Method for processing laminated body, method for producing processed film, and laminated body processing device

Abstract

The present method is a method for processing a stack (10) having a plurality of optical films (12) using a tool (44), which comprises: a step A, in which a rotating tool (44) having a blade (44c) is moved relative to the stack (10) while in contact with the stack (10), thereby cutting or grinding the stack (10); and a step B, in which dry ice particles are caused to collide with the tool (44).

Description

Technical Field

[0001] The present invention relates to a method for processing a laminate, a method for producing a processed film, and an apparatus for processing a laminate. Background Art

[0002] Conventionally, there is known a technique for cutting a laminate of optical films such as polarizing plates using a rotating tool having a blade such as an end mill to ensure dimensional accuracy.

[0003] Prior Art Literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-018308 Summary of the invention

[0006] Problems to be solved by the invention

[0007] However, there are cases where chips of the optical film adhere to the blade of a tool such as an end mill. In particular, when the optical film includes a pressure-sensitive adhesive layer, this tendency becomes significant.

[0008] If chips adhere to the cutting edge of the tool, the working accuracy will be reduced, which is not preferable.

[0009] The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for processing a laminate, a method for producing a processed film, and a laminate processing apparatus capable of suppressing adhesion of chips to a blade of a rotating tool such as an end mill.

[0010] Means for solving problems

[0011] The method of the present invention for processing a stacked body having multiple optical films using a tool comprises: step A, in which a rotating tool having a blade is brought into contact with the stacked body and moves relative to the stacked body, thereby cutting or grinding the stacked body; and step B, in which dry ice particles are caused to collide with the tool in step A.

[0012] Here, the tool may include: a columnar portion having a blade portion and a shank portion and extending in the axial direction of the rotation; and the blade provided on an outer peripheral surface of the blade portion.

[0013] In addition, the chip discharge direction of the tool may be from the front end of the blade portion toward the shank portion, or from the shank portion toward the front end of the blade portion.

[0014] In the collision step, the dry ice particles are caused to collide with the blade portion in a direction opposite to the chip discharge direction and in a direction inclined with respect to the axis of the columnar portion.

[0015] In addition, the chip discharge direction of the tool may be from the front end of the blade portion toward the handle portion, and in the collision process, the dry ice particles are caused to collide with the blade portion in a direction from the handle portion toward the front end of the blade portion and in a direction inclined relative to the axis of the columnar portion.

[0016] In addition, the blade may be a right-handed right-handed helix, rotating clockwise when viewed from the handle, or the blade may be a left-handed left-handed helix, rotating counterclockwise when viewed from the handle.

[0017] Furthermore, in the step A, the outer peripheral surface of the blade portion may be brought into contact with the end surface of the stacked body after the axis is arranged in parallel with the thickness direction of the stacked body.

[0018] Furthermore, in the step A, the columnar portion may be relatively moved with respect to the stacked body along an end surface of the stacked body and in a direction orthogonal to a thickness direction of the stacked body.

[0019] Furthermore, in the step A, the direction of movement of the columnar portion may be a tangential direction with respect to the rotation direction of the tool.

[0020] In addition, in the B step, when observed from the axial direction of rotation of the tool, the angle θ formed by the line B connecting the axis Q of rotation of the tool and the point A where the blade of the tool separates from the end surface and the ejection direction EJ of the dry ice particles is measured as 0 to 180 degrees in the rotation direction of the tool with the line B as the starting point.

[0021] Furthermore, in the step A, the tool may be brought into contact with a convex portion, a concave portion, or a non-linear portion of the end surface when the laminate is viewed in the thickness direction.

[0022] Furthermore, in the step B, the dry ice particles may be ejected from a nozzle having an opening portion having a long hole shape, and the opening portion may be arranged at a position facing the blade portion.

[0023] Furthermore, in the step A, after arranging the axis in parallel with the thickness direction of the laminate,

[0024] The columnar portion is moved relative to the stacked body so that the columnar portion penetrates the stacked body.

[0025] Here, at least one of the optical films may have one or more adhesive layers.

[0026] Furthermore, the pressure-sensitive adhesive layer may have a thickness of 50 μm or more.

[0027] Furthermore, the total thickness of the adhesive layers may account for 30% or more of the thickness of the laminate.

[0028] The method for producing a processed film of the present invention includes the step of processing a laminated body formed by laminating a plurality of optical films by any of the above-mentioned methods for processing a laminated body using a tool.

[0029] The laminated body processing device of the present invention comprises:

[0030] A fixing mechanism that clamps a stacked body formed by stacking a plurality of optical films from both sides in a stacking direction to fix the stacked body;

[0031] A tool having a cutting edge;

[0032] a rotating portion that rotates the tool;

[0033] a moving portion that causes the rotating tool to move relative to the stacked body while in contact with the stacked body; and

[0034] The nozzle is configured to spray dry ice particles toward the blade.

[0035] Here, the nozzle may be configured to spray the dry ice particles toward the blade while moving relative to the stacked body together with the tool.

[0036] Furthermore, the tool may include: a columnar portion having a blade portion and a shank portion and extending in the axial direction of rotation; and the blade provided on an outer peripheral surface of the blade portion.

