Laminated sheet and method of manufacturing the same

Abstract

The present invention provides a laminated sheet having a front plate and a polarizing layer, which is manufactured by cutting a long laminate into a single sheet of a predetermined shape using a laser. The present invention aims to provide a laminated sheet having a front plate and a polarizing layer, wherein the adsorption force is difficult to reduce when a surface protection film is peeled off from the laminated sheet having a front plate and a polarizing layer. A front plate, a polarizing layer, a first adhesive layer, and a first resin film are laminated in this order, wherein the first resin film is peelable from the first adhesive layer, and the height of the burr at the outer periphery of the first resin film is 6.0 μm or less.

Description

Technology Field

[0001] The present invention relates to a laminated sheet and a method for manufacturing the same. Background Technology

[0002] A laminated sheet having a front plate and a polarizing layer is laminated to a display panel via an adhesive layer formed on the polarizing layer side to form a display device. To prevent the surface of the laminated sheet from being contaminated or scratched while the laminated sheet is laminated, a separator film is laminated on the adhesive layer and a surface protection film is laminated on the front plate. When laminating a resin film having a coloring layer on the front plate or attaching a new surface protection film, the separator film side is first held by adsorption. Then, the surface protection film on the front plate is peeled off to expose the front plate, and a resin film having a coloring layer is laminated or a new surface protection film is attached.

[0003] A laminated sheet having a front plate and a polarizing layer is manufactured by cutting a long, rectangular laminate into a single sheet of a predetermined shape using a laser. In particular, when the laminated sheet has a layer in which a polymerizable liquid crystal compound is cured, cutting by a laser is superior to cutting by a blade in that it is difficult to cause minute cracks (e.g., the length thereof is 200 μm or less) at the ends of the laminated sheet. When a display device is flexible, if minute cracks exist at the ends of the laminated sheet, there is a risk that the laminated sheet may break when bent due to the minute cracks acting as a trigger; therefore, it is desirable to cut by a laser. Prior art literature

[0004] WO2016 / 158300 The problem to be solved

[0005] It has been found that when cutting is performed using a laser, burrs are generated on the outer periphery of the surface of the laminated sheet. These burrs reduce the adsorption force of the separator film when peeling the surface protection film from the laminated sheet, causing a problem in which the laminated sheet is not maintained. The present invention aims to provide a laminated sheet in which the adsorption force is difficult to reduce when peeling the surface protection film from the laminated sheet. means of solving the problem

[0006] [1] The polarization layer, the first adhesive layer, and the first resin film are laminated in this order, and

[0007] The first resin film is peelable from the first adhesive layer, and

[0008] A laminated sheet in which the height of the burr at the outer periphery of the first resin film is 6.0 μm or less.

[0009] [2] The front plate, polarizing layer, first adhesive layer, and first resin film are laminated in this order, and the first resin film is peelable from the first adhesive layer, and

[0010] A laminated sheet in which the height of the burr at the outer periphery of the first resin film is 6.0 μm or less.

[0011] [3] A laminated sheet as described in [1] or [2], the height of the burr is 0.1 μm or more.

[0012] [4] The above polarizing layer is a laminated sheet described in any one of [1] to [3] having a layer of a polymerizable liquid crystal compound that has been cured.

[0013] [5] The polarizing layer, the first adhesive layer, the first resin film, and the second protective film are laminated in this order, and

[0014] The second protective film has a second adhesive layer on one side of the second resin film, and

[0015] The second protective film is laminated to the first resin film via the second adhesive layer, and

[0016] The first resin film is peelable from the first adhesive layer, and

[0017] The above second protective film comprises a preparation process for preparing a laminate that is peelable from the above first resin film, and

[0018] A method for manufacturing a laminated sheet, comprising a cutting process for obtaining a laminated sheet by irradiating a laser beam onto a laminate from the polarization layer side to cut the laminate into a predetermined shape.

[0019] [6] The front plate, polarizing layer, first adhesive layer, first resin film, and second protective film are laminated in this order, and

[0020] The second protective film has a second adhesive layer on one side of the second resin film, and

[0021] The second protective film is laminated to the first resin film via the second adhesive layer, and

[0022] The first resin film is peelable from the first adhesive layer, and

[0023] The above second protective film comprises a preparation process for preparing a laminate that is peelable from the above first resin film, and

[0024] A method for manufacturing a laminated sheet, comprising a cutting process for obtaining a laminated sheet by irradiating a laser beam onto a laminate from the front plate side to cut the laminate into a predetermined shape.

[0025] [7] A method for manufacturing a laminated sheet as described in [5] or [6], wherein in the above-mentioned foundation process, the output of the laser light is 50W or more and 200W or less.

[0026] [8] A method for manufacturing a laminated sheet as described in any one of [5] to [7], wherein in the above cutting process, the laminated body is cut into a predetermined shape by full cutting.

[0027] [9] A method for manufacturing a laminated sheet as described in any one of [5] to [8], wherein the thickness of the second resin film is 40 μm or more.

[0028]

[10] A method for manufacturing a laminated sheet as described in any one of [5] to [9], wherein the polarizing layer has a layer in which a polymerizable liquid crystal compound is cured. Effects of the invention

[0029] According to the present invention, when peeling a surface protection film from a laminated sheet, it is possible to provide a laminated sheet in which the adsorption force is difficult to decrease. Brief explanation of the drawing

[0030] FIG. 1 is a schematic cross-sectional view showing an example of a laminated sheet of the present invention. FIG. 2 is a schematic cross-sectional view showing an example of a laminated sheet of the present invention. FIG. 3 is a schematic cross-sectional view showing an example of a laminate used when manufacturing the laminated sheet of the present invention. FIG. 4 is a schematic cross-sectional view showing an example of a laminated sheet of the present invention. FIG. 5 is a schematic cross-sectional view showing an example of a laminated sheet of the present invention. Specific details for implementing the invention

[0031] Embodiments of the present invention will be described below with reference to the drawings, but the present invention is not limited to the following embodiments. In all of the following drawings, the scale has been appropriately adjusted to facilitate understanding of each component, and the scale of each component shown in the drawings does not necessarily correspond to the actual scale of the component.

[0032] Laminated Sheet

[0033] FIG. 1 is a schematic cross-sectional view illustrating an example of a laminated sheet of the present invention. The laminated sheet (300) shown in FIG. 1 has a front plate (1), a polarizing layer (2), a first adhesive layer (102), and a first resin film (101) laminated in this order. The front plate (1) and the polarizing layer (2) are laminated by a lamination layer (3). The polarizing layer (2) has a straight polarizing plate (20) and a phase difference film (22) from the front plate (1) side. The first adhesive layer (102) may be an adhesive layer for laminating the laminated sheet to a display panel. The first resin film (101) corresponds to a so-called separator film. The first resin film (101) is peelable from the first adhesive layer (102), and the surface of the first resin film (101) is treated to be peelable from the first adhesive layer (102).

[0034] FIG. 4 is a schematic cross-sectional view illustrating an example of a laminated sheet of the present invention. The laminated sheet (302) shown in FIG. 4 has a polarizing layer (2), a first adhesive layer (102), and a first resin film (101) laminated in this order. The polarizing layer (2) has a phase difference film (22) and a linear polarizer (20) on the side of the first resin film (101). The first adhesive layer (102) may be an adhesive layer for laminating the laminated sheet to a display panel. The first resin film (101) corresponds to a so-called separator film. The first resin film (101) is peelable from the first adhesive layer (102), and the surface of the first resin film (101) is treated to be release-resistant so that it can be peeled from the first adhesive layer (102).

