives (e.g., tackifier, coupling agent, polymerization inhibitor, cross-linking retarder, catalyst, plasticizer, softener, filler, colorant, metal Powders, UV absorbers, light stabilizers, antioxidants, antidegradants, surfactants, antistatic agents, surface lubricants, leveling agents, corrosion inhibitors, particles of inorganic or organic materials (metal compound particles (metal oxide particles, etc.), resin particles, etc.)). However, the constituent components of the adhesive are not limited to these.

The thickness of the first adhesive layer is, for example, 3 μm or more and 50 μm or less, and may be 5 μm or more and 30 μm or less.

(Other adhesive layers)
When the long laminate includes a second substrate film, a second pressure-sensitive adhesive layer may be interposed between the second substrate film and the glass member. Further, when the first substrate film or the second substrate film is a multilayer film, the layers constituting the multilayer film may be adhered with an adhesive layer. These adhesive layers can also be formed by placing an adhesive between the layers to be adhered, as in the case of the first adhesive layer.

Examples of adhesives constituting adhesive layers other than the first adhesive layer, including the second adhesive constituting the second adhesive layer, include the adhesives exemplified for the first adhesive. The thickness of the pressure-sensitive adhesive layer other than the first pressure-sensitive adhesive layer can be selected, for example, from the range described for the thickness of the first pressure-sensitive adhesive layer.

<Physical property measurement method 1>
(1) Storage elastic modulus (1-1) Base film The storage elastic modulus of each of the first base film and the second base film is determined as a tensile storage elastic modulus in accordance with JIS K 7244-1: 1998. can be measured. Specifically, first, each base film is cut into a predetermined size to prepare a test piece. Using this test piece, a dynamic viscoelasticity measuring device (for example, a multi-function dynamic viscoelasticity measuring device “DMS6100” manufactured by Hitachi High-Tech Science Co., Ltd.) was used to measure viscoelasticity under the following conditions. Determine the tensile storage modulus at °C. Measurement may be performed 5 times or more and an average value may be obtained.

Measurement conditions Temperature range: -100°C to +200°C
Heating rate: 2°C/min
Mode: Tensile Sample width: 10mm
Distance between chucks: 20mm
Frequency: 10Hz
Strain amplitude: 10 μm
Atmosphere: Air (250 ml/min)
Data acquisition interval: 0.5 min (every 1°C)

(1-2) Adhesive Layer The storage elastic modulus of the adhesive layer can be measured as a tensile storage elastic modulus in the same manner as in the case of the substrate film. Specifically, first, the adhesive is formed into a film and cured to produce a cured film having a thickness of about 20 μm. This film is cut into a predetermined size to prepare a test piece. Using this test piece, the viscoelasticity is measured in the same manner as the base film, and the tensile storage modulus at 25°C is determined. Measurement may be performed 5 times or more and an average value may be obtained.

(1-3) Adhesive layer The storage modulus of the adhesive layer can be measured in a torsional mode in accordance with JIS K 7244-1:1998. Specifically, a coating film of an adhesive is sandwiched between parallel plates, and a dynamic viscoelasticity measuring device (for example, "Advanced Rheometric Expansion System (ARES)" manufactured by Rheometric Scientific) is used to measure viscoelasticity under the following conditions. is measured to determine the storage modulus at 25°C. Measurement may be performed 5 times or more and an average value may be obtained.

Measurement conditions Deformation mode: Torsion Measurement frequency: 1Hz
Measurement temperature: -40°C to +150°C
Heating rate: 5°C/min

(2) Adhesive strength The adhesive strength between the first adhesive layer and the glass member was measured using a surface/interface property analyzer "SAICAS DN-20" manufactured by Daipla-Wintes Co., Ltd. under the following conditions and methods. Measure in As shown in FIG. 4A, the surface/interface property analysis device 41 includes a blade 42 having the following characteristics, and a moving device and a pressure measuring section (not shown). Blade 42 is movable. The blade 42 has a cutting edge 43 formed at the tip.

Characteristics of blade 42 Material of blade 42: Single crystal diamond Width of blade edge 43: 1 mm
Rake angle of cutting edge 43: 10°

First, as shown in FIG. 4A, the laminate is set in the analysis device 41. The cutting edge 43 is pushed into the first base film 100 while being moved to one side in the horizontal direction D1 (corresponding to the surface direction of the laminate) so as to be inclined with respect to the vertical direction D2 (corresponding to the thickness direction of the laminate). , to cut the first base film 100 with the cutting edge 43 . The horizontal velocity is 10 μm/sec and the vertical velocity is 0.5 μm/sec. For the measurement, a laminate in which no frame-shaped groove is formed in the first base film 100 is used. The laminate includes a first base film 100, a glass member 200, and a first adhesive layer 300 interposed therebetween.