[0037] In addition, the chip discharge direction of the tool may be from the front end of the blade portion toward the shank portion, or from the shank portion toward the front end of the blade portion.

[0038] The nozzle is configured to cause the dry ice particles to collide with the blade portion in a direction opposite to the chip discharge direction and in a direction inclined with respect to the axis of the columnar portion.

[0039] Furthermore, the moving portion may be configured to bring the outer peripheral surface of the columnar portion into contact with the end surface of the stacked body after the rotating tool is arranged so that the axis of rotation is parallel to the thickness direction of the stacked body.

[0040] Furthermore, the moving unit may be configured to move the rotating tool relative to the stacked body along the end surface of the stacked body and in a direction orthogonal to the axis of rotation.

[0041] Furthermore, the moving unit may be configured to move the rotating tool in a direction tangential to the rotation direction of the tool.

[0042] In addition, the nozzle may be configured so that, when viewed from the axial direction of rotation of the tool, an angle θ formed by a line B connecting the axis Q of rotation of the tool and a point A where the blade of the tool separates from the end face and the axis of the nozzle is measured from the line B as the starting point in the rotation direction of the tool to be 0 to 180°.

[0043] Furthermore, the opening of the nozzle may have a long hole shape, and the opening may be configured to face the blade portion.

[0044] In addition, a dry ice particle supply unit may be connected to the nozzle.

[0045] Effects of the Invention

[0046] According to the present invention, there are provided a method for processing a laminate, a method for producing a processed film, and a laminate processing apparatus capable of suppressing adhesion of chips to a blade of a rotating tool such as an end mill. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 This is an end view of a laminated body according to one embodiment.

[0048] Figure 2 (a) to (e) are plan views of a laminated body according to one embodiment, respectively.

[0049] Figure 3 It is a schematic diagram of a laminated body processing apparatus according to one embodiment.

[0050] Figure 4 (a) and (b) are cross-sectional views perpendicular to the axis near the end mill, respectively showing a case where the moving direction of the end mill cuts up and a case where the end mill cuts down with respect to the rotation direction of the end mill.

[0051] Figure 5 (a) to (d) are schematic diagrams showing the spray direction EJ of dry ice particles when the blade portion of the end mill is right-edge right spiral, right-edge left spiral, left-edge right spiral, and left-edge left spiral, respectively.

[0052] Figure 6 This is a flowchart showing the structure of the dry ice pellet supply unit according to one embodiment.

[0053] Figure 7 (a) and (b) are schematic diagrams each showing a method of machining by an end mill.

[0054] Figure 8 Each of the diagrams is a schematic diagram showing one aspect of machining by an end mill.

[0055] Fig. 9 It is a schematic diagram showing a nozzle and an end mill 44 according to another embodiment.

[0056] Fig.10 It is a schematic diagram showing a nozzle and an end mill 44 according to another embodiment. DETAILED DESCRIPTION

[0057] One embodiment of the present invention will be described with reference to the accompanying drawings. Figure 1 The laminated body 10 to be processed will be described. Figure 1 , the Z direction is the thickness direction, and the X direction and the Y direction are directions perpendicular to the Z direction.

[0058] The laminated body 10 has a plurality of optical films 12. Each optical film 12 may be a single-layer film or a laminated film.

[0059] Examples of monolayer films are resin films. Examples of resins are cellulose resins (triacetyl cellulose, etc.), polyolefin resins (polypropylene resins, etc.), cyclic olefin resins (norbornene resins, etc.), acrylic resins (polymethyl methacrylate resins, etc.), polyester resins (polyethylene terephthalate resins, etc.), and polyimide resins (polyimide, polyamide-imide), etc. These monolayer films may be optical films such as protective films, substrate films, phase difference films, and window films.

[0060] A laminated film is a film having a plurality of layers. Examples of laminated films are polarizing films, circular polarizing plates, and touch sensors.

[0061] For example, a polarizing film includes at least a substrate and a polarizer.

[0062] The circular polarization plate includes, for example, a polarizing plate and a phase difference (1 / 4λ) film.

[0063] The touch sensor may include a transparent substrate, a sensing pattern layer, and sensing lines.

[0064] The laminated film may further include layers such as a pressure-sensitive adhesive layer, a bonding agent layer, a release film, and a protective film.

[0065] At least one laminate film typically has one or more adhesive layers. Adhesive refers to a layer that has adhesive properties and can be directly attached to other components at room temperature. Examples of adhesives are acrylic adhesives, silicone adhesives, and urethane adhesives. At the time of processing in the laminate processing device, the adhesive layer in the laminate 10 has adhesive properties.

[0066] The adhesive layer in the present invention may also include an adhesive layer that can be crosslinked and cured by heat, light, or the like.

[0067] The adhesive layer is an adhesive layer that has adhesiveness before curing and can be attached to other components at room temperature, and the adhesive strength is improved if cross-linked and cured by heat, light, etc. An example of the adhesive is an acrylic adhesive. It should be noted that at the time point of processing in the laminate processing device, the adhesive in the laminate 10 is before curing and has adhesiveness.

[0068] When the laminated body 10 includes an adhesive layer, the cutting chips of the adhesive layer and the like are easily attached to the blade, so that the effect of the present invention is remarkable.