[0035] The laminated sheet may have a third protective film on the side opposite to the polarizing layer side in the front plate, or on the side opposite to the first resin film side in the polarizing layer. FIGS. 2 and FIGS. 5 are schematic cross-sectional views showing an example of the laminated sheet of the present invention. The laminated sheet (301) shown in FIG. 2 has a third protective film (5), a front plate (1), a polarizing layer (2), a first adhesive layer (102), and a first resin film (101) laminated in this order. The front plate (1) and the polarizing layer (2) are laminated by a lamination layer (3). The polarizing layer (2) has a straight polarizing plate (20) and a phase difference film (22) from the front plate (1) side. The third protective film (5) corresponds to a so-called surface protective film and has a third adhesive layer (50) on one side of the third resin film (51). The third protective film (5) is laminated onto the front plate (1) with the third adhesive layer (50) interposed therebetween. The third protective film (5) is peelable from the front plate (1), and the adhesive strength of the third adhesive layer (50) is adjusted so that it is peelable from the front plate (1).

[0036] The laminated sheet (303) shown in FIG. 5 has a third protective film (5), a polarizing layer (2), a first adhesive layer (102), and a first resin film (101) laminated in this order. The polarizing layer (2) has a phase difference film (22) and a linear polarizer (20) on the side of the first resin film (101). The third protective film (5) corresponds to a so-called surface protective film and has a third adhesive layer (50) on one side of the third resin film (51). The third protective film (5) is laminated to the polarizing layer (2) with the third adhesive layer (50) interposed therein. The third protective film (5) is peelable from the polarizing layer (2), and the adhesive force of the third adhesive layer (50) is adjusted so that it is peelable from the polarizing layer (2).

[0037] The laminated sheet may have layers other than those shown in FIGS. 1 and 2 and FIGS. 4 and 5. The laminated sheet may, for example, have a touch sensor layer, an impact-resistant film disposed between the front plate (1) and the polarizing layer (2), and a resin film.

[0038] The laminated sheet of the present invention has a burr height of 6.0 μm or less at the outer periphery of the first resin film. The burr is a residue outside the geometric shape at the edge of the corner of the laminated sheet and may be a residue on the laminated sheet after undergoing a machining or molding process.

[0039] Specifically, the burr may be formed by the melting and solidification of a material constituting a laminated sheet (particularly the material of the first resin film) present on the outer periphery as a surface opposite to the first adhesive layer side of the first resin film. The burr may be formed by laser processing. When viewed in a planar view, the burr may be present on at least a portion of the entire circumference of the outer periphery of the first protective film, and may be present on the entire circumference of the outer periphery.

[0040] In FIG. 1, the burr (40) is a surface opposite to the surface of the first adhesive layer (102) in the first resin film (101), and is located at the outer periphery when viewed in a plane. The height of the burr corresponds to the height indicated by reference numeral 41.

[0041] By making the height of the burr at the outer periphery of the first resin film 6.0 μm or less, the gap between the laminated sheet and the adsorption device can be reduced. Therefore, it is presumed that the force adsorbing the laminated sheet is less likely to decrease. For this reason, the height of the burr is preferably 5.0 μm or less, more preferably 4.0 μm or less, and may be 3.0 μm or less.

[0042] The lower limit of the burr height is not specifically limited, but the burr height may be 0.01 μm or more, 0.1 μm or more, 0.5 μm or more, or 1.0 μm or more. If the burr height is within the above range, it is easy to prevent defects (multiple extraction) in which multiple laminated sheets are extracted when the top laminated sheet is extracted from a laminate of multiple laminated sheets in which multiple laminated sheets are overlapped.

[0043] The height of the burr can be measured using a stylus-type film thickness gauge. Examples of stylus-type film thickness gauges include the DEKTAK32 (manufactured by VEECO).

[0044] The laminated sheet may have burrs on the surface opposite to the first resin film side. Specifically, the burrs may exist on the outer periphery as a surface opposite to the third adhesive layer side in the third protective film. The burrs may be formed when the material constituting the laminated sheet (particularly the material of the third resin film) melts and solidifies. The height of the burrs that may exist on the surface opposite to the first resin film side may be greater than 0 μm and less than or equal to 100 μm, and may be greater than the height of the burrs on the outer periphery of the first resin film.

[0045] A laminated film comprising a front plate (1) and a polarizing layer (2) that constitutes a laminated sheet is preferably capable of being bent in a direction in which at least the front plate (1) is turned inward and the polarizing layer (2) is turned outward (so-called in-folding method). Being capable of being bent means that the front plate (1) can be bent inward and the polarizing layer (2) can be turned outward without cracking.

[0046] In another embodiment, the laminated film having a polarizing layer (2) constituting the laminated sheet is preferably capable of being bent in a direction in which at least the straight polarizing plate (20) is positioned inward and the phase difference film (22) is positioned outward (so-called in-folding method). Being capable of being bent means that it can be bent without cracking in a direction in which the straight polarizing plate (20) is positioned inward and the phase difference film (22) is positioned outward.

[0047] The shape of the laminated sheet in the plane direction may be, for example, a square shape, preferably a square shape having a long side and a short side, and more preferably a rectangular shape. When the shape of the laminated sheet in the plane direction is rectangular, the length of the long side may be, for example, 10 mm to 1400 mm, and preferably 50 mm to 600 mm. The length of the short side may be, for example, 5 mm to 800 mm, preferably 30 mm to 500 mm, and more preferably 50 mm to 300 mm. Each layer constituting the laminated sheet may have its corners rounded, its ends notched, or holes drilled.

[0048] The thickness of the laminated sheet is not particularly limited as it varies depending on the function required of the laminated sheet and the use of the laminated sheet, but for example, it is 20㎛ to 1,000㎛, and preferably 50㎛ to 500㎛.

[0049] [First Resin Film]

[0050] The first resin film corresponds to a so-called separator film and is laminated on the first adhesive layer. The first resin film is laminated on a polarizing layer via the first adhesive layer. Typically, when the laminated sheet is laminated to, for example, a display panel or other optical member, the first resin film is peeled off. Therefore, the first resin film is peelable from the first adhesive layer, and its surface is treated with a release agent so that the first resin film can be peeled off from the first adhesive layer. As a release agent, a release agent such as a silicone-based or fluorine-based agent may be used.

[0051] The resin constituting the first resin film may be a thermoplastic resin such as a polyethylene-based resin like polyethylene, a polypropylene-based resin like polypropylene, a polyester-based resin like polyethylene terephthalate or polyethylene naphthalate, or a polycarbonate-based resin. Preferably, it is a polyester-based resin such as polyethylene terephthalate. The first resin film may have a single-layer structure or a multi-layer structure, but from the perspective of ease of manufacturing and manufacturing cost, it is preferably a single-layer structure.

[0052] The thickness of the first resin film may be, for example, 20 μm or more and 200 μm or less, or 30 μm or more and 150 μm or less. The thickness of the first resin film refers to the thickness of the central part (not the outer periphery) of the laminated sheet.

[0053] [First adhesive layer]

[0054] The first adhesive layer may be an adhesive layer for laminating a laminated sheet to a display panel. The first adhesive layer may be composed of an adhesive composition having a resin as the main component, such as a (meth)acrylic, rubber, urethane, ester, silicone, or polyvinyl ether resin. Among these, an adhesive composition having a (meth)acrylic resin as the base polymer, which has excellent transparency, weather resistance, and heat resistance, is preferred. The adhesive composition may be an active energy beam curing type or a thermosetting type.

