Method for manufacturing synthetic resin film

Abstract

The present invention relates to a method for manufacturing a synthetic resin film, which manufactures a synthetic resin film with a desired shape and size by cutting the sides of a laminate formed by stacking multiple thin sheet-like synthetic resin film materials using a cutting machine. The method is characterized by comprising: a laminate forming step S1, forming a laminate; and a cutting step S2, using multiple end mills to cut the sides of the laminate, thereby processing the synthetic resin film material into the desired shape and size. Each end mill has a cutting area assigned to it in the circumferential direction of the sides of the laminate. In the cutting step S2, the multiple end mills cut along virtual cutting lines set on the laminate to the cutting areas assigned to each end mill. According to the method for manufacturing a synthetic resin film of the present invention, even when the laminate is fixed by a method where the end mills cannot continuously circumferentially wrap around the sides of the laminate, the sides of the laminate can be cut around the entire circumference.

Description

Technical Field

[0001] This invention relates to a method for manufacturing synthetic resin films. Background Technology

[0002] Previously, synthetic resin films were widely used. For example, optical films, as a type of synthetic resin film, are used in a wide range of applications, such as anti-reflective coatings for LCD panels and protection for LCD panels, and the demand for them continues to grow. In the following specification, optical films will be used as an example of synthetic resin films.

[0003] Especially in industries such as automotive, optical films are essential for preventing reflections and glass shattering in LCD panels used in car navigation systems. Because in-vehicle equipment needs to operate in harsh environments, not only durability but also aesthetics are important considerations.

[0004] Conventionally, methods for manufacturing such optical films include cutting a thin sheet of optical film material (the material for the optical film) using equipment such as a stamping machine, and then manufacturing an optical film with a desired shape and size. For example, as an optical film material, a coating is applied to one side (surface) of a substrate made of a material such as PET (Polyethylene terephthalate) as a surface treatment, and a protective film layer is formed on the surface of the coating. Alternatively, an adhesive layer can be formed on the other side (back side) of the substrate, and an optical film material with a release liner attached to the adhesive layer can also be used.

[0005] When shearing optical film materials with this structure using a stamping machine, the sheared surface may sometimes be conical, leading to cracks or adhesive defects. Adhesive defects occur when the adhesive layer is stretched during shearing, causing the adhesive to peel off. If adhesive defects occur, not only will the bonding process in that area not be normal, but the defective area will also exhibit color differences compared to other areas, resulting in a decrease in the quality of the optical film.

[0006] To address this issue, in recent years, as a method different from shearing, a method has been proposed to manufacture an optical film with a desired shape and size from the laminated body after cutting the sides of the laminated body (for example, see Patent Document 1).

[0007] The optical film manufacturing method described in Patent Document 1 is a method of manufacturing an optical film with a desired shape and size by using an end mill to cut the side of the laminate.

[0008] Figure 13This diagram illustrates the cutting process in the manufacturing method of the optical film described in Patent Document 1. In the manufacturing method of the optical film described in Patent Document 1, as follows... Figure 13 As shown, an end mill 910 is continuously moved along the side of the laminate 920 to perform full-circumference cutting on the side of the laminate 920. Specifically, as... Figure 13 As shown in (a), cutting is performed starting from corner C1 of the laminate 920, according to... Figure 13 (b)~ Figure 13 (e) The end mill 910 is moved along the side of the stack 920 while cutting is performed in the sequence of steps (e). This cutting process is used to manufacture... Figure 13 The optical film is of the shape shown in (e). Furthermore, although in Figure 13 Not shown, but usually when machining the laminate 920, the side surface of the laminate 920 is machined while the laminate 920 is held and fixed by the upper pad (referred to as the first pad) and the lower pad (referred to as the second pad).

[0009] [Preliminary Technology Documents]

[0010] [Patent Document 1] Japanese Patent Application Publication No. 2020-1160

[0011] As described above, the method for manufacturing the optical film described in Patent Document 1 involves cutting each side of the laminate 920 by continuously rotating the end mill 910 around the side of the laminate 920 once in the circumferential direction while the laminate 920 is held and fixed by the first and second pads.