[0069] The thickness of each optical film 12 is not particularly limited, and can be, for example, 20 μm to 500 μm, preferably 50 μm to 500 μm, and more preferably 50 μm to 200 μm.

[0070] When the laminated film includes an adhesive layer, the thickness of each adhesive layer may be 50 μm or more, or 100 μm or more, or 250 μm or less.

[0071] As described above, the laminate 10 includes a plurality of optical films 12 as described above, but the number of optical films 12 in the laminate 10 is not particularly limited as long as it is two or more, and is usually 5 or more, and may be 10 or more, or may be 50 or more. The optical films 12 of the laminate 10 are usually optical films 12 having the same laminate structure as each other, but optical films 12 having different laminate structures may be laminated.

[0072] The thickness of the laminate 10 can be, for example, 10 mm to 60 mm, and preferably 20 mm to 50 mm.

[0073] The total thickness of the adhesive layers may account for 30% or more, or 40% or more of the thickness of the laminate 10. A thicker total thickness of the adhesive layers makes it easier to adhere to the blade, and thus the effect is significant.

[0074] In order to prevent the optical film 12 from being damaged when the stack 10 is fixed between a pair of contact members 22 (described in detail later) of the stack processing device 100, the stack 10 may have a protective film 14 at one or both ends in the stacking direction in addition to the plurality of optical films 12.

[0075] An example of the protective film 14 is a resin film. Examples of the resin include polystyrene, polyethylene terephthalate, and the like in addition to the resins exemplified in the above-mentioned resin film.

[0076] The thickness of the protective film 14 can be, for example, 0.2 mm to 1.0 mm, preferably 0.3 mm to 0.8 mm, and more preferably 0.3 mm to 0.6 mm.

[0077] The outer shape (shape when viewed from the thickness direction) of the optical film 12 is not particularly limited. Figure 2 1 and 2 are diagrams showing various examples of the laminate 10 as viewed from the thickness direction (Z direction). Figure 2 As shown in (a) to (e) respectively, the outer shape of the laminate 10 can be a rectangle, a rounded rectangle, a shape with a concave portion PD, a shape with a convex portion PP, or a shape with a hole portion TH. Here, an example of a non-linear portion is a portion R with rounded corners.

[0078] The outer shapes of the optical films 12 in one laminated body 10 are usually substantially the same.

[0079] For example, by cutting out each optical film 12 from a film blank using a Thomson knife or the like, a plurality of optical films 12 having substantially the same outer shape can be obtained. Figure 2 As shown, the outer shapes are stacked in the same direction, and as Figure 1 As shown in FIG. 1 , the outer end surface EF of the laminate 10 is formed by the outer end surface of each optical film 12. Figure 2 When each optical film 12 has a hole portion TH as shown in (e), Figure 1 As shown by the middle dotted line, in addition to the outer end surface EF, an inner end surface EF is formed in the hole portion TH.

[0080] The size of each optical film 12 is not particularly limited, and for example, the length of one side of the film may be 100 mm or more.

[0081] Next, an example of a laminated body processing apparatus 100 for processing the laminated body 10 will be described. Figure 3 It is a side view of the laminated body processing apparatus 100 according to the present embodiment.

[0082] The stacked body processing apparatus 100 of the present embodiment includes a fixing mechanism 20 for fixing the stacked body 10 and a processing unit 40 .

[0083] The fixing mechanism 20 is configured to clamp and fix the stacked body 10 from both sides in the stacking direction. Specifically, the fixing mechanism 20 mainly includes a pair of contact members 22 , a fixing portion 61 , and a pressing portion 60 .

[0084] The pair of contact members 22 are plate-like members, each of which is arranged with its thickness direction along the Z direction (the pressing direction and the thickness direction of the laminate), and is arranged to be separated in the vertical direction so as to clamp the laminate 10 of the film from both sides in the thickness direction. Figure 3 In the figure, the X and Y directions are horizontal directions, and the Z direction is the vertical direction.

[0085] The size of the contact member 22 as viewed in the Z direction can be appropriately set within a range smaller than the outer shape of the surface (surface perpendicular to the thickness direction) of the laminated body 10 of the film to be fixed.

[0086] like Figure 3 As shown, when the stacked body 10 is clamped by a pair of contact members 22 before processing, the protrusion amount T of the outer end surface EF of the stacked body 10 from the end surface AP in the contact member 22 is preferably 0.8 mm to 1.5 mm. For example, the protrusion amount T before processing can be set to 1 mm. The protrusion amount T of the stacked body after processing can be set to 0.3 to 0.8 mm, and can be set to 0.5 mm.

[0087] The contact members 22 are preferably metal members, respectively. Examples of metals include aluminum, steel, stainless steel, alloy tool steel (eg, SKD11), and the like.

[0088] The lower contact member 22 is fixed to the fixing portion 61 via the connecting portion 24 , and the upper contact member 22 is fixed to the pressing portion 60 via the connecting portion 24 .

[0089] The pressing portion 60 is disposed above the fixing portion 61, and is configured to enable the upper contact member 22 to move in the up-down direction relative to the fixing portion 61. Therefore, the pressing portion 60 can press the upper contact member 22 toward the lower contact member 22. That is, the laminate 10 can be pressed from both sides in the thickness direction between the pair of contact members 22 to be fixed.