[0055] As a (meth)acrylic resin (base polymer) used in an adhesive composition, a polymer or copolymer having one or more monomers of (meth)acrylic acid esters such as butyl (meth)acrylate, ethyl (meth)acrylate, isooctyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate is preferably used. Polar monomers may be copolymerized into the base polymer. Examples of polar monomers include monomers having carboxyl groups, hydroxyl groups, amide groups, amino groups, epoxy groups, etc., such as (meth)acrylic acid, 2-hydroxypropyl (meth)acrylate, hydroxyethyl (meth)acrylate, (meth)acrylamide, N,N-dimethylaminoethyl (meth)acrylate, and glycidyl (meth)acrylate.

[0056] The adhesive composition may include a crosslinking agent. Examples of crosslinking agents include a metal ion with a divalent or higher value that forms a metal carboxylic acid salt with a carboxyl group; a polyamine compound that forms an amide bond with a carboxyl group; a polyepoxy compound or a polyol that forms an ester bond with a carboxyl group; and a polyisocyanate compound that forms an amide bond with a carboxyl group. Among these, a polyisocyanate compound is preferred.

[0057] The adhesive composition may include additives such as fine particles for imparting light scattering properties, beads (resin beads, glass beads, etc.), glass fibers, resins other than base polymers, tackifiers, fillers (metal powders or other inorganic powders, etc.), antioxidants, ultraviolet absorbers, dyes, pigments, colorants, defoaming agents, corrosion inhibitors, and photopolymerization initiators.

[0058] It can be formed by applying an organic solvent diluted solution of the above adhesive composition onto a substrate and drying it.

[0059] The thickness of the first adhesive layer is preferably 10 μm or more, and more preferably 20 μm or more. The upper limit of the thickness of the first adhesive layer is not particularly limited, but may be 50 μm or less, or 40 μm or less.

[0060] [Front Edition]

[0061] The front plate (1) may be a layer constituting the outermost surface of the display device when viewed from the perspective of the observer, or a layer placed inside the display device. That is, after peeling off the third protective film, a resin film, a resin film having a colored layer, a glass film, or a glass film having a colored layer may also be laminated on the front plate (1). As long as the front plate (1) is a plate-like body capable of transmitting light, the material and thickness are not limited, and it may be composed of only one layer or two or more layers. Examples include a resin film and a glass film. It is preferable for the front plate to have a resin film. The front plate (1) may be a laminate of a resin film and a glass film.

[0062] The thickness of the front plate (1) may be, for example, 30 to 200 μm, preferably 50 to 150 μm, and more preferably 50 to 100 μm.

[0063] When the front plate (1) has a resin film, the material may be, for example, an acrylic resin such as polymethyl (meth)acrylate and polyethyl (meth)acrylate; a polyolefin resin such as polyethylene, polypropylene, polymethylpentene and polystyrene; a cellulose resin such as triacetylcellulose, acetylcellulose butylate, propionylcellulose, butyrylcellulose and acetylpropionylcellulose; a polyvinyl resin such as ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol and polyvinyl acetal; a sulfone resin such as polysulfone and polyethersulfone; a ketone resin such as polyetherketone and polyetheretherketone; polyetherimide; a polycarbonate resin; a polyester resin; a polyimide resin; a polyamideimide resin; Examples include polyamide resins. These polymers can be used alone or in a mixture of two or more types. Among them, from the perspective of improving strength and transparency, it is preferable to use polycarbonate resins, polyester resins, polyimide resins, polyamideimide resins, or polyamide resins.

[0064] The thickness of the resin film may be, for example, 10 to 100 μm, preferably 20 to 70 μm, and more preferably 30 to 60 μm.

[0065] The front plate (1) may be a film in which a hard coating layer is provided on at least one side of a resin film to further improve hardness. The hard coating layer may be formed on one side of the resin film or on both sides. By providing a hard coating layer, the front plate can be made to have improved hardness and scratch resistance. The hard coating layer is, for example, a cured layer of a UV-curing resin. Examples of UV-curing resins include acrylic resin, silicone resin, polyester resin, urethane resin, amide resin, epoxy resin, etc. The hard coating layer may contain additives to improve hardness. The additives are not limited and may include inorganic fine particles, organic fine particles, or a mixture thereof.

[0066] It is preferable that an abrasion-resistant layer be formed on the visible side of the above-mentioned hard coating layer to improve abrasion resistance or to prevent contamination by sebum, etc. The front plate may have an abrasion-resistant layer, and the abrasion-resistant layer may be a layer constituting the visible side surface of the front plate. The abrasion-resistant layer includes a structure derived from a fluorine compound. As for the fluorine compound, a compound having silicon atoms and having hydrolyzable groups such as alkoxy groups or halogens on the silicon atoms is preferred. The hydrolyzable groups can form a coating film by undergoing a dehydration condensation reaction, and can also improve the adhesion of the abrasion-resistant layer by reacting with active hydrogen on the surface of the substrate. Furthermore, it is preferable that the fluorine compound have a perfluoroalkyl group or a perfluoropolyether structure, as this can impart water repellency. Particularly preferred is a fluorine-containing polyorganosiloxane compound having a perfluoropolyether structure and a long-chain alkyl group having four or more carbon atoms. It is also preferable to use two or more types of compounds as the fluorine compound. A fluorine compound that is desirable to include further is a fluorine-containing organosiloxane compound containing an alkylene group having 2 or more carbon atoms and a perfluoroalkylene group.

[0067] The thickness of the wear-resistant layer is, for example, 1 to 20 nm. In addition, the wear-resistant layer has water repellency, and the water contact angle is, for example, about 110 to 125°. The contact angle hysteresis and gliding angle measured by the gliding method are about 3 to 20° and 2 to 55°, respectively. In addition, the wear-resistant layer may contain various additives, such as silanol condensation catalysts, antioxidants, rust inhibitors, ultraviolet absorbers, light stabilizers, antifungal agents, antibacterial agents, anti-biodegradation agents, deodorizers, pigments, flame retardants, and antistatic agents, within a range that does not impede the effects of the present invention.

[0068] A primer layer may be provided between the wear-resistant layer and the hard coating layer. As a primer, examples include UV-curing, heat-curing, moisture-curing, or two-component curing epoxy-based compounds. Additionally, as a primer, polyamic acid may be used, and it is also preferable to use a silane coupling agent. The thickness of the primer layer is, for example, 0.001 to 2 μm.

[0069] A method for obtaining a laminate comprising a wear-resistant layer and a hard coating layer can be formed by applying, drying, and curing a primer agent as needed on the hard coating layer to form a primer layer, and then applying and drying a composition containing a fluorine compound (a composition for coating a wear-resistant layer). Examples of application methods include dip coating, roll coating, bar coating, spin coating, spray coating, die coating, gravure coating, etc. Additionally, it is preferable to perform a hydrophilization treatment, such as plasma treatment, corona treatment, or UV treatment, on the coated surface before applying the primer agent or the composition for coating a wear-resistant layer. This laminate may be directly laminated onto a front plate, or laminated onto another transparent substrate and then bonded to the front plate using an adhesive or pressure-sensitive adhesive.

[0070] When the front plate (1) has a glass film, the glass film is preferably made of tempered glass for display. The thickness of the glass film may be, for example, 10 μm or more and 500 μm or less, or 20 μm or more and 100 μm or less. By using a glass film, a front plate (1) having excellent mechanical strength and surface hardness can be constructed.

[0071] When a laminated sheet is used in a display device, the front plate (1) may have a function as a window film in the display device. The front plate (1) may also have a function as a touch sensor, a blue light cut function, a viewing angle adjustment function, etc.