After the cutting edge 43 is cut into the first base film 100, the cutting edge 43 is also cut into the first adhesive layer 300 as shown in FIG. 4B. When the cutting edge 43 reaches the interface between the first adhesive layer 300 and the glass member 200, the cutting edge 43 is horizontally moved to the one side. Thereby, the first adhesive layer 300 is peeled off from the glass member 200 . The peel strength at this time is measured as the adhesive strength between the first adhesive layer 300 and the glass member 200 .

Note that the adhesive force between the first adhesive layer 300 and the first base film 100 can also be similarly measured by switching the top and bottom of the laminate in FIGS. 4A and 4B. However, when measuring the adhesive force between the first adhesive layer 300 and the first base film 100, the cutting edge 43 is pushed into the first base film 100, and the cutting edge 43 is cut into the first base film 100. Let When the cutting edge 43 reaches the interface between the first base film 100 and the first adhesive layer 300 , the cutting edge 43 is moved horizontally to the one side so that the first adhesive layer 300 is separated from the first base film 100 . The peel strength at the time of peeling is measured as the adhesive strength.

FIG. 1A is a plan view showing the configuration of a long laminated body 10C according to one embodiment, and FIG. 1B shows a cross section of the long laminated body 10C of FIG. 1A cut along the bb line in the direction of the arrow. 1 is a schematic cross-sectional view when viewed from above. A long first base film 100 in which a plurality of rectangular frame-shaped grooves G are formed is laminated on a long carrier film 400 with a first pressure-sensitive adhesive layer 500 interposed therebetween. Further, a long film-like glass member 200 is laminated on the first base film 100 with a first adhesive layer 300 interposed therebetween. The groove G is formed by forming the laminate of the carrier film 400, the first base film 100, and the first adhesive layer 500 interposed therebetween before applying the first adhesive to form the first adhesive layer 300. It is formed by shaving or cutting the first base film 100 in a frame shape at a plurality of locations in a state (also referred to as a base laminate). The arrangement, number, etc. of the frame-shaped grooves G are not limited to the illustrated example, and can be set as appropriate. In FIGS. 1A and 1B, the width of the frame-shaped groove G is indicated by Wg.

2A, 2B, and 2C are schematic cross-sectional views each showing an embodiment of a long laminate containing a second base film. These figures are cross-sectional views showing a cut plane parallel to the thickness direction of the long laminate as viewed from a direction parallel to the length direction of the long laminate, as in FIG. 1B.

In the long laminate of FIG. 2A, the second base film 600 is formed on the glass member 200 with the second adhesive layer 700 interposed therebetween. 2B, the second base film 600 is formed on the glass member 200 with the second adhesive layer 800 interposed therebetween. Other than these configurations, it is the same as the long laminate 10C of FIGS. 1A and 1B, and the description of FIGS. 1A and 1B can be referred to.

The long laminate in FIG. 2C has a second base film 600 formed on a glass member 200 with a second pressure-sensitive adhesive layer 800 interposed therebetween, as shown in FIG. 2B. The laminate structure of the carrier film 400 and the first adhesive layer 500 is the same as in FIGS. 1A and 1B. However, the long laminate of FIG. 2C includes a multi-layer first substrate film 1100 instead of the single-layer first substrate film 100 . The first base film 1100 includes a separator 120 on the first adhesive layer 500 side, and a polarizing plate 110 laminated on the separator 120 with an adhesive layer 130 interposed therebetween. A glass member 200 is laminated on the polarizing plate 110 with a first adhesive layer 300 interposed therebetween. Although the first substrate film 1100 has a multilayer structure, it is made entirely of a resin material, so that the grooves G can be easily formed by laser light or the like in the state of the substrate laminate. After forming the grooves G in the first base film 1100, the first adhesive is applied to the portion other than the grooves G on the first main surface (the main surface on the polarizing plate 110 side) of the first base film 1100, and the glass is adhered to the glass. The first adhesive layer 300 is formed by stacking the member 200 or a laminate of the glass member 200, the second base film 600, and the second adhesive layer 800 interposed therebetween, and curing the first adhesive. is formed. In the illustrated example, the first adhesive applied to the first main surface travels along the end face (or wall surface) of the first base film 1100 in the groove G and enters the groove G to cover the end face. A case where an adhesive layer 300 is formed is shown.

During the manufacturing process of the long laminate, the first adhesive layer may be formed in the groove as described above. Also, the first adhesive layer may be formed between the end of the groove on the first main surface side of the first base film and the glass member. In the long laminate of the present disclosure, a gap is formed at least either between the edge of the groove on the first main surface side of the first base film and the glass member and within the groove. Therefore, the glass member can be cleanly cut by irradiating the region corresponding to the groove of the long laminate with the laser beam.

3A to 3E are schematic cross-sectional views for explaining the state of the first adhesive layer in the groove of the long laminate and its vicinity, or the division of the glass member or the long laminate by laser light irradiation. In these figures, the grooves are shown enlarged so that the state of the grooves and the first adhesive layer in the vicinity thereof can be easily understood.