[0090] The specific structure of the pressing part 60 is not particularly limited, and for example, a known moving mechanism such as a screw jack or a hydraulic jack may be used. It may be a single-axis type or a multi-axis type.

[0091] The processing unit 40 includes an end mill (a tool having a blade) 44 , a rotating unit 42 for rotating the end mill, a moving unit 46 for moving the rotating end mill 44 relative to the stacked body, and a nozzle 420 for spraying dry ice particles.

[0092] The type of end mill 44 is not particularly limited, but is generally as follows Figure 3As shown, it has a columnar portion 44z having a blade portion 44b and a shank (shank) portion 44a and extending in the axial direction of rotation, and a blade 44c provided on the outer surface of the blade portion 44b. As the end mill 44, for example, a milling machine type end mill or the like can be preferably used. The length (Z-axis direction) of the blade portion 44b of the end mill 44 is preferably longer than the thickness of the stacked body 10. The blade portion 44b of the end mill has a blade 44c on the outer peripheral surface, but may also have a blade at the front end 44t.

[0093] The rotating unit 42 rotates the end mill 44 around its axis. In the present embodiment, the rotating unit 42 rotates the end mill 44 around an axis parallel to the thickness direction (Z direction) of the stacked body 10 .

[0094] The moving unit 46 moves the rotating end mill 44 in a direction perpendicular to the thickness direction of the stacked body 10 along the end face EF with the outer peripheral surface of the blade 44b of the end mill 44 in contact with the end face EF of the stacked body 10. Examples of the moving unit 46 are a three-axis (XYZ) drive device or a robot arm.

[0095] Here, the moving portion 46 may move the end mill 44 in the upward cutting direction or the downward cutting direction relative to the rotation of the end mill.

[0096] Figure 4 (a) and (b) are diagrams showing a state where the rotating end mill 44 is moved while in contact with the stacked body 10, and are viewed from the shank 44a side (from top to bottom). Figure 3 The blade portion 44b rotates in the direction of arrow D1, and the blade portion 44b moves along the end surface EF relative to the laminated body 10 in the direction of arrow D2.

[0097] Figure 4 (a) is a horizontal cross-sectional view showing the condition in which the end mill 44 is moving in the upward cutting direction. When the direction in which the blade 44c is moving when the blade 44c contacts the laminate 10 at point P is the same as the moving direction D2 of the end mill 44, the end mill 44 is said to be moving in the upward cutting direction. Figure 4 (b) is a horizontal cross-sectional view showing the condition where the end mill 44 is moving in the down-cutting direction. When the blade 44c is separated from the stack 10 at point P and the direction of advance of the blade 44c is opposite to the moving direction D2 of the end mill 44, the end mill 44 is said to be moving in the down-cutting direction.

[0098] From the viewpoint of suppressing the adhesion of chips to the end surface of the processed stacked body 10 , the moving portion 46 preferably moves the end mill 44 in the upcutting direction relative to the rotation of the end mill 44 .

[0099] like Figure 3 As shown, the dry ice pellet supply unit 300 described later is connected to the nozzle 420 so that the dry ice pellets can be sprayed.

[0100] The nozzle 420 is fixed to the moving part 46 by the connecting part 424. In addition, the axis of the nozzle 420, that is, the ejection direction EJ of the dry ice particles is toward the blade part 44b of the end mill 44. Therefore, even when the end mill 44 moves, the ejection direction EJ of the nozzle 420 is toward the blade part 44b of the end mill 44, so that the chips attached to the blade part 44b can be continuously removed during cutting. The opening of the nozzle 420 is circular. The diameter of the opening of the nozzle 420 can be set to 1 to 10 mm.

[0101] Next, refer to Figure 5 , the axial direction of the nozzle 420, that is, the ejection direction EJ of the dry ice particles from the nozzle 420 will be described in detail.

[0102] Specifically, the ejection direction EJ is preferably arranged in a direction opposite to the discharge direction of the machining chips of the end mill 44 and inclined with respect to the axis of the columnar portion 44 z of the end mill.

[0103] For example, Figure 5 As shown in (a), when the end mill is a right-edged right-helical cutter / that is, when viewed from the shank 44a side, the cutting edge 44c is formed in a spiral shape clockwise from the shank 44a toward the front end of the cutting edge portion 44b and the back cutting edge 44d is arranged on the front end side of the cutting edge portion 44b than the cutting edge 44c, the end mill 44 rotates clockwise when viewed from the shank 44a, and the chip discharge direction is from the front end of the cutting edge portion 44b toward the shank 44a.

[0104] like Figure 5 As shown in (b), when the end mill 44 is a right-edged left-helix, that is, when viewed from the shank 44a side, the cutting edge 44c is formed in a spiral shape counterclockwise from the shank 44a toward the front end of the cutting edge portion 44b, and the back cutting edge 44d is arranged on the shank 44a side than the cutting edge 44c, the end mill 44 rotates clockwise when viewed from the shank 44a, and the chip discharge direction is from the shank 44a toward the front end of the cutting edge portion 44b.