[0072] [Polarization layer]

[0073] The polarization layer may have a linear polarizer and a phase difference film from the side closer to the front plate. The polarization layer may be a circular polarizer (including an elliptical polarizer). Since a circular polarizer can absorb external light reflected from within a display device, it can impart a function as an anti-reflective film to the laminated sheet. It is preferable that the polarization layer has a layer in which a polymerizable liquid crystal compound is cured. According to the present invention, while having a layer in which a polymerizable liquid crystal compound is cured, the height of the burr can be reduced to improve flexibility.

[0074] [Straight Polarizer]

[0075] A linear polarizer has the function of selectively transmitting linearly polarized light in one direction, which consists of non-polarized light rays such as natural light. The linear polarizer may be provided as a polarizer with a stretched film or stretched layer adsorbed with a dichroic pigment, a cured product of a polymerizable liquid crystal compound, and a liquid crystal layer containing a dichroic pigment, wherein the dichroic pigment is dispersed and oriented within the layer in which the polymerizable liquid crystal compound is cured. A linear polarizer using a liquid crystal layer as a polarizer is preferred because, compared to a stretched film or stretched layer adsorbed with a dichroic pigment, there is no restriction in the bending direction.

[0076] (Polarizer, which is an extended film or extended layer adsorbing a dichroic pigment)

[0077] A polarizer, which is a stretched film adsorbed with a dichroic pigment, can typically be manufactured by a process of uniaxially stretching a polyvinyl alcohol-based resin film, a process of adsorbing the dichroic pigment by dyeing the polyvinyl alcohol-based resin film with a dichroic pigment such as iodine, a process of treating the polyvinyl alcohol-based resin film adsorbed with the dichroic pigment with an aqueous boric acid solution, and a process of washing with water after treatment with the aqueous boric acid solution.

[0078] The thickness of the polarizer is typically 30 μm or less, preferably 18 μm or less, and more preferably 15 μm or less. Making the thickness of the polarizer thin is advantageous for thinning the laminated sheet. The thickness of the polarizer is typically 1 μm or more, and may be, for example, 5 μm or more.

[0079] Polyvinyl alcohol-based resins are obtained by saponifying polyvinyl acetate-based resins. As polyvinyl acetate-based resins, in addition to polyvinyl acetate, which is a homopolymer of vinyl acetate, copolymers of vinyl acetate and other monomers copolymerizable thereto are used. Examples of other monomers copolymerizable to vinyl acetate include unsaturated carboxylic acid compounds, olefin compounds, vinyl ether compounds, unsaturated sulfone compounds, and (meth)acrylamide compounds having ammonium groups.

[0080] The degree of saponification of the polyvinyl alcohol-based resin is typically 85 mol% or more and 100 mol% or less, preferably 98 mol% or more. The polyvinyl alcohol-based resin may be modified, and polyvinyl formal, polyvinyl acetal, etc. modified by aldehydes may also be used. The degree of polymerization of the polyvinyl alcohol-based resin is typically 1000 or more and 10000 or less, preferably 1500 or more and 5000 or less.

[0081] A polarizer, which is an extended layer adsorbed with a dichroic pigment, can typically be manufactured by the following steps: applying a coating solution containing the polyvinyl alcohol-based resin onto a base film; uniaxially stretching the obtained laminated film; dyeing the polyvinyl alcohol-based resin layer of the uniaxially stretched laminated film with a dichroic pigment to adsorb the dichroic pigment and form it into a polarizer; treating the film adsorbed with the dichroic pigment with an aqueous boric acid solution; and washing with water after treatment with the aqueous boric acid solution. The base film used to form the polarizer may be used as a protective layer for the polarizer. If necessary, the base film may be peeled off from the polarizer. The material and thickness of the base film may be the same as the material and thickness of the resin film described later.

[0082] A polarizer, which is a stretched film or stretched layer adsorbed with a dichroic pigment, may be used as a straight polarizer as is, or a resin film may be laminated to one or both sides thereof and used as a straight polarizer. The thickness of the straight polarizer is preferably 2 μm or more and 40 μm or less.

[0083] Examples of resin films include films known in the art, such as cyclopolyolefin resin films; cellulose acetate resin films made of resins such as triacetylcellulose and diacetylcellulose; polyester resin films made of resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate; polycarbonate resin films; (meth)acrylic resin films; and polypropylene resin films. The polarizer and the protective layer may be laminated by interposing a lamination layer described later.

[0084] The thickness of the resin film is, for example, 100 μm or less, preferably 80 μm or less, more preferably 60 μm or less, even more preferably 40 μm or less, and even more preferably 30 μm or less, and is also typically 10 μm or more, and is preferably 15 μm or more from the perspective of increasing the absorption rate of the laser.

[0085] A hard coating layer may be formed on the resin film. The hard coating layer may be formed on one side of the resin film or on both sides. By providing a hard coating layer, a thermoplastic resin film with improved hardness and scratch resistance can be produced. The hard coating layer may be formed in the same manner as the hard coating layer formed on the resin film described above.

[0086] (Polarizer, which is a liquid crystal layer)

[0087] A polymerizable liquid crystal compound used to form a liquid crystal layer is a compound having a polymerizable reactive group and also exhibiting liquid crystal properties. A polymerizable reactive group is a group involved in a polymerization reaction, and it is preferable that it be a photopolymerizable reactive group. A photopolymerizable reactive group refers to a group capable of participating in a polymerization reaction by means of active radicals or acids generated from a photopolymerization initiator. Examples of photopolymerizable reactive groups include vinyl groups, vinyloxy groups, 1-chlorovinyl groups, isopropenyl groups, 4-vinylphenyl groups, acryloyloxy groups, methacryloyloxy groups, oxiranyl groups, oxetanyl groups, etc. Among these, acryloyloxy groups, methacryloyloxy groups, vinyloxy groups, oxiranyl groups, and oxetanyl groups are preferred, and acryloyloxy groups are more preferred. The type of polymerizable liquid crystal compound is not particularly limited, and rod-shaped liquid crystal compounds, disc-shaped liquid crystal compounds, and mixtures thereof may be used. The liquid crystallization of the polymerizable liquid crystal compound may be thermotropic liquid crystal or lyotropic liquid crystal, and as for the phase order structure, it may be nematic liquid crystal or smectic liquid crystal.

[0088] As a dichroic pigment used in a polarizer that is a liquid crystal layer, it is preferable to have an absorption maximum wavelength (λMAX) in the range of 300 to 700 nm. Examples of such dichroic pigments include acridine pigments, oxazine pigments, cyanine pigments, naphthalene pigments, azo pigments, and anthraquinone pigments, among which azo pigments are preferred. Examples of azo pigments include monoazo pigments, bis-azo pigments, tris-azo pigments, tetrakis-azo pigments, and stilbene-azo pigments, and preferably bis-azo pigments and tris-azo pigments. The dichroic pigment may be used alone or in combination of two or more types, but it is preferable to combine three or more types. In particular, it is more preferable to combine three or more azo compounds. Some of the dichroic pigments may have reactive groups and may also possess liquid crystal properties.

[0089] A polarizer, which is a liquid crystal layer, can be formed, for example, by applying a polarizer-forming composition comprising a polymerizable liquid crystal compound and a dichroic pigment onto an alignment layer formed on a substrate film, and then polymerizing and curing the polymerizable liquid crystal compound. The substrate film used to form the polarizer may also be used as a protective layer for the polarizer. The material and thickness of the substrate film may be the same as the material and thickness of the resin film described above.