In FIG. 3A, as in FIGS. 1B, 2A, and 2B, the first adhesive layer 300 is formed between the portion other than the grooves G on the first main surface of the first base film 100 and the glass member 200. formed only in In other words, all portions between the end of the groove G on the first main surface side and the glass member 200 and within the groove G are voids. The long laminate in FIG. 3A does not have the second base film 600 and the outermost layer is the glass member 200 . The carrier film 400 and the first pressure-sensitive adhesive layer 500 are peeled off from the long laminate, and glass is applied to the area corresponding to the groove G of the long laminate after peeling (in this case, specifically the glass member 200). By irradiating the laser light L from the member 200 side, the glass member 200 can be easily cut. Therefore, along the shape of the groove G, the glass member 200 can be divided. In this way, it is possible to obtain a laminated body with a glass member that is divided into individual pieces in a shape surrounded by a frame.

3B to 3D do not have the second base film 600, and the outermost layer is the glass member 200, as in the case of FIG. 3A. However, in FIGS. 3B to 3D, the state of the first adhesive layer 300 in or near the groove G is different from that in FIG. 3A. More specifically, in FIG. 3B, the end surfaces (or wall surfaces) of the first base film are coated with the first adhesive layer 300 in the grooves G as in FIG. 2C. In FIG. 3B, an air gap is formed inside the groove G, as in FIG. 2C. In FIG. 3B, the glass member 200 can be divided neatly by irradiating the laser light L as in the case of FIG. 3A.

In FIGS. 3C and 3D, the end face (or wall surface) of the first base film is coated with the first adhesive layer 300 in the groove G, as in FIG. 3B. Additionally, a first adhesive layer 300 is formed on the top or bottom of the groove G. As shown in FIG. More specifically, in FIG. 3C, the first adhesive layer 300 is formed between the end of the groove G on the first main surface side and the glass member 200 and at the upper end portion within the groove G. As shown in FIG. In FIG. 3D, the first adhesive layer 300 is formed on the bottom of the groove G (the end on the first adhesive layer 500 side). In these examples as well, a gap is ensured within the groove G, and the thickness _T1 of the first adhesive layer 300 formed on the top or bottom of the groove is small. Therefore, even if the laser beam L is irradiated from the glass member 200 side, the glass member 200 can be cleanly cut, and the unnecessary first adhesive layer 300 formed on the top or bottom of the groove G can be removed by the laser beam L. can be easily removed with Therefore, the glass member 200 can be neatly divided, and the individualized laminated body with the glass member can be easily manufactured.

FIG. 3E is an example of singulating a long laminate having a second base film. The long laminate in FIG. 3E includes a second base film 600 laminated on a glass member 200 with a second adhesive layer 700 interposed therebetween. In the long laminate of FIG. 3E, a first adhesive layer 300 is formed in the groove G in the same manner as in the case of FIG. 3D. In this case, first, the carrier film 400 and the first adhesive layer 500 are peeled off. Next, the second substrate film 600 and the second adhesive layer 700 are cut by irradiating the laser light L from the glass member 200 side (in other words, from the second substrate film 600 side). Next, the first adhesive layer 300 formed on the bottom of the groove G is removed by irradiating the laser beam L through the groove G from the second main surface side of the first base film 100. , the glass member 200 is cleanly cut. In this way, by irradiating the laser light L from above and below, the long laminated body can be divided, and individualized laminated bodies with glass members can be easily manufactured. This method is also effective when the first adhesive layer 300 is formed in the groove G in FIG. 3E as shown in FIG. 3C.

[Long Laminate and Method for Producing Laminate]
Next, an example of a method for manufacturing a long laminate (hereinafter referred to as "manufacturing method A") will be described. For the constituent elements of the long laminate, the description of the long laminate can be referred to.
Manufacturing method A can generally be classified into three stages.
The first step is to prepare a long base material laminate.
The second step is to prepare a long laminate from the substrate laminate and the glass member.
The third step is to further process the long laminate.

<First stage>
The first stage has the step of preparing a substrate laminate. The substrate laminate is a laminate obtained by bonding together a long first substrate film and a long carrier film with a first pressure-sensitive adhesive layer. At this point, the first base film does not have a plurality of frame-shaped grooves. The step of preparing the substrate laminate is not particularly limited, and may be performed by a roll-to-roll method.

For example, the substrate laminate is obtained by applying a first adhesive to one of the opposed surfaces of a long carrier film and a first long substrate film to form a first adhesive layer and attaching it to the other. Prepared by combining. The first pressure-sensitive adhesive is applied to one main surface of the carrier film or the first base film using coating, transfer, or the like. Alternatively, a roll of a substrate laminate in which a carrier film and a first substrate film are laminated via a first pressure-sensitive adhesive layer may be prepared by purchasing or the like.

This step may further include, for example, unwinding the long base material laminate wound into a roll by an unwinding section. The unwound substrate laminate is supplied to subsequent stages (or processes). In addition, the process of preparing the substrate laminate may be performed as one of a series of processes for forming the long laminate.