[0105] like Figure 5 As shown in (c), when the end mill is a left-edged right-helical cutter, that is, when viewed from the shank 44a side, the cutting edge 44c is formed in a spiral shape clockwise from the shank 44a toward the front end of the cutting edge 44b, and the back cutting edge 44d is arranged on the shank 44a side than the cutting edge 44c, the end mill 44 rotates counterclockwise when viewed from the shank 44a, and the chip discharge direction is from the shank 44a toward the front end of the cutting edge 44b.

[0106] like Figure 5As shown in (d), the end mill 44 is a left-edged left-helix, that is, when viewed from the shank 44a side, the cutting edge 44c is formed in a spiral shape counterclockwise from the shank 44a toward the front end of the cutting edge portion 44b, and the back cutting edge 44d is arranged on the front end side of the cutting edge portion 44b than the cutting edge 44c. When viewed from the shank 44a, the end mill 44 rotates counterclockwise, and the chip discharge direction is from the front end of the cutting edge portion 44b toward the shank 44a.

[0107] Therefore, the spray direction EJ of the dry ice particles is configured in a manner that is opposite to the discharge direction of the machining chips of the end mill 44 and is inclined with respect to the axis of the columnar portion 44z of the end mill as follows. Figure 5 As in (a) and (d), when the chip discharge direction is from the front end of the blade portion 44b toward the shank portion 44a, the ejection direction EJ is from the shank portion 44a toward the front end of the blade portion 44b and is inclined relative to the axis of the columnar portion 44z. Figure 5 As in (b) and (c), when the chip discharge direction is from the shank 44a toward the front end of the blade portion 44b, the ejection direction EJ becomes a direction from the front end of the blade portion 44b toward the shank 44a and inclined relative to the axis of the columnar portion 44z.

[0108] Based on the ease of chip removal during machining, Figure 5 As in (a) or (d), the discharge direction of the machining chips is preferably from the front end of the blade portion 44b toward the shank portion 44a.

[0109] exist Figure 5 In the embodiment, the angle (acute angle) α formed by the axis of the columnar portion 44z and the ejection direction EJ can be set to 5 to 85°, and preferably 10 to 65°.

[0110] Next, refer to Figure 4 The ejection direction EJ when viewed from the axial direction of the columnar portion 44z of the end mill 44 will be described.

[0111] When viewed from the axial direction of the rotation of the tool, the ejection direction EJ of the dry ice particles, that is, the direction of the axis of the nozzle 420 only needs to be toward the blade portion 44 b , and the ejection direction EJ preferably passes through the rotation axis Q.

[0112] The spray direction EJ of the dry ice particles is preferably such that an angle θ formed by a line B connecting the rotation axis Q of the end mill 44 and a point A where the blade 44c of the end mill 44 separates from the end surface EF and the spray direction EJ of the ice particles is 0 to 180 degrees measured in the rotation direction of the end mill 44 with the line B as a starting point. This is the same for both the upcut and the downcut.

[0113] exist Figure 4In the case of the upcut of (a), from the viewpoint of preventing machining chips from adhering to the end surface of the stack, the angle θ is preferably 45 to 135°. Figure 4 In the case of the undercut of (b), from the same viewpoint, the angle θ is preferably 90 to 180°. Examples of the machining scraps include film scraps, adhesive scraps, and the like.

[0114] Next, the dry ice pellet supply unit 300 will be described. Figure 6 As shown, the dry ice pellet supply unit 300 includes a liquid carbon dioxide source 310 , a conveying gas source 330 , a pipeline L1 connecting the liquid carbon dioxide source 310 and the nozzle 420 , and a pipeline L2 connecting the conveying gas source 330 and the nozzle 420 .

[0115] The pipeline L1 is provided with a valve 340 and an orifice 350 , and the pipeline L2 is provided with a valve 360 ​​.

[0116] The valve 340 is opened, and the liquid of the liquid carbon dioxide source 310 is adiabatically expanded by the throttle hole 350 to generate dry ice particles (dry ice snow), and the dry ice particles are transported to the nozzle 420. The valve 360 ​​is opened, and gas is supplied from the transport gas source 330 to the nozzle 420, and the dry ice particles are blown out from the nozzle 420 by the gas, so that the dry ice particles can be ejected toward the blade portion 44b of the end mill 44 and collide with the blade portion 44b.

[0117] The average particle diameter of the collided dry ice particles is not particularly limited, but is preferably 100 μm or more from the viewpoint of efficiently removing the adhesive chips in the processing chips. In addition, from the viewpoint of suppressing the adhesive layer from being damaged by the collision of the dry ice, it is preferably 1000 μm or less. The average particle diameter of the dry ice particles can be measured by a laser Doppler flow meter.

[0118] The speed of the colliding dry ice particles can be set to 5 m / sec to 100 m / sec.

[0119] The transport gas for dry ice is not particularly limited, and may be, for example, nitrogen, air, or carbon dioxide gas.

[0120] The particle diameter of the dry ice particles can be adjusted by the distance from adiabatic expansion at the orifice 350 to being blown out from the nozzle 420 (adiabatic expansion distance) and the distance between the nozzle 420 and the supply target of the dry ice particles (injection distance).

[0121] The distance (injection distance) between the nozzle 420 and the blade portion 44b is preferably set to less than 20 mm. In addition, the adiabatic expansion distance can be set to, for example, 10 to 500 mm.