[0090] Examples of a composition for forming a polarizer comprising a polymerizable liquid crystal compound and a dichroic pigment, and a method for manufacturing a polarizer using the composition, may be those described in Japanese Patent Publication No. 2013-37353, Japanese Patent Publication No. 2013-33249, Japanese Patent Publication No. 2017-83843, etc. The composition for forming a polarizer may further include, in addition to the polymerizable liquid crystal compound and the dichroic pigment, additives such as a solvent, a polymerization initiator, a crosslinking agent, a leveling agent, an antioxidant, a plasticizer, and a sensitizer. Each of these components may be used individually or in combination of two or more types.

[0091] The polymerization initiator that may be contained in the composition for forming a polarizer is a compound capable of initiating a polymerization reaction of a polymerizable liquid crystal compound, and a photopolymerizable initiator is preferred in that it can initiate a polymerization reaction under lower temperature conditions. Specifically, a photopolymerization initiator capable of generating active radicals or acids upon the action of light may be cited, and among these, a photopolymerization initiator that generates radicals upon the action of light is preferred.

[0092] The content of the polymerization initiator is preferably 1 to 10 parts by weight, and more preferably 3 to 8 parts by weight, based on 100 parts by weight of the total amount of the polymerizable liquid crystal compound. Within this range, the reaction of the polymerizable group proceeds sufficiently, and it is also easy to stabilize the orientation state of the liquid crystal compound.

[0093] The thickness of the polarizer, which is a liquid crystal layer, is typically 10 μm or less, preferably 0.5 μm or more and 8 μm or less, and more preferably 1 μm or more and 5 μm or less.

[0094] A polarizer having a liquid crystal layer may be used as a linear polarizer without peeling off the substrate film, or the substrate film may be peeled off from the polarizer to form a linear polarizer. A polarizer having a liquid crystal layer may be used as a linear polarizer by forming a protective layer on one or both sides thereof. As the protective layer, the resin film described above may be used.

[0095] A polarizer, which is a liquid crystal layer, may have an overcoating layer on one or both sides of the polarizer for purposes such as protection of the polarizer. The overcoating layer can be formed, for example, by applying a material (composition) for forming an overcoating layer onto the polarizer. Examples of materials constituting the overcoating layer include photocurable resins and water-soluble polymers. As materials constituting the overcoating layer, (meth)acrylic resins and polyvinyl alcohol resins may be used.

[0096] [Phase difference film]

[0097] The phase difference film included in the polarizing layer may consist of a single phase difference layer or be a laminate of two or more phase difference layers. It is preferable for the phase difference film to have a phase difference layer comprising a layer in which a polymerizable liquid crystal compound is cured. If the phase difference film is a laminate of two phase difference layers, it is preferable that at least one of the phase difference layers comprises a layer in which a polymerizable liquid crystal compound is cured. The phase difference film is laminated on the side opposite to the front plate side (or the third protective film side) of the polarizer. The phase difference film may have an overcoating layer that protects its surface, a substrate film that supports the phase difference film, etc.

[0098] The phase difference film preferably has a λ / 4 layer as a phase difference layer, and may also have at least one of a λ / 2 layer or a positive C layer. The phase difference layer may have an alignment layer. When the phase difference film has a phase difference layer that is a λ / 2 layer, the λ / 2 layer and the λ / 4 layer may be laminated in order from the polarizer side. When the phase difference film includes a phase difference layer that is a positive C layer, the λ / 4 layer and the positive C layer may be laminated in order from the polarizer side, or the positive C layer and the λ / 4 layer may be laminated in order from the polarizer side.

[0099] The thickness of the phase difference layer is, for example, 0.1 μm or more and 10 μm or less, preferably 0.5 μm or more and 8 μm or less, and more preferably 1 μm or more and 6 μm or less.

[0100] The phase difference layer may be formed from a resin film exemplified as a material for the protective layer, or may be formed from a cured layer of a polymerizable liquid crystal compound. The phase difference layer may further include an alignment layer. The phase difference film may have a lamination layer for laminating the λ / 4 layer, the λ / 2 layer, and the positive C layer. The lamination layer may be formed as an adhesive layer or a pressure-sensitive adhesive layer, as described below.

[0101] When a phase difference layer is formed by curing a polymerizable liquid crystal compound, the phase difference layer can be formed by applying a composition containing the polymerizable liquid crystal compound to a substrate film and curing it. An alignment layer may be formed between the substrate film and the coating layer. The material and thickness of the substrate film may be the same as the material and thickness of the resin film. When a phase difference layer is formed as a layer formed by curing a polymerizable liquid crystal compound, the phase difference layer may be incorporated into a laminated sheet having an alignment layer and a substrate film. The phase difference layer may be laminated with a linear polarizer through a lamination layer.

[0102] [Touch sensor layer]

[0103] The touch sensor layer may have at least a transparent conductive layer and may also have a resin film. The touch sensor layer may have a transparent conductive layer and a resin film in order from the front plate side (or the third protective film side). The touch sensor layer may also have a resin film and a transparent conductive layer in order from the front plate side (or the third protective film side). The touch sensor layer may not have a resin film. In addition to the transparent conductive layer and the resin film, the touch sensor layer may have a separation layer, a bonding layer, and a protective layer.

[0104] As for the touch sensor layer, it is a sensor capable of detecting a touched location on the surface of a display device, and as long as it is configured to have a transparent conductive layer, the detection method is not limited. Examples of detection methods for the touch sensor layer include resistive film methods, capacitive methods, optical sensor methods, ultrasonic methods, electromagnetic inductive coupling methods, and surface acoustic wave methods. Among these, a capacitive touch sensor layer is preferably used in terms of low cost, fast response speed, and thin film formation.

[0105] The transparent conductive layer may be a transparent conductive layer made of a metal oxide such as ITO, or a metal layer made of a metal such as aluminum, copper, silver, gold, or an alloy thereof.

[0106] The separation layer may be formed on a substrate such as glass and may be a layer for separating a transparent conductive layer formed on the separation layer from the substrate together with the separation layer. Preferably, the separation layer is an inorganic layer or an organic layer. Examples of materials for forming the inorganic layer include silicon oxide. Examples of materials for forming the organic layer include a (meth)acrylic resin composition, an epoxy resin composition, a polyimide resin composition, etc.

[0107] [Third Protective Film]

[0108] The third protective film corresponds to a so-called surface protective film and has a third adhesive layer on one side of the third resin film. The third protective film can be laminated to a front plate with the third adhesive layer interposed therein. The third protective film is peeled off by each third adhesive layer it has when a resin film having a coloring layer is laminated onto the front plate or when a new surface protective film is attached. Therefore, the third protective film is peelable from the front plate, and the adhesive strength of the third adhesive layer is adjusted so that it is peelable from the front plate.

[0109] In another embodiment, the third protective film may be laminated to the polarizing layer via a third adhesive layer. When the front plate is laminated or a new surface protective film is applied, the third protective film is peeled off by each third adhesive layer it possesses. Accordingly, the adhesive force is adjusted so that the third protective film can be peeled off from the polarizing layer and the third adhesive layer can be peeled off from the polarizing layer.

[0110] [Third adhesive layer]

[0111] The third adhesive layer can be composed of an adhesive composition similar to that of the first adhesive layer.

[0112] The thickness of the third adhesive layer is preferably 10 μm or more, and more preferably 20 μm or more. The upper limit of the thickness of the first adhesive layer is not particularly limited, but may be 50 μm or less, or 40 μm or less.

[0113] [Third Resin Film]

[0114] As a resin constituting the third resin film, a resin similar to the resin constituting the first resin film may be used. The resin constituting the third resin film is preferably a polyester-based resin such as polyethylene terephthalate. The third resin film may have a single-layer structure or a multi-layer structure, but from the perspective of ease of manufacturing and manufacturing cost, it is preferably a single-layer structure. The thickness of the third resin film may be, for example, 20 μm or more and 200 μm or less, or 30 μm or more and 150 μm or less.