<Second stage>
In the second step, a long laminate is formed using the substrate laminate obtained in the first step. The second step comprises a first step of forming grooves in the first substrate film of the substrate laminate supplied from the first step, a second step of laminating a glass member, and forming a first adhesive layer. and a third step. The second step may include a fourth step of laminating a second base film, if necessary. The fourth stage may optionally be performed in a roll-to-roll fashion. Moreover, the second step may include a fifth step of forming a surface coat layer on the glass member or the second base film, if necessary.

(First step)
In the first step, a plurality of frame-shaped grooves that penetrate the first substrate film in the thickness direction are formed in the substrate laminate. The frame-shaped groove is not particularly limited, and can be formed, for example, mechanically or using a laser beam in the first substrate film of the substrate laminate. Each groove may be formed, for example, by scraping off the first base film in a frame shape, forming two large and small frame-like slits, and forming the first base film between the slits (having a width between the slits It may be formed by removing the frame-shaped first base film). In the present disclosure, the latter method is advantageous because it forms relatively wide grooves. In particular, it is convenient to form by a half-cut technique using laser light. Even if the first pressure-sensitive adhesive layer is cut through the first base film by half-cutting, the first pressure-sensitive adhesive layer has fluidity, so the adhesiveness is impaired in holding the first base film. neither will it be Moreover, even if the first pressure-sensitive adhesive layer is partially damaged, it will be removed together with the carrier film later, so the product will not be affected.

The frame-shaped portion between the slits of the first base film can be removed, for example, by pushing up the side edges of the frame-shaped portion from below the carrier film to lift it up and pulling the lifted portion.

In the roll-to-roll method, grooves may be formed in a portion of the base material laminate while it is being unwound and transported or when transport is stopped. The substrate laminate on which the first step has been performed may be temporarily wound into a roll by a winding section. The substrate laminate that has been subjected to the first step may be subjected to subsequent steps after being wound up on the winding unit or without being wound up.

(Second step)
In the second step, after the grooves are formed in the first step, a first adhesive is applied to the first main surface of the first base film, and the glass member is laminated via the first adhesive. The second step may include a first substep of applying the first adhesive to the first substrate film and a second substep of laminating the glass member.

(Application of adhesive (first substep))
The first adhesive is applied so that at least one of a gap is formed between the end of the groove on the first main surface side and the glass member and inside the groove. From this point of view, it is preferable, for example, to apply the first adhesive to the regions of the first main surface excluding the grooves. In addition, the viscosity of the first adhesive is within the above range, or the thickness of the first adhesive layer between the first main surface of the first base film (the region excluding the grooves) and the glass member is already adjusted. It is preferable to apply the first adhesive so that the above range is achieved. In addition, the first bonding is performed so that the minimum thickness of the first adhesive layer formed between the end of the groove on the first main surface side and the glass member and at least one part of the inside of the groove is within the range described above. It is also preferred to apply the agent (eg, control the amount applied or the thickness of the coating).

For example, in the roll-to-roll method, on the first main surface of the first substrate film of the substrate laminate during or when the substrate laminate after the grooves are being conveyed is being conveyed. Alternatively, the first adhesive may be applied continuously or intermittently.

For the type of the first adhesive, the description of the first adhesive forming the first adhesive layer of the long laminate can be referred to. The type and composition of the first adhesive are such that the adhesive strength between the first adhesive layer and the glass film and the adhesive strength between the first adhesive layer and the first base film are both, for example It is preferable to select 0.1 N/mm or more.

As a method for applying the first adhesive, a coating method, a printing method, or the like is used. Coating methods include air doctor coating, blade coating, knife coating, reverse coating, transfer roll coating, gravure roll coating, kiss coating, cast coating, spray coating, slot orifice coating, calendar coating, electrodeposition coating, dip coating, die coating and the like. Printing methods include letterpress printing (flexographic printing, etc.), intaglio printing (direct gravure printing, offset gravure printing, etc.), lithographic printing (offset printing, etc.), stencil printing (screen printing, etc.), etc. is mentioned.

(Lamination of glass members (second substep))
Following the first sub-step, the glass member is laminated on the first main surface of the first base film via the applied first adhesive. As described above, as the glass member, a long glass member (such as a glass film) may be continuously overlaid on the first base film, and a large-sized glass member may be formed on the first main surface of the first base film. A plurality of glass members may be arranged side by side.

In the second sub-step, the glass member may be laminated on the first base film by itself.

Alternatively, the glass member may be laminated on the first main surface of the first base film in a state in which the glass member is laminated in advance with the second base film via the second adhesive layer or the second pressure-sensitive adhesive layer. . In the laminate of the glass member, the second base film, and the second adhesive layer interposed therebetween, for example, the second adhesive is applied to at least one of the facing surfaces of the glass member and the second base film. is applied, the other is laminated, and the second adhesive is cured to form a second adhesive layer. Application of the second adhesive can be performed by the application method described for the first adhesive, or the like. For the curing of the second adhesive, the description of the third step described later can be referred to. A laminate of a glass member, a second base film, and a second pressure-sensitive adhesive layer interposed therebetween, for example, has a second pressure-sensitive adhesive applied to at least one of the facing surfaces of the glass member and the second base film. It can be formed by applying to form a second pressure-sensitive adhesive layer and attaching the other so as to come into contact with the second pressure-sensitive adhesive layer. Application of the second pressure-sensitive adhesive can be performed using coating, transfer, or the like.