[0122] (End surface processing method and method for producing end surface processing film)

[0123] Next, an end surface processing method and an end surface processing film manufacturing method according to an embodiment of the present invention will be described.

[0124] First, the above-mentioned laminated body 10 is prepared. The end surface EF of the laminated body is a processing target in this embodiment.

[0125] Then, if Figure 3 As shown, the stacked body 10 is sandwiched between a pair of contact members 22 , and one contact member 22 is pressed toward the other contact member 22 by the pressing portion 60 , thereby fixing the stacked body 10 .

[0126] Next, in a state where the laminate 10 is fixed, the outer peripheral surface of the blade portion 44b of the end mill 44 rotating around an axis parallel to the thickness direction of the laminate 10 is brought into contact with the end face EF of the laminate 10, and the end mill 44 is moved along the end face EF in a direction orthogonal to the thickness direction, such as the long side or short side direction, so as to process each end face EF (process A). As a specific example of processing, cutting can be cited. Thus, the planar shape (size, right angle, etc.) of each optical film 12 constituting the laminate 10 can be made into a predetermined shape with high precision.

[0127] Here, 75% or more of the entire end surface EF of the laminate 10 may be processed, and 90% or more, 95% or more, 99% or more, or 100% of the entire end surface EF may be processed.

[0128] Simultaneously with the cutting process, dry ice pellets are ejected from the nozzle 420 and collide with the blade 44b (step B). Here, it is preferred that dry ice pellets are continuously ejected toward the blade 44b of the end mill 44 while the end mill 44 is relatively moving along the end surface EF of the stacked body 10 for grinding.

[0129] After the cutting is completed, the pressing by the pressing part 60 is released and the laminate 10 is taken out from between the pair of contact members 22, thereby obtaining a laminate 10 with a highly accurate end surface processed. If necessary, each optical film 12 is separated from the laminate 10 to obtain a separated optical film 12.

[0130] According to this embodiment, during cutting, the dry ice pellets collide with the blade 44b of the end mill 44, so that the machining chips generated during grinding can be removed from the blade 44b of the end mill 44. This can prevent the machining accuracy from being reduced due to the chips attached to the blade.

[0131] In particular, when the laminate 10 has an adhesive layer, adhesive chips are likely to adhere to the blade portion. However, according to the present embodiment, adhesive chips can be removed from the blade portion during cutting, so the effect is remarkable.

[0132] The present invention is not limited to the above-described embodiment, and various modifications are possible.

[0133] For example, the shape of the film and the laminate 10 is not limited to Figure 2 The shape of the laminate 10 can be any shape. For example, the outer shape can also be an ellipse (including an oblong) or a circle. It should be noted that the cutting process of process A is preferably carried out by making the end mill contact with the convex part, concave part or non-linear part of the end face of the laminate 10 when the laminate is observed from the thickness direction.

[0134] In the above embodiment, the processing target in step A is the outer end surface EF of the laminate 10 , but it may not be the end surface EF but may be an inner end surface such as the inside of a hole.

[0135] For example, you can also Figure 7 As in (a), in the A step, the axis of the end mill 44 is arranged parallel to the thickness direction of the laminate 10, and the columnar portion 44z is relatively moved relative to the laminate 10 in such a manner that the columnar portion 44z forms a recessed portion on the upper surface 10S in the thickness direction of the laminate 10, thereby opening a hole in the laminate 10. At this time, in the A step, the columnar portion 44z can be relatively moved relative to the laminate 10 in such a manner that the columnar portion 44z penetrates in the thickness direction of the laminate 10. Thus, a through hole portion can be provided in the laminate 10, and a through hole can be opened in each optical film 12.

[0136] In addition, you can also Figure 7 As shown in (b), in the step A, after the hole is penetrated, the end mill 44 is rotated in a spiral shape to increase the diameter of the hole TH.

[0137] Moreover, it is also possible to Figure 8 As shown in FIG. 1 , in step A, the axis of the end mill 44 is arranged parallel to the thickness direction of the stacked body 10, and the end mill 44 is moved in a helix shape from the upper surface 10S toward the lower surface 10B of the stacked body 10. As a result, the columnar portion 44z increases the diameter of the recessed portion and the depth from the upper surface 10S in the thickness direction of the stacked body 10, thereby forming a large through hole.

[0138] Furthermore, when performing each of the above-mentioned A steps, by performing the above-mentioned B step, it is also possible to suppress the adhesion of chips to the blade portion 44 b of the end mill.

[0139] Furthermore, the shape of the opening of the nozzle 420 is not limited to a circle. Fig. 9As shown in FIG. 1 , the shape of the opening 42a of the nozzle 420 is set to a long hole shape. In this case, it is preferably configured so that the axial direction of the long hole is parallel to the axis of the columnar portion 44z, that is, the opening 42a faces the blade portion 44b. The axial length of the long hole can be appropriately set according to the length of the blade portion 44b.

[0140] In the above embodiment, the nozzle 420 is fixed to the moving part 46 in order to blow dry ice particles to the tool that moves during cutting, but it may be fixed to the rotating part 42 .