[0012] However, for different laminates that are to be processed, there is a problem that it is difficult to perform cutting processing using the optical film manufacturing method described in Patent Document 1. For example, this problem exists when the laminate to be processed is a long strip-shaped laminate that is long in one direction (e.g., laterally). Examples of long strip-shaped laminates that are long laterally are optical films used in automotive in-vehicle equipment. Nowadays, it is increasingly common to have information displays that display various information (speed display, distance display, alarm display, etc.) and central control information displays integrated with car navigation systems within the driver's field of vision. The surface of such displays is generally covered with long strip optical films that have various functions such as anti-reflection, impact resistance, and fingerprint resistance.

[0013] Optical films come in various thicknesses, ranging from approximately 200 μm to 350 μm. Their transverse (long side) and longitudinal (short side) lengths also vary, with recent demands for elongated optical films measuring 400 mm to 700 mm transversely and 100 mm to 200 mm longitudinally.

[0014] When manufacturing such a strip-shaped optical film using the optical film manufacturing method described in Patent Document 1, since a single end mill 910 continuously cuts around the side of a strip-shaped laminate made of multiple strip-shaped optical film materials in the circumferential direction, the cutting efficiency is naturally low. Furthermore, depending on the method of fixing the laminate (for example, depending on the shape, size, and arrangement of the first pad pressing body used to press the first pad), the end mill 910 sometimes cannot continuously cut around the side of the laminate 920 in the circumferential direction.

[0015] Figure 14 This is an example diagram used to illustrate that an end mill cannot continuously circle the side of a laminate in the circumferential direction. Figure 14 middle, Figure 14 (a) is a floor plan. Figure 14 (b) is viewed along the direction of arrow Yb1. Figure 14 (a) Side view. For example... Figure 14 As shown, the laminate 950 has a strip-shaped structure whose length along the x-axis (sometimes referred to as the transverse length) is longer than its length along the y-axis (sometimes referred to as the longitudinal length), and it is held between a first pad 960 and a second pad 970. Here, it is assumed that the second pad 970 is mounted on a base 980 of a cutting machine.

[0016] exist Figure 14 In the diagram, the dashed line L1 drawn on the laminate 950 represents a cutting line (hereinafter referred to as cutting line L1), which indicates that each side of the laminate 950 (first side 951, second side 952, third side 953, and fourth side 954) is machined to the cutting line L1. Therefore, the first pad 960 and the second pad 970 press the laminate 950 within the range of the cutting line L1.

[0017] The first pad 960 is pressed by an elongated first pad pressing body 990, which is longer along the x-axis than the first pad 960. On the other hand, since the second pad 970 is placed on the base 980 of the cutting machine, the first pad 960 is pressed by the first pad pressing body 990, and the second pad 970 bears the pressing force of the first pad pressing body 990 between itself and the base 980, so that the base 980 functions as the second pad pressing body.

[0018] Since the laminate 950 is a long strip-shaped laminate with a relatively long transverse length, it is crucial to apply uniform pressing pressure to the laminate 950 using the first pad 960 across approximately the entire transverse direction. Otherwise, it will be impossible to maintain the laminate 950, which consists of multiple strip-shaped optical film materials, as a single unit in the longitudinal direction (transverse direction), resulting in unstable cutting by the cutting edge 911 of the end mill 910 and the inability to achieve high-quality cutting.

[0019] To avoid such problems, the first pad pressing body 990 for pressing the first pad 960 is configured as an elongated strip longer than the lateral length of the laminate 950, and is configured to extend further outward than one end (third side 953) and the other end (fourth side 954) of the laminate 950 along the x-axis (see reference). Figure 14 (b) In this way, the first pad pressing body 990 can apply a uniform pressing force to the entire transverse direction (along the x-axis) of the first pad 960.

[0020] However, if the first pad pressing body 990 is configured to extend further outward than one end (third side 953) and the other end (fourth side 954) of the laminate 950 along the x-axis, the end mill 910 cannot continuously circle the side of the laminate 950 circumferentially, thus preventing machining of all sides (first side 951 to fourth side 954) of the laminate 950. The reason is explained below.

[0021] End mill 910, for example Figure 14 Starting from position P1, the end mill 910 moves along the direction of arrow x1 along one side (first side 951) of the laminate 950 in the longitudinal direction while performing cutting through the cutting edge 911. In this case, when the end mill 910 cuts from position P1 to position P2, due to the presence of the first pad pressing body 990, it is impossible to cut the third side 953 (refer to) of the laminate 950. Figure 14 (b)) is to be cut.