(Third step)
In the third step, the first adhesive layer is formed by curing the first adhesive applied in the second step. As a result, a long laminate is obtained in which the glass member is laminated via the first adhesive layer on the substrate laminate in which a plurality of frame-shaped grooves are formed in the first substrate film.

Curing of the first adhesive can be carried out using heating or light irradiation depending on the type of the first adhesive. Since the glass member is transparent, the photocurable first adhesive can be used, and curing can be efficiently performed. When using the ultraviolet curing first adhesive, the first adhesive layer is formed by irradiating the first adhesive with ultraviolet rays through the glass member.

The long laminate or its precursor obtained in the third step may be temporarily wound into a roll by a winding unit. After the long laminate that has been subjected to the third step is wound on the winding unit, or without winding, further steps or steps (e.g., fourth step, fifth step, third step) may be served to When the precursor is obtained in the third step, the long laminate may be completed by performing the fourth step and/or the fifth step.

FIG. 5 is an explanatory diagram showing an example of a method for manufacturing a long laminate. The manufacturing method of the long laminate is a roll-to-roll method, and progresses sequentially in the direction of the arrow in FIG. FIG. 5(a) schematically shows at least a part of the steps for preparing the substrate laminate in the first stage, in which the unwinding unit 1 winds the substrate laminate 456 wound into a roll. May include issuing. The substrate laminate 456 is a laminate in which a long carrier film 400 and a long first substrate film 100 are bonded together with a first pressure-sensitive adhesive layer 500 . The unwound substrate laminate 456 is supplied to the subsequent first step of the second stage.

FIG. 5(b) schematically shows at least part of the first step of the second stage, and first shows how the slit S is formed by the half-cut device 2 using laser light. . The slits S are formed so as to describe a set of two frame-like rectangles, one large and one small. A plurality of such frame-shaped rectangular sets are continuously formed in the length direction and width direction of the base material laminate 456 . Then, a plurality of frame-shaped grooves G are formed by removing a portion (frame-shaped portion) 100a between the two large and small frame-shaped slits S of the first base film 100 .

FIG. 5(c) schematically shows at least part of the second step, showing how the first adhesive 300a is applied in the first substep. In the schematic cross-sectional view, the first adhesive 300a is applied to portions other than the grooves G on the first main surface of the first base film 100. As shown in FIG.

FIG. 5(d) schematically shows at least part of the second step, and shows how long glass members 200 are laminated in the second substep. The roll-shaped glass member 200 is unwound from the unwinding section 4 and laminated on the substrate laminate in which the frame-shaped groove G is formed. Then, by curing the first adhesive 300a, a long laminated body 10C as shown in the schematic cross-sectional view is formed. By irradiating the first adhesive 300a with ultraviolet rays through the glass member 200, the first adhesive 300a is cured and the first adhesive layer 300 is formed. In this manner, a long laminated body 10C is formed. The substrate laminated body in which the glass member 200 is laminated may press the glass member 200 against the first adhesive through the nip of the pair of nip

rollers

3a and 3b.

The long laminate 10C may be wound into a roll by the winding unit 5, as shown in FIG. 5(e). In this case, from the viewpoint of protecting the glass member 200, it is preferable to wind the roll so that the inside of the roll becomes the glass member 200. FIG.

The illustrated example shows an example in which the length direction of the rectangular glass member 200 and the MD direction of the long carrier film are parallel. Not limited.

FIG. 6 is a plan view showing an arrangement example of a plurality of frame-shaped grooves G in the substrate laminate. FIG. 6(a) is an arrangement similar to the substrate laminate 456 shown in FIG. FIG. 6(b) shows an example in which the length direction of the rectangular frame-shaped groove G is parallel to the TD direction of the long carrier film. FIG. 6(c) shows an example in which the length direction of the rectangular frame-shaped groove G and the TD direction of the long carrier film are inclined at a predetermined angle.

In the case of optical laminates used for display panels of flexible flat panel displays (FPDs), glass films are required to be rolled or bent. When the direction in which the glass film is rolled or bent (that is, the circumferential direction of the peripheral surface formed when the glass film is rolled or bent) is the first direction, the first direction and the MD direction are the same. The arrangement direction of the frame-shaped grooves G in the long laminate may be determined so as to be parallel (the first direction and the TD direction are perpendicular).