[0141] like Fig.10 As shown, it is possible to implement even if there is a moving portion 46' for the nozzle 420 which is different from the moving portion 46 of the end mill 44. In this case, when viewed from a direction perpendicular to the axis of the columnar portion 44z of the end mill 44, the ejection direction EJ of the nozzle 420 is set to a direction orthogonal to the columnar portion 44z of the end mill, and the nozzle 420 is made to perform a reciprocating scanning motion along the axial direction of the columnar portion of the end mill 44.

[0142] The forms of the processing portion 40 and the pressing portion 60 are certainly not limited to the above-mentioned forms. For example, in the above-mentioned embodiment, an end mill 44 is used as a tool, but a tool other than an end mill, such as a planer, may also be used. In addition, a surface grinding tool having a cutting blade provided on one surface of a rotating circular plate may also be used. In addition, a tool having abrasive grains may also be used as a blade, in which case a grinding process may be performed instead of a cutting process. In the above-mentioned case, during cutting and grinding, the dry ice particles are made to collide with the blade of the tool, thereby suppressing a reduction in cutting accuracy and a reduction in grinding efficiency caused by the adhesion of processing chips.

[0143] In the above embodiment, the fixing portion 61 is located at the bottom and the pressing portion 60 is located at the top, but the configuration may be reversed, or the fixing portion may be omitted and a pair of pressing portions 60 may be disposed at the top and the bottom, respectively.

[0144] In the above embodiment, the end mill 44 is moved relative to the stacked body 10 by the moving unit 46 , but the end mill and the stacked body 10 may be moved relative to each other. For example, the end mill 44 may be fixed and the stacked body 10 may be moved relative to the end mill by the moving unit.

[0145] The laminated body processing apparatus 100 only needs to include one processing unit 40, but from the viewpoint of rapidly performing processing, it may include two or more processing units 40. In this case, the nozzle 420 may be provided in each processing unit.

[0146] Example

[0147] (Preparation of Film and Laminate)

[0148] A raw film having a layer structure of separator (PET) / adhesive layer / protective film (TAC) / polarizer (PVA) / protective film (TAC) / optically functional film layer (laminate including adhesive layer) / adhesive layer / separator (PET) was prepared.

[0149] The protective film and the polarizing plate were bonded together with a water-based adhesive. The thickness of the raw film was 367 μm.

[0150] The blank film was punched out into a rectangular shape having a size of 155.6×75.6 mm using a Thomson knife to obtain an optical film 12 . Next, 50 optical films 12 were stacked to obtain a laminated body 10 .

[0151] The ratio of the total thickness of the adhesive layers to the thickness of the laminate 10 was 47%.

[0152] (Example 1)

[0153] Prepare Figure 1 The stacked body processing device 100 shown in FIG. Figure 5 As shown in (a), it is a right-hand helix with a right blade, and the chip discharge direction is from the front end of the blade toward the shank, so that the end mill rotates clockwise.

[0154] The blade 44b of the end mill 44 is arranged so that the axis of the columnar portion 44z is parallel to the thickness direction of the stack 10, and while the outer peripheral surface of the columnar portion 44z is in contact with the end face of the stack 10, the columnar portion 44z is moved relative to the stack 10 along the end face EF of the stack 10 and in a direction orthogonal to the thickness direction of the stack 10, thereby cutting the end face (cutting depth 0.4mm). The length after cutting is set to the length of the long side, that is, 155.6mm. Here, as Figure 4 As shown in (a), the moving direction of the end mill is set to the cutting direction relative to the rotation direction of the end mill.

[0155] While the stacked body 10 is being cut by the end mill, dry ice particles transported by air are ejected from the nozzle 420 and collide with the blade 44b of the end mill. Figure 5 As shown in (a), the spray direction EJ of the dry ice particles collides with the blade portion 44b in a direction opposite to the chip discharge direction and in a direction inclined with respect to the axis of the columnar portion 44z. The angle α is set to 60°.

[0156] in addition, Figure 4 The θ in is set to about 70°.

[0157] After cutting, the adhesion state of the adhesive chips on the blade portion of the end mill and the adhesion state of the adhesive chips on the end surface of the laminate were visually checked.

[0158] (Example 2)

[0159] In addition to Figure 4 The same as in Example 1 is achieved except that the moving direction of the end mill is set to the direction of cutting downward relative to the rotation direction of the end mill as shown in (b).

[0160] (Comparative Example 1)

[0161] The process is the same as that of the first embodiment except that the air not containing dry ice particles is ejected from the nozzle 420 .

[0162] (Comparative Example 2)

[0163] The process is the same as that of the first embodiment except that neither gas nor particles are ejected from the nozzle 420 .

[0164] The results are shown in Table 1. ⊙ indicates that there is no adhesion of the adhesive, ○ indicates that a small amount of the adhesive is adhered, and × indicates that a large amount of the adhesive is adhered.

[0165] [Table 1]

[0166]

[0167] Description of reference numerals:

[0168] 10…laminated body; 12…optical film; 20…fixing mechanism; 42…rotating portion; 42a…opening portion; 44a…handle portion (tool handle); 44b…blade portion; 44c…blade; 44t…front end; 44z…columnar portion; 44…end mill (tool); 46, 46'…moving portion; 100…laminated body processing device; 300…dry ice particle supply portion; 420…nozzle; AP…end face; EF…end face; PD…concave portion; PP…convex portion; R…non-linear portion; Q…axis.