[0115] [Laminated layer]

[0116] The lamination layer may be a layer for laminating each layer, or a layer composed of a pressure-sensitive adhesive or an adhesive. Each lamination layer may be made of the same material or different materials. When a phase difference film has multiple phase difference layers, the phase difference layers may be laminated to each other by an adhesive layer or by a pressure-sensitive adhesive layer. It is preferable that the linear polarizer and the phase difference film be laminated by a pressure-sensitive adhesive layer.

[0117] As an adhesive layer constituting the bonding layer, an adhesive layer similar to the first adhesive layer or the third adhesive layer described above may be used.

[0118] As an adhesive, it may be formed by combining one or more types among, for example, water-based adhesives and active energy beam curing adhesives. Examples of water-based adhesives include aqueous solutions of polyvinyl alcohol-based resins and water-based two-component urethane-based emulsion adhesives. An active energy beam curing adhesive is an adhesive that is cured by irradiating with active energy beams such as ultraviolet rays; examples include an adhesive containing a polymerizable compound and a photopolymerization initiator, an adhesive containing a photoreactive resin, and an adhesive containing a binder resin and a photoreactive crosslinking agent. Examples of the polymerizable compound include photopolymerizable monomers such as photocurable epoxy monomers, photocurable acrylic monomers, and photocurable urethane monomers, and oligomers derived from these monomers. Examples of the photopolymerization initiator include a compound containing a substance that generates active species such as neutral radicals, anionic radicals, and cationic radicals when irradiated with active energy beams such as ultraviolet rays.

[0119] When the laminated layer is an adhesive layer, the thickness of the adhesive layer is preferably 1 μm or more and 30 μm or less, more preferably 2 μm or more and 20 μm or less, and 3 μm or more and 10 μm or less. When the laminated layer is an adhesive layer, the thickness of the adhesive layer is preferably 0.01 μm or more and 5 μm or less, and more preferably 0.1 μm or more and 3 μm or less.

[0120] Method for manufacturing laminated sheets

[0121] A method for manufacturing a laminated sheet includes a preparation process for preparing a laminate and a cutting process for obtaining a laminated sheet from the laminate. The method for manufacturing a laminated sheet may also include a peeling process for peeling off a second protective film.

[0122] The laminate prepared in the preparation process comprises a front plate, a polarizing layer, a first adhesive layer, a first resin film, and a second protective film laminated in this order. As described above, the laminate prepared in the preparation process may have a third protective film laminated on the front plate. The second protective film has a second adhesive layer on one side of the second resin film, and the second protective film is laminated to the first resin film with the second adhesive layer interposed therebetween. The first resin film is peelable from the first adhesive layer, and the second protective film is peelable from the first resin film. The laminate may have a layer (touch sensor layer, impact-resistant film, resin film, etc.) that may be provided by the laminated sheet. The laminate may be in the form of a long sheet or a single sheet of a predetermined size. The first protective film, the front plate, and the polarizing layer, etc., may be those described above.

[0123] In another embodiment, the laminate prepared in the preparation process is a polarizing layer, a first adhesive layer, a first resin film, and a second protective film laminated in this order. As described above, the laminate prepared in the preparation process may have a third protective film laminated on the polarizing layer. The second protective film has a second adhesive layer on one side of the second resin film, and the second protective film is laminated to the first resin film with the second adhesive layer interposed therebetween. The first resin film is peelable from the first adhesive layer, and the second protective film is peelable from the first resin film. The laminate may have a layer (touch sensor layer, impact-resistant film, resin film, etc.) that may be provided by the laminated sheet. The laminate may be in the form of a long sheet or a single sheet of a predetermined size. The first protective film and the polarizing layer, etc., may be those described above.

[0124] The laminate (400) shown in FIG. 3 has a front plate (1), a polarizing layer (2), a first adhesive layer (102), a first resin film (101), and a second protective film (200) laminated in this order. The second protective film (200) has a second adhesive layer (202) on one side of the second resin film (201). The second protective film (200) is laminated to the first resin film (101) with the second adhesive layer (202) interposed therein. The first resin film (101) is peelable from the first adhesive layer (102), and the second protective film (200) is peelable from the first resin film (101).

[0125] [Second protective film]

[0126] The second protective film corresponds to a so-called surface protective film and has a second adhesive layer on one side of the second resin film. The second protective film is laminated to the first resin film with the second adhesive layer interposed therebetween. After the cutting process of obtaining a laminated sheet from the laminate is completed, the second protective film is peeled off by each second adhesive layer it has. Accordingly, the second protective film is peelable from the first resin film, and the adhesive strength of the second adhesive layer is adjusted so that it is peelable from the first resin film.

[0127] It is preferable that the adhesion force of the second protective film to the first resin film is smaller than the adhesion force of the first resin film to the first adhesive layer. When peeling off the second protective film, it is difficult for a defect to occur in which the first resin film is unintentionally peeled off.

[0128] The thickness of the second protective film may be, for example, 30㎛ or more and 200㎛ or less, or 40㎛ or more and 150㎛ or less.

[0129] [Second Resin Film]

[0130] As a resin constituting the second resin film, a resin similar to the resin constituting the first resin film may be used. The resin constituting the second resin film is preferably a polyester-based resin such as polyethylene terephthalate. The second resin film may have a single-layer structure or a multi-layer structure, but from the perspective of ease of manufacturing and manufacturing cost, it is preferably a single-layer structure. The thickness of the second resin film may, for example, be 20 μm or more and 100 μm or less, 30 μm or more and 80 μm or less, or 40 μm or more.

[0131] [Second adhesive layer]

[0132] The second adhesive layer may be composed of an adhesive composition similar to that of the first adhesive layer. The thickness of the second adhesive layer is preferably 3 μm or more, and more preferably 5 μm or more. The upper limit of the thickness of the first adhesive layer is not particularly limited, but may be 50 μm or less, or 40 μm or less.

[0133] A laminate is manufactured by laminating each layer together, and the order in which each layer is laminated is not particularly limited. The laminate is obtained by a manufacturing method comprising, for example, a process of laminating a front plate and a polarizing layer, a process of laminating a first adhesive layer and a first resin film to the polarizing layer, and a process of laminating a second protective film to the first resin film. In another embodiment, the laminate is obtained by a manufacturing method comprising, for example, a process of laminating a first adhesive layer and a first resin film to the polarizing layer, and a process of laminating a second protective film to the first resin film.

[0134] The cutting process for obtaining a laminated sheet from a laminate is performed by cutting the laminate into a predetermined shape by irradiating the laminate with laser light from the front panel side (from the viewing side). That is, the surface on the laser light emission side is formed by a second protective film. Since the laminate is equipped with a second protective film, the first resin film is not a layer constituting the outermost surface of the laminate, but a layer existing inside the laminate. A burr that is relatively large is prone to forming on the outer periphery of the laser light emission side surface compared to the outer periphery of the layer existing inside the laminate. Therefore, since the laminate is equipped with a second protective film, the height of the burr on the outer periphery of the first resin film is easily reduced to 6.0 μm or less.

[0135] For example, a laser that emits light with a wavelength in the range of 200 nm to 11 µm is used. The laser may be a continuous wave (CW) laser or a pulsed laser. Examples of laser types include gas lasers such as CO2 lasers, solid-state lasers such as YAG lasers, and semiconductor lasers. A CO2 laser is preferred because it is easy to match the absorption range of the laminated sheet.