(Fourth step)
The second step may include a fourth step of laminating a second base film, if necessary. When the second base film is not provided, or when the laminate including the glass member and the second base film is laminated in the second step, this step is not particularly required. However, this is not the only case, and even when a laminate including a glass member and a second base film (more specifically, a partial layer of the second base film) is laminated in the second step, in the fourth step, Further, a second base film (more specifically, a partial layer of the second base film) may be laminated to make the entire second base film into a multilayer film.

In the fourth step, a long second base film is usually laminated on the main surface of the glass member opposite to the first base film side via a second pressure-sensitive adhesive layer or a second adhesive layer. be. For the lamination of the second base film, the description of the second step of laminating the second base film on the glass member can be referred to. Further, according to this case, a part of the layers of the second base film can be further laminated on a part of the layers of the second base film. When the layers constituting the second base film are laminated without a pressure-sensitive adhesive layer or an adhesive layer interposed therebetween, for example, a coating agent constituting the layers is applied to the layer to be laminated and solidified. Multi-layering is performed.

(Fifth step)
For example, in the case of forming a surface coat layer on the surface of the glass member or the second base film in the long laminate, the surface coat layer may be formed in the fifth step. As for the surface coat layer, the description of the surface coat layer formed on the surface of the glass member can be referred to. The surface coat layer can be formed, for example, by applying a coating agent as a material to at least part of the surface of the glass member or the second base film and solidifying it.

The fifth step may be performed on the laminated glass member after laminating the glass member on the substrate laminate in the second substep of the second step or after the third step. Moreover, after laminating|stacking a 2nd base film in a 4th process, you may perform a 5th process with respect to a 2nd base film. However, it is not limited to these cases. From the viewpoint of protection of the glass member or workability, it is preferable to form a surface coat layer in advance on the glass member by the fifth step before laminating the glass member on the substrate laminate in the second step. When forming a surface coat layer on the second base film, from the viewpoint of workability, the surface coat layer is formed in advance in the fifth step on the second base film before being laminated in the fourth step. It is preferable to keep

<Third stage>
In the third stage, the long laminate obtained in the second stage is further processed. More specifically, the long laminate is processed to form a plurality of laminates with glass members each including a plurality of singulated glass members.

The third step includes, for example, the sixth step of peeling off the carrier film, the seventh step of dividing the glass member, the eighth step of dividing the second base film, etc., depending on the configuration of the long laminate. If necessary, a ninth step of forming a surface coat layer on the surface of the glass member or the second base film may be performed.

Before separating the glass members into individual pieces in the seventh step, the tenth step of forming a large sheet including part of the plurality of frame-shaped grooves may be performed.

(6th step)
In the sixth step, the carrier film and the first adhesive layer are removed from the long laminate. From the viewpoint of reducing the risk of breakage of the singulated glass ends, the sixth step is preferably performed before the seventh step. Either the sixth step or the eighth step may be performed first. For example, after performing the sixth step, the eighth step may be performed, and after the eighth step, the seventh step may be performed.

When the long laminated body is wound into a roll, the sixth step may include, for example, unwinding the rolled long laminated body by an unwinding section.

The carrier film removed in the sixth step may be wound into a roll by the winding section together with the first adhesive layer.

(Seventh step)
In the seventh step, a long laminate (more specifically, a laminate obtained by removing the carrier film and the first pressure-sensitive adhesive layer from the long laminate) is coated on the glass member side or the first substrate in the region corresponding to the groove. A laser beam is irradiated from the material film side to divide the glass member. By irradiating the glass member with a laser beam, the glass member is divided (or cut) into shapes surrounded by frames along the grooves. When the long laminate does not include the second base film, the glass member can be cut by irradiating the glass portion with laser light, as shown in FIGS. 3A to 3D. Since the glass member can be cut by irradiating the region corresponding to the groove of the long laminate with the laser beam, damage to the first base film by the laser beam is suppressed. Further, as shown in FIGS. 3A to 3D, even if the first adhesive layer is formed by entering into the groove, since a gap is formed in the groove, the optical path of the laser beam does not interfere with the first adhesive layer. Even if the agent layer exists, it can be easily removed when cutting the glass member. Therefore, it is possible to easily form a laminate including the individualized glass member and the first base film with a clean cut surface. In addition, even if the long laminate does not have the second base film, by first removing the carrier film and the first pressure-sensitive adhesive layer in the sixth step, the grooves can be formed from the first base film side. A region can be irradiated with laser light to divide the glass member. In this case, more specifically, the glass member is irradiated with laser light through the groove. In this specification, the laminate after removing the carrier film and the first pressure-sensitive adhesive layer from the long laminate may also be referred to as the long laminate for convenience.

When the long laminate contains the second base film, for example, in the sixth step, after removing the carrier film and the first adhesive layer, preferably the eighth step is performed, and then in the seventh step By irradiating a region corresponding to the groove with a laser beam from the 1 base film side, the glass member can be divided. In this case, in the seventh step, the glass member is irradiated with laser light through the groove. An example of this case is shown in FIG. 3E. In the present disclosure, as shown in FIG. 3E, even if the first adhesive layer is formed in the groove, there are many gaps in the groove and the thickness of the first adhesive layer is small. It can be easily removed and the glass member can be cut cleanly.