[0022] In this case, such as Figure 14 As shown by the dashed line in (b), the end mill 910 is temporarily raised so that the tip e1 of the cutting edge 911 is positioned above the upper surface 990a of the first pad pressing body 990. After moving laterally across the first pad pressing body 990 in the direction of arrow y1 and then descending again, the other side (second side 952) of the long side of the stack 950 can be machined by moving the other side (second side 952) of the stack 950 from position P3 to position P4 in the direction of arrow x2. However, in this case, the end mill 910 is also unable to machine the fourth side 954 (refer to) of the stack 950 due to the presence of the first pad pressing body 990. Figure 14 (b) Perform cutting.

[0023] As described above, although the first side 951 and the second side 952 along the length direction of the x-axis of the laminate 950 can be cut by the end mill 910, when the first pad pressing body 990 is set to extend further outward than one end (third side 953) and the other end (fourth side 954) of the laminate 950 along the x-axis, the third side 953 and the fourth side 954 along the y-axis of the laminate 950 cannot be cut due to the presence of the first pad pressing body 990.

[0024] Therefore, as in the optical film manufacturing method described in Patent Document 1, when an end mill continuously cuts around the side of the laminate in the circumferential direction to process each side of the laminate, and then passes through the... Figure 14 When the stacked body is fixed by the fixing method shown, that is, when the end mill 910 cannot continuously rotate around the side of the stacked body 950 in the circumferential direction, it is impossible to perform cutting machining on the side of the stacked body 950 in the entire circumference.

[0025] It should be noted that the above example describes the case of cutting a long strip-shaped laminate, but it is not limited to the case of cutting a long strip-shaped laminate. As long as the laminate is fixed by a method that cannot continuously wrap around the side of the laminate 950 in the circumferential direction using an end mill 910, the same problem as the manufacturing method described in Patent Document 1 will occur.

[0026] The present invention was made in view of the above circumstances, and its object is to provide a method for manufacturing a synthetic resin film that enables the side surface of the laminate to be cut around the entire circumference even when the end mill is fixed in a way that does not allow the laminate to be continuously circumferentially around the side surface of the laminate. Summary of the Invention

[0027] [1] The method for manufacturing a synthetic resin film according to the present invention manufactures a synthetic resin film having a desired shape and size by cutting the side surface of a laminate formed by stacking multiple thin sheet-like synthetic resin film materials using a cutting machine, characterized in that it comprises:

[0028] The laminate formation process forms the laminate; and

[0029] The cutting process utilizes multiple end mills to cut and machine the sides of the laminate, thereby processing the synthetic resin film material into the desired shape and size.

[0030] In this process, the plurality of end mills are assigned a cutting area on the circumferential direction of the side of the stacked body. In the cutting process, the plurality of end mills perform cutting on the cutting area assigned to each end mill along a virtual cutting line set on the stacked body.

[0031] [2] In the method for manufacturing the synthetic resin film of the present invention,

[0032] When the laminate exists on the xy plane of the three-dimensional orthogonal coordinate system with its side facing vertically along the z-axis of the three-dimensional orthogonal coordinate system formed by the x-axis, y-axis and z-axis,

[0033] The cutting machine includes:

[0034] Two end mills serve as the first and second end mills of the plurality of end mills;

[0035] The first pad, having a specified length along the x-axis and a specified length along the y-axis, fixes the upper surface of the laminate within a range slightly narrower than the range enclosed by an imaginary cutting line defined on the laminate.

[0036] The second pad, having a specified length along the x-axis and a specified length along the y-axis, fixes the lower surface of the laminate within a range slightly narrower than the range enclosed by the imaginary cutting line set on the laminate.

[0037] The first pad pressing body applies a pressing force along the z-axis from the upper side to the lower side to the first pad; and

[0038] The second pad pressing body applies a pressing force along the z-axis from the bottom to the top of the second pad.

[0039] Wherein, the length of the first pad pressing body along the x-axis is longer than the length of the laminate along the x-axis, and the length of the first pad pressing body along the y-axis is the same as or slightly shorter than the length of the first pad along the y-axis. The first pad pressing body is extended further outward than one end and the other end of the laminate along the x-axis.

[0040] The length of the second pad press body along the x-axis is equal to or slightly shorter than the length of the second pad along the x-axis, and the length of the second pad press body along the y-axis is slightly longer than the length of the laminate along the y-axis. The second pad press body extends further outward than one end and the other end of the laminate along the y-axis.