[0136] The height of the burr at the outer edge of the first resin film tends to decrease as the laser output increases. When using a CO2 laser, the laser output is preferably 50W or more, more preferably 60W or more, and even more preferably 100W or more. The upper limit of the laser output is not particularly limited, but, for example, can be 200W or less.

[0137] In the same regard, the energy of the laser light irradiated by a unit length scan (hereinafter referred to as irradiation energy) is preferably 100 mJ / mm or more, more preferably 200 mJ / mm or more, and more preferably 250 mJ / mm or more. The upper limit of the irradiation energy is not particularly limited, but, for example, it may be 1000 mJ / mm or less, and may be 500 mJ / mm or less.

[0138] The speed at which the laser beam travels on the surface of the laminate (hereinafter referred to as the travel speed) is preferably 50 mm / sec or more and 2000 mm / sec or less, more preferably 100 mm / sec or more and 1000 mm / sec or less, and more preferably 150 mm / sec or more and 700 mm / sec or less, and may be 300 mm / sec or more.

[0139] When focusing laser light by a lens, the focus of the laser light may be aligned with the surface of the front plate side of the laminate, the surface of the second protective film side, or the interior of the laminate. The spot size of the laser light may be 5㎛ or more and 100㎛ or less, or 10㎛ or more and 70㎛ or less. The depth of focus (DOF) of the lens may be 10㎛ or more and 500㎛ or less, or 100㎛ or more and 300㎛ or less.

[0140] The cutting process may be performed by full cutting, or by first making a notch to a depth where the laminate is not cut using half cutting, and then irradiating the laminate with a laser light once or multiple times to completely cut the laminate. Full cutting means cutting all layers along the lamination direction with a single laser irradiation. It is preferable to perform the cutting process by full cutting from the perspective of reducing the height of the burr at the outer edge of the first protective film.

[0141] The method for manufacturing a laminated sheet may include a peeling process for peeling off a second protective film. By peeling off the second protective film, a laminated sheet in which a front plate, a polarizing layer, a first adhesive layer, and a first resin film are laminated in this order can be obtained. In another embodiment, by peeling off the second protective film, a laminated sheet in which a polarizing layer, a first adhesive layer, and a first resin film are laminated in this order can be obtained.

[0142] When a third protective film is laminated on the front plate of a laminated sheet, the third protective film may be peeled off to expose a surface, and a resin film or a glass film may be laminated, or another protective film may be laminated. This process may include adsorbing and holding the separator film side and peeling off the third protective film.

[0143] <Display device>

[0144] A display device is obtained by peeling off a first resin film to expose a first adhesive layer and laminating a laminated sheet to a display panel with the first adhesive layer interposed therein. The laminated sheet is particularly preferred for use on the display surface of a flexible display panel. The display panel may be configured to be foldable with the viewing side surface facing inward, or configured to be rollable. Specific examples of the display panel include a liquid crystal display element, an organic EL display element, an inorganic EL display element, a plasma display element, and a field emission display element.

[0145] Display devices can be used as mobile devices such as smartphones and tablets, televisions, digital photo frames, electronic signboards, measuring instruments or instruments, office equipment, medical equipment, computer equipment, etc.

[0146] Examples

[0147] The present invention will be explained in more detail below by way of examples, but the present invention is not limited thereto. In the examples, the unit "part" of the ratio of materials is based on weight unless otherwise specified.

[0148] [Measurement of Burr Height]

[0149] Measurements were taken using a pen-type film thickness gauge (DEKTAK32, manufactured by VEECO). The height of the burr was measured at 11 locations within a 60 mm range along the short side of the laminated sheet, and the average was calculated. The same operation was repeated 5 times, and the average was taken as the height of the burr.

[0150] [First resin film attached to the first adhesive layer]

[0151] A polyethylene terephthalate film (thickness 50 μm) with one surface treated with a release agent was prepared. An acrylic adhesive layer (first adhesive layer) was formed on the release agent surface.

[0152] [Second protective film]

[0153] A surface protection film was prepared in which an acrylic adhesive layer (thickness 6㎛) was formed on one side of a polyethylene terephthalate film (thickness 50㎛).

[0154] [Third Protective Film]

[0155] A surface protection film was prepared in which an acrylic adhesive layer (thickness 10㎛) was formed on one side of a polyethylene terephthalate film (thickness 125㎛).

[0156] [Front Edition]

[0157] As a front plate, a polyimide (PI) film with a hard coating layer formed on one surface was used. The thickness of the polyimide film was 50 μm, and the thickness of the hard coating layer was 10 μm.

[0158] [Circular Polarizer]

[0159] An alignment layer was formed on one surface of a triacetylcellulose (TAC) film. A composition having a polymerizable liquid crystal compound and a dichroic pigment was applied onto the alignment layer. The film was aligned and cured to obtain a polarizer. A UV-curable resin was applied onto the polarizer. The film was cured to form an overcoating layer. In this way, a linear polarizer was obtained. The thickness of the TAC film was 25 μm, the thickness of the polarizer was 2.5 μm, and the thickness of the overcoating layer was 1.0 μm. The polarizer was aligned such that the dichroic pigment was dispersed within the layer in which the polymerizable liquid crystal compound was cured.

[0160] As phase difference layers, a λ / 4 layer having a layer of a polymerizable liquid crystal compound cured and a positive C layer having a layer of a polymerizable liquid crystal compound cured were prepared. Both were laminated using a UV-curing adhesive to produce a phase difference film.

[0161] A linear polarizer and a phase difference film were laminated using an acrylic adhesive layer to obtain a circular polarizer. The phase difference film was laminated on the overcoating layer side of the linear polarizer. The angle formed by the absorption axis of the polarizer and the ground axis of the λ / 4 layer was 45°.

[0162] [Examples 1–4, Comparative Example 2]

[0163] A front plate and a circular polarizer were laminated together with an acrylic adhesive layer interposed therebetween. The thickness of the acrylic adhesive layer was 25 μm. The front plate was laminated to the TAC film side of the circular polarizer.

[0164] An acrylic adhesive layer (first adhesive layer) formed on a first resin film was laminated onto a circular polarizer. The thickness of this acrylic adhesive layer was 25 μm.

[0165] A third protective film was laminated onto a front plate via an adhesive layer provided by a third protective film. A second protective film was laminated onto a first resin film via an adhesive layer provided by a second protective film. In this way, a laminate was produced in which a third protective film, a front plate, a circular polarizer, a first adhesive layer, a first resin film, and a second protective film were laminated in this order. The first resin film was peelable from the first adhesive layer, the second protective film was peelable from the first resin film, and the third protective film was peelable from the front plate.

[0166] By irradiating the laminate with laser light under the conditions shown in Table 1, the laminate was cut into a predetermined shape (length 20 mm × width 100 mm) to obtain a laminated sheet. The second protective film was peeled off, and the height of the burr was measured at the outer periphery of the first resin film. The results are shown in Table 1.

[0167] [Examples 5 to 6]

[0168] An acrylic adhesive layer (first adhesive layer) formed on a first resin film was laminated onto a circular polarizer. The thickness of this acrylic adhesive layer was 25 μm. Additionally, the first adhesive layer was laminated on the phase difference film side of the circular polarizer.

[0169] A third protective film was laminated onto a circular polarizer via an adhesive layer provided by the third protective film. A second protective film was laminated onto a first resin film via an adhesive layer provided by the second protective film. In this way, a laminate was produced in which the third protective film, the circular polarizer, the first adhesive layer, the first resin film, and the second protective film were laminated in this order. The first resin film was peelable from the first adhesive layer, the second protective film was peelable from the first resin film, and the third protective film was peelable from the circular polarizer.