Even when the long laminate contains the second base film and the second adhesive layer, when the second base film and the second pressure-sensitive adhesive layer are removed, the second base film and the second pressure-sensitive adhesive After performing the sub-step of removing the layer, the glass member may be cut by irradiating the region corresponding to the groove with laser light from the glass member side, as shown in FIGS. 3A-3D.

If the first adhesive layer remains in the groove after the laser light is irradiated from the glass member side, the laser light may be irradiated through the groove from the first base film side as necessary. good too. As a result, the first adhesive layer remaining in the grooves can be removed and the first base film can be divided again.

In the seventh step, the type of laser light is not particularly limited, and depending on the laser light oscillation medium, for example, a semiconductor laser, gas laser (CO ₂ laser, etc.), solid-state laser (YAG laser, ultraviolet laser), etc. may be used. good. The laser light irradiation conditions are determined according to, for example, the thickness and composition of the glass member and the first adhesive layer.

(8th step)
When the long laminate includes the second base film, suitable irradiation conditions often differ between the second base film and the glass member. It is preferable to irradiate a laser beam from the glass member side (more specifically, the second base film side) to cut the second base film and the second adhesive layer or the second adhesive layer. In addition, since the second adhesive layer can be removed without irradiating the laser beam, when removing the second base film and the second adhesive layer, only the second base film is irradiated with the laser beam. It may be removed by irradiation.

In the eighth step, the type of laser light is not particularly limited, and includes the lasers mentioned for the seventh step. The laser light irradiation conditions are determined according to, for example, the thickness and composition of the second substrate film, the second adhesive layer or the second pressure-sensitive adhesive layer, the layer structure of the second substrate film, and the like.

When it is necessary to perform both the seventh step and the eighth step, the other step may be performed after performing one step, or both steps may be performed in parallel, but the eighth step may be performed. , preferably before the seventh step. When the 8th step is performed before the 7th step, the 6th step may be performed before or after the 8th step, but before the 7th and 8th steps preferably.

When the long laminate is wound into a roll before laser irradiation, the eighth step includes, for example, unwinding the long laminate wound into a roll by an unwinding unit. It's okay.

(9th step)
The surface coat layer may be formed in the fifth step or the ninth step of the third step in the second step of manufacturing the long laminate. When the surface coat layer is formed in the third step, from the viewpoint of workability, the ninth step is preferably performed after the sixth step and before the seventh and eighth steps. Further, after the seventh and eighth steps, a surface coat layer may be formed on the surfaces of the individualized glass members or the second base film by a ninth step, if necessary. The description of the fifth step can be referred to for the formation of the surface coat layer.

(Tenth step)
The tenth step is performed before singulating the glass member (that is, before the seventh step). When performing the eighth step, the tenth step may be performed before the eighth step. The tenth step may be performed before the sixth step or after the sixth step.

In the tenth step, the long laminated body is cut outside the frame-shaped grooves of the long laminated body to form a large sheet including a part of the plurality of frame-shaped grooves. Before or after the tenth step, after performing the sixth step, a large sheet (more specifically, a large sheet from which the carrier film and the first pressure-sensitive adhesive layer have been removed) is supplied to the seventh step. The glass member is singulated in seven steps. Although the seventh step and the eighth step may be performed in parallel using the large-sized sheet, from the viewpoint of reducing breakage of the glass member, the large-sized sheet is first supplied to the eighth step, and after the eighth step It is preferred to supply to the seventh step. When performing the ninth step, for example, the large sheet from which the carrier film and the first adhesive member layer have been removed is subjected to the ninth step before the eighth and seventh steps, or the glass member is It is preferable to perform the ninth step on the laminated body that has been divided into individual pieces.

FIG. 7 is an explanatory diagram showing an example of a series of steps for singulating a laminate from a long laminate. In the illustrated example, first, a large sheet 10E including a plurality of frame-shaped grooves is cut out from the long laminate 10C. Before or after this cutting, the carrier film and the first adhesive layer are removed by the sixth step. Then, using the large sheet from which the carrier film and the first pressure-sensitive adhesive layer have been removed, the glass member 200 is divided in the seventh step to obtain the individualized laminate with glass member 10 .

More specifically, the large sheet 10E is formed by cutting the long laminate 10C along a cutting line LB passing through the outside of the frame-shaped groove G in the long laminate 10C. In the illustrated example, the cutting line LB is set in a portion that does not cross the frame-shaped groove G from one end to the other end in the width direction of the long laminate 10C (FIG. 7A).

The long laminated body 10C is cut along the cutting line LB, and is interposed between the glass member 200 and the first base film 100 in which a plurality of frame-shaped grooves G (nine in the illustrated example) are formed. A large sheet 10E including the first adhesive layer 300 is formed (FIG. 7(b)). The length of the large sheet 10E is arbitrarily selected in consideration of ease of handling.