[0041] The cutting edge of the first end mill is positioned downwards along the z-axis, and the cutting edge of the second end mill is positioned upwards along the z-axis. Both the first and second end mills can move up and down along the z-axis, respectively.

[0042] When the first end mill performs cutting, it descends along the z-axis from its rising state. In this descending state, the cutting edge of the first end mill abuts against the side of the laminate, thereby performing cutting on the cutting area allocated to the first end mill.

[0043] When the second end mill is performing cutting, it rises along the z-axis from a descending state. In this rising state, the cutting edge of the second end mill abuts against the side of the laminate, thereby performing cutting on the cutting area allocated to the second end mill.

[0044] [3] In the method for manufacturing the synthetic resin film of the present invention,

[0045] In the rising state, the tip of the cutting edge of the first end mill is located above the first pad pressing body. In this state, the cutting edge of the first end mill can move in any direction on the xy plane. In the falling state, the cutting edge of the first end mill can move along the x-axis in a straight line and a curve.

[0046] In the descending state, the tip of the cutting edge of the second end mill is located below the second pad pressing body. In this state, the cutting edge of the second end mill can move in any direction on the xy plane. In the ascending state, the cutting edge of the second end mill can move along the y-axis in a straight line and a curve.

[0047] [4] In the method for manufacturing the synthetic resin film of the present invention,

[0048] The cutting area allocated to the first end mill is: the side surface of the laminate on one side of the first pad pressing body along the x-axis and the side surface of the laminate on the other side of the first pad pressing body along the x-axis.

[0049] The cutting area allocated to the second end mill is defined as: the side surface of the laminate located on one side of the second pad pressing body along the y-axis and the side surface of the laminate located on the other side of the second pad pressing body along the y-axis.

[0050] The cutting process includes:

[0051] In the first step, with the first end mill in a lowered state, the side surface of the laminated body located on one side along the x-axis of the first pad pressing body is cut.

[0052] In the second step, after the first step, the first end mill rises and immediately descends after moving laterally across the surface above the first pad pressing body; and

[0053] In the third step, with the first end mill in the lowered state, the side surface of the laminate located on the other side of the first pad pressing body along the x-axis is machined.

[0054] The cutting process further includes:

[0055] In the fourth step, with the second end mill in the raised state, the side of the laminated body located on one side along the y-axis of the second pad pressing body is cut.

[0056] In the fifth step, after the fourth step, the second end mill descends and immediately rises after moving laterally across the surface below the second pad pressing body; and

[0057] In the sixth step, with the second end mill in the raised state, the side surface of the laminate located on the other side of the second pad pressing body along the y-axis is machined.

[0058] [5] In the method for manufacturing the synthetic resin film of the present invention,

[0059] At the corners forming curved surfaces between the side surfaces of the laminate along the x-axis and the side surfaces of the laminate along the y-axis, the cutting operations of the first end mill and the second end mill are performed overlappingly.

[0060] [6] In the method for manufacturing the synthetic resin film of the present invention,

[0061] The first pad pressing body and the second pad pressing body are cross-arranged in a manner that sandwiches the first pad, the stack body and the second pad, and the intersection area of ​​the first pad pressing body and the second pad pressing body is summarized within the area surrounded by the cutting line.

[0062] [7] In the method for manufacturing the synthetic resin film of the present invention,

[0063] The cutting process involves roughing in the cutting area assigned to each end mill, followed by finishing.

[0064] [8] In the method for manufacturing the synthetic resin film of the present invention,

[0065] The cutting machine is provided with a chip removal section for removing chips generated during the cutting process.

[0066] [9] In the method for manufacturing the synthetic resin film of the present invention,

[0067] The chip removal unit has a gas ejection section capable of ejecting gas, and the gas ejected from the gas ejection section is used to blow away the chips.

[0068]

[10] In the method for manufacturing the synthetic resin film of the present invention,

[0069] The gas ejected from the gas ejector is a cooling gas capable of cooling at least one of the cutting edges of the end mills and the cutting area of ​​the laminate.

[0070]

[11] In the method for manufacturing the synthetic resin film of the present invention,

[0071] The chip removal section further includes a chip dust collection section for collecting the chips.

[0072]

[12] In the method for manufacturing the synthetic resin film of the present invention,

[0073] The synthetic resin film is an optical film, which has at least one of the following functions: anti-reflection, impact resistance, anti-fingerprint adhesion, ultraviolet protection, and glass splash protection.