Claims

1. A method for processing a laminated body, which is a method for processing a laminated body having a plurality of optical films using a tool, wherein: The method for processing a laminate comprises: A step of cutting or grinding the laminated body by causing a rotating tool having a blade to move relative to the laminated body while in contact with the laminated body; and Step B, in step A, causing dry ice particles to collide with the tool, The tool comprises: a columnar portion having a blade portion and a shank portion and extending in the axial direction of the rotation; and the blade provided on the outer peripheral surface of the blade portion. In the step A, the outer peripheral surface of the blade portion is brought into contact with the end surface of the stacked body after the axis is arranged parallel to the thickness direction of the stacked body. In the step A, the columnar portion is relatively moved with respect to the stacked body along the end surface of the stacked body and in a direction perpendicular to the thickness direction of the stacked body. In the step A, the direction of movement of the columnar portion is a direction tangential to the direction of rotation of the tool. In the step B, when viewed from the axial direction of rotation of the tool, an angle (θ) formed by a line (B) connecting the axis (Q) of rotation of the tool and a point (A) at which the blade of the tool separates from the end surface and the ejection direction (EJ) of the dry ice particles is measured in a range of 45 to 135 degrees in the rotation direction of the tool with the line (B) as a starting point.

2. The method according to claim 1, wherein: The chip discharge direction of the tool is from the front end of the blade portion toward the shank portion or from the shank portion toward the front end of the blade portion. In the collision step, the dry ice particles are caused to collide with the blade portion in a direction opposite to the chip discharge direction and in a direction inclined with respect to the axis of the columnar portion.

3. The method according to claim 1, wherein: The chip discharge direction of the tool is from the front end of the blade portion toward the handle portion. In the collision step, the dry ice particles are caused to collide with the blade portion in a direction from the handle portion toward the front end of the blade portion and in a direction inclined with respect to the axis of the columnar portion.

4. The method according to any one of claims 1 to 3, wherein: The blade is a right-handed right-handed helix, rotating clockwise when viewed from the handle, or the blade is a left-handed left-handed helix, rotating counterclockwise when viewed from the handle.

5. The method according to any one of claims 1 to 3, wherein: In the step A, the tool is brought into contact with a convex portion, a concave portion, or a non-linear portion of the end surface when the laminate is viewed in the thickness direction.

6. The method according to any one of claims 1 to 3, wherein: In the step B, dry ice particles are ejected from a nozzle having an opening portion having a long hole shape, and the opening portion is arranged at a position facing the blade portion.

7. The method according to any one of claims 1 to 3, wherein: At least one of the optical films has one or more adhesive layers.

8. The method according to claim 7, wherein: The adhesive layer has a thickness of 50 μm or more.

9. The method according to claim 7, wherein: The total thickness of the adhesive layers accounts for 30% or more of the thickness of the laminate.

10. A method for producing a processed film, wherein: The method for producing the processed film includes the step of processing a laminated body formed by laminating a plurality of optical films by the method according to any one of claims 1 to 9.

11. A laminate processing device, wherein: The laminated body processing device comprises: A fixing mechanism that clamps a stacked body formed by stacking a plurality of optical films from both sides in a stacking direction to fix the stacked body; A tool having a cutting edge; a rotating portion that rotates the tool; a moving portion that causes the rotating tool to move relative to the stacked body while in contact with the stacked body; and a nozzle configured to spray dry ice particles toward the blade, The tool comprises: a columnar portion having a blade portion and a handle portion and extending along the axial direction of the rotation; and the blade provided on the outer peripheral surface of the blade portion. The moving part is configured such that the outer peripheral surface of the columnar part contacts the end surface of the stacked body after the rotating tool is arranged in a manner such that the axis of rotation is parallel to the thickness direction of the stacked body. The moving part is configured to move the rotating tool relative to the stacked body along the end surface of the stacked body and in a direction orthogonal to the axis of rotation. The moving part is configured to move the rotating tool in a direction tangential to the rotation direction of the tool, The nozzle is configured such that, when viewed from the axial direction of rotation of the tool, an angle (θ) formed by a line (B) connecting the axis of rotation of the tool (Q) and the point (A) at which the blade of the tool separates from the end surface and the axis of the nozzle is measured in the rotation direction of the tool with the line (B) as the starting point to be 45 to 135 degrees.

12. The device according to claim 11, wherein The nozzle is configured to spray the dry ice particles toward the blade while moving relatively to the stacked body together with the tool.

13. The device according to claim 11 or 12, wherein: The chip discharge direction of the tool is from the front end of the blade portion toward the shank portion or from the shank portion toward the front end of the blade portion. The nozzle is configured to cause the dry ice particles to collide with the blade portion in a direction opposite to the chip discharge direction and in a direction inclined with respect to the axis of the columnar portion.

14. The device according to claim 11 or 12, wherein: The opening of the nozzle has a long hole shape, and the opening is configured to face the blade portion.

15. The device according to claim 11 or 12, wherein: The nozzle is connected to a dry ice particle supply unit.

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