Then, in the sixth step, the carrier film and the first adhesive are removed from the large sheet 10E. In the seventh step, the glass member 200 is cut along the cutting line LA along the frame shape of the grooves G by irradiating the region corresponding to the grooves G of the obtained large sheet with a laser beam. As a result, the laminated body 10 with the glass member is obtained, which is separated from the large-sized sheet (FIG. 7(c)).

FIG. 8 is a schematic cross-sectional view of the section of the laminated body 10 with a glass member that has been separated into pieces in FIG. Since the laminated body 10 is obtained by dividing the glass member 200 in a state in which the grooves G are formed in the first base film 100 in advance, the end surfaces of the glass member 200 are the portions of the divided first base film 100. It is in a state of extending outward from the end face.

FIG. 9 shows an example of a process chart for forming a laminated body with a glass member that is separated from a long laminated body. FIG. 10 is another example of a process diagram for forming a laminated body with a glass member that is separated from a long laminated body.

In FIG. 9, for example, in the sixth step, the carrier film and the first adhesive layer are removed from the long laminate unwound from the unwinding section (S6). Next, in the seventh step, the regions corresponding to the grooves of the long laminate from which the carrier film and the first pressure-sensitive adhesive layer have been removed are irradiated with a laser beam from the glass member side to separate the glass members (S7 ). Then, a laminated body with a glass member that is separated into individual pieces is obtained.

In FIG. 10, for example, in the sixth step, the carrier film and the first adhesive layer are removed from the long laminate containing the second base film unwound from the unwinding section (S6). Next, in the eighth step, in the long laminate from which the carrier film and the first pressure-sensitive adhesive layer have been removed, the region corresponding to the groove is irradiated with a laser beam from the glass member side (more specifically, from the second base film side). Light is applied to cut the second base film (S8). At this time, the second adhesive layer or the second pressure-sensitive adhesive layer may be cut with a laser beam along with the second base film. After the eighth step, in the seventh step, a laser is applied to the glass member through the groove from the first base film side to the region corresponding to the groove of the long laminate from which the carrier film and the first adhesive layer have been removed. The glass member is cut by irradiating it with light (S7). In this manner, a laminated body with a glass member that is separated into individual pieces is obtained.

Although the present invention has been described in terms of its presently preferred embodiments, such disclosure should not be construed as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art to which the invention pertains after reading the above disclosure. Therefore, the appended claims are to be interpreted as covering all variations and modifications without departing from the true spirit and scope of the invention.

The present disclosure can contribute to improving the performance and productivity of optical laminates used for display panels of flat panel displays (FPDs), for example.

10: Individualized laminate with glass member 10C: Long laminate 10E: Large sheet 100, 1100: First base film 110: Polarizing film 120: Separator 130: Adhesive layer 200: Glass film 300: Third 1 adhesive layer L: laser light 300a: first adhesive 456: base laminate 400: carrier film 500: first adhesive layer 600: second base film 700: second adhesive layer 800: second adhesive Agent layer G: Groove 1, 4: Unwinding part 2: Half cut

device

3a, 3b: Nip roller 5: Winding part S: Slit

Claims

a long first base film having a first principal surface and a second principal surface opposite to the first principal surface;
a glass member laminated on the first main surface side of the first base film;
A long carrier film laminated on the second main surface side of the first base film;
a first adhesive layer interposed between the first base film and the glass member;
and a first adhesive layer interposed between the first base film and the carrier film,
A plurality of frame-shaped grooves penetrating the first base film in the thickness direction are formed in the first base film,
A long laminate, wherein a void is formed in the groove.
The first adhesive layer is formed in a part of the groove,
2. The long laminate according to claim 1, wherein the minimum thickness of said first adhesive layer formed in a part of said groove is 0 [mu]m or more and 3 [mu]m or less.
The long laminate according to claim 1 or 2, wherein at least part of the end face of the first base film in the groove is covered with the first adhesive layer.
The long laminate according to any one of claims 1 to 3, wherein the groove has a width of 5 mm or more.
The adhesive strength between the first adhesive layer and the first base film and the adhesive strength between the first adhesive layer and the glass member are both 0.1 N/mm or more, according to claims 1 to 1 5. The long laminate according to any one of 4.
The long laminate according to any one of claims 1 to 5, wherein the first adhesive that forms the first adhesive layer is an ultraviolet curing type.
The long laminate according to any one of claims 1 to 6, wherein the first adhesive forming the first adhesive layer has a viscosity at 25°C of 0.1 mPa s or more and 100 mPa s or less. .
Any one of claims 1 to 7, wherein the thickness of the first adhesive layer interposed between the portion of the first base film excluding the groove and the glass member is 0.5 μm or more and 5 μm or less. The long laminate according to item 1.
moreover,
a long second base film laminated on the main surface of the glass member opposite to the first base film side;
The long laminate according to any one of claims 1 to 8, comprising a second adhesive layer or a second adhesive layer interposed between the second base film and the glass member.