[0170] By irradiating the laminate with laser light under the conditions shown in Table 2, the laminate was cut into a predetermined shape (length 20 mm × width 100 mm) to obtain a laminated sheet. The second protective film was peeled off, and the height of the burr was measured at the outer periphery of the first resin film. The results are shown in Table 2.

[0171] [Comparative Examples 1, 3 ~ 4]

[0172] A front plate and a circular polarizer were laminated together with an acrylic adhesive layer interposed therebetween. The thickness of this acrylic adhesive layer was 25 μm. The front plate was laminated on the TAC film side of the circular polarizer. An acrylic adhesive layer (first adhesive layer) formed on a first resin film was laminated onto the circular polarizer. The thickness of this acrylic adhesive layer was 25 μm. A third protective film was laminated onto the front plate with an adhesive layer provided by a third protective film interposed therebetween. In this way, a laminate was produced in which the third protective film, the front plate, the circular polarizer, the first adhesive layer, and the first resin film were laminated in this order. The first resin film was peelable from the first adhesive layer, and the third protective film was peelable from the front plate.

[0173] By irradiating the laminate with laser light under the conditions shown in Table 1, the laminate was cut into a predetermined shape (length 20 mm × width 100 mm) to obtain a laminated sheet. The height of the burr was measured at the outer periphery of the first resin film. The results are shown in Table 1.

[0174] [Comparative Examples 5 ~ 6]

[0175] An acrylic adhesive layer (first adhesive layer) formed on a first resin film was laminated onto a circular polarizer. The thickness of this acrylic adhesive layer was 25 μm. Additionally, the first adhesive layer was laminated on the phase difference film side of the circular polarizer. A third protective film was laminated onto the circular polarizer by interposing the adhesive layer provided by the third protective film. In this way, a laminate was produced in which the third protective film, the circular polarizer, the first adhesive layer, and the first resin film were laminated in this order. The first resin film was peelable from the first adhesive layer, and the third protective film was peelable from the circular polarizer.

[0176] By irradiating the laminate with laser light under the conditions shown in Table 2, the laminate was cut into a predetermined shape (length 20 mm × width 100 mm) to obtain a laminated sheet. The height of the burr was measured at the outer periphery of the first resin film. The results are shown in Table 2.

[0177] [Table 1]

[0178]

[0179] [Table 2]

[0180]

[0181] In the table, one laser beam irradiation means that the laminate is cut by full cutting, and ten laser beam irradiations means that all layers across the lamination direction are completely cut by the tenth irradiation. In the table, "from the visible side" means, for example, irradiating the laser in a direction toward the second protective film (200) from the front plate (1) in FIG. 3, and "from the anti-visible side" means, for example, irradiating the laser in a direction toward the front plate (1) from the second protective film (200) in FIG. 3.

[0182] The laminated sheet of the present invention has a burr height of 6.0 μm or less at the outer periphery of the first protective film, and when peeling the surface protective film from the laminated sheet, the adsorption force is unlikely to decrease. Explanation of the symbols

[0183] 1: Front plate 2: Polarizing layer 3: Lamination layer 5: Third protective film 20: Linear polarizer 22: Phase difference film 40: Burr 41: Height of the burr 50: Third adhesive layer 51: Third resin film 101: First resin film 102: First adhesive layer 200: Second protective film 201: Second resin film 202: Second adhesive layer 300: Laminated sheet 301: Laminated sheet 302: Laminated sheet 303: Laminated sheet 400: Laminate

Claims

Claim 1 A laminated sheet comprising a polarizing layer, a first adhesive layer, and a first resin film, wherein the polarizing layer comprises a linear polarizer and a phase difference film, wherein the linear polarizer, the phase difference film, and the first adhesive layer are laminated in this order, wherein the phase difference film comprises, as a phase difference layer, at least a λ / 4 layer and a λ / 2 layer or a positive C layer, wherein the first resin film is peelable from the first adhesive layer, and the height of a burr at the outer periphery of the first resin film is 0.01 μm or more and 4.0 μm or less. Claim 2 A laminated sheet comprising a front plate, a polarizing layer, a first adhesive layer, and a first resin film, wherein the polarizing layer comprises a linear polarizing plate and a phase difference film, wherein the linear polarizing plate, the phase difference film, and the first adhesive layer are laminated in this order, wherein the phase difference film comprises, as a phase difference layer, at least a λ / 4 layer and a λ / 2 layer or a positive C layer, wherein the first resin film is peelable from the first adhesive layer, and the height of a burr at the outer periphery of the first resin film is 0.01 μm or more and 4.0 μm or less. Claim 3 A laminated sheet according to claim 1 or 2, wherein the height of the burr is 0.1 μm or more. Claim 4 In claim 1 or 2, the polarizing layer is a laminated sheet having a layer of a polymerizable liquid crystal compound that has been cured. Claim 5 A laminated sheet according to claim 1 or 2, wherein the first adhesive layer is also laminated and configured on the outer periphery of the polarizing layer. Claim 6 A laminated sheet according to claim 1 or 2, wherein the height of the burr at the outer periphery of the side opposite to the first adhesive layer side of the first resin film is 0.01 μm or more and 4.0 μm or less. Claim 7 delete Claim 8 A method for manufacturing a laminated sheet, comprising: a preparation process for preparing a laminated body, wherein a polarizing layer, a first adhesive layer, a first resin film, and a second protective film are laminated in this order, the polarizing layer comprises a linear polarizing plate and a phase difference film, the linear polarizing plate, the phase difference film, and the first adhesive layer are laminated in this order, the phase difference film comprises, as a phase difference layer, at least a λ / 4 layer and a λ / 2 layer or a positive C layer, the second protective film has a second adhesive layer on one side of the second resin film, the second protective film is laminated to the first resin film with the second adhesive layer interposed therebetween, the first resin film is peelable from the first adhesive layer, and the second protective film is peelable from the first resin film, and the method comprising a cutting process for obtaining a laminated sheet by cutting the laminated body into a predetermined shape by irradiating the laminated body from the polarizing layer side. Claim 9 A method for manufacturing a laminated sheet, comprising: a front plate, a polarizing layer, a first adhesive layer, a first resin film, and a second protective film, wherein the polarizing layer comprises a linear polarizing plate and a phase difference film, wherein the linear polarizing plate, the phase difference film, and the first adhesive layer are laminated in this order, wherein the phase difference film comprises, as a phase difference layer, at least a λ / 4 layer and a λ / 2 layer or a positive C layer, wherein the second protective film has a second adhesive layer on one side of the second resin film, wherein the second protective film is laminated to the first resin film with the second adhesive layer interposed therebetween, wherein the first resin film is peelable from the first adhesive layer, and the second protective film is peelable from the first resin film; and a cutting process for obtaining a laminated sheet by cutting the laminated sheet into a predetermined shape by irradiating the laminated sheet with laser light from the front plate side. Claim 10 A method for manufacturing a laminated sheet according to claim 8 or 9, wherein in the cutting process, the output of the laser light is 50W or more and 200W or less. Claim 11 A method for manufacturing a laminated sheet according to claim 8 or 9, wherein in the cutting process above, the laminated body is cut into a predetermined shape by full cutting. Claim 12 A method for manufacturing a laminated sheet according to claim 8 or 9, wherein the thickness of the second resin film is 40 μm or more. Claim 13 A method for manufacturing a laminated sheet according to claim 8 or 9, wherein the polarizing layer comprises a layer in which a polymerizable liquid crystal compound is cured. Claim 14 A method for manufacturing a laminated sheet according to claim 8 or 9, wherein the first adhesive layer is also laminated and configured on the outer periphery of the polarizing layer.

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