[0074]

[13] The method for manufacturing the synthetic resin film of the present invention further includes:

[0075] The coating agent application process involves applying a coating agent to the sides of the laminate after the cutting process.

[0076] Invention Effects

[0077] According to the method for manufacturing the synthetic resin film of the present invention, each end mill is assigned a cutting area in the circumferential direction on the side surface of the laminate, and cutting is performed on the cutting area assigned to each end mill. Therefore, even when the laminate is fixed by a method in which the end mill cannot continuously circumferentially wrap around the side surface of the laminate, cutting can be performed on the side surface of the laminate over the entire circumference. Attached Figure Description

[0078] Figure 1 This is an example diagram of the laminate 100 used as the cutting target in the method for manufacturing a synthetic resin film according to the embodiment.

[0079] Figure 2 It constitutes Figure 1 A diagram of an optical film material 110 of the laminate 100 before machining.

[0080] Figure 3 This is a diagram of a cutting machine used in the manufacture of the synthetic resin film according to this embodiment.

[0081] Figure 4This is a diagram used to illustrate the intersection area Cr of the first pad pressing body 230 and the second pad pressing body 240.

[0082] Figure 5 This is a flowchart of the manufacturing process of the synthetic resin film manufacturing method according to the embodiments.

[0083] Figure 6 This is a diagram used to illustrate the specific cutting process of the first end mill 310.

[0084] Figure 7 This is a diagram used to illustrate the specific cutting process of the second end mill 320.

[0085] Figure 8 This is an example diagram of an optical film manufactured by the synthetic resin film manufacturing method according to the embodiment;

[0086] Figure 9 This is another example of a laminate made of multiple layers of long strip optical film material.

[0087] Figure 10 This is an example diagram of a laminate made of multiple planar optical film materials that are nearly circular or square in shape.

[0088] Figure 11 This is a top view used to illustrate the case where a through hole 108 is formed on the laminate 100.

[0089] Figure 12 yes Figure 5 The flowchart shown is a process flow diagram for applying a coating agent to the cutting surface after the cutting process (step S2).

[0090] Figure 13 This is a diagram illustrating the cutting process in the manufacturing method of the optical film described in Patent Document 1.

[0091] Figure 14 This is an example diagram used to illustrate that an end mill cannot rotate continuously circumferentially along the side of a stack. Detailed Implementation

[0092] Hereinafter, embodiments of the present invention will be described in detail. In the embodiments described below, a synthetic resin film will be used as an example of an optical film, therefore, in the following description, the synthetic resin film will sometimes be referred to as an optical film.

[0093] Figure 1 This is an example diagram of the laminate 100 used as the cutting target in the method for manufacturing the synthetic resin film according to the embodiment, wherein, Figure 1 (a) is a perspective view of the stacked body 100 as the object to be machined. Figure 1 (b) is viewed from the direction of arrow b. Figure 1 (a) is a stereoscopic view. Figure 1 The laminate 100 shown is formed by stacking dozens to hundreds of thin sheet-shaped optical film materials 110, which serve as optical films.

[0094] exist Figure 1 In the diagram, the dashed line L1, as described above, indicates the cutting point to which the material is cut, and is referred to as the cutting line L1. This cutting line L1 is a virtual line and does not actually exist; it represents the shape of the synthetic resin film (optical film) manufactured by the synthetic resin film manufacturing method according to the embodiment.

[0095] The laminate 100 is a quadrilateral that is relatively long laterally (along the x-axis) and has a curve that is arc-shaped on one side. Figure 1 In this process, the four circumferential sides of the laminate 100 are designated as first side 101, second side 102, third side 103, and fourth side 104, and these first side 101 to fourth side 104 are cut to the cutting line L1. Furthermore, the first corner C1 between the first side 101 and the third side 103, the second corner C2 between the third side 103 and the second side 102, the third corner C3 between the second side 102 and the fourth side 104, and the fourth corner C4 between the fourth side 104 and the first side 101 are each curved surfaces.

[0096] Figure 2 It constitutes Figure 1 The diagram shows an optical film material 110 of the laminate 100 before machining. "Optical film material 110 before machining" is abbreviated as "optical film material 110". Figure 2 (a) is a top view (plan view) of the optical film material 110. Figure 2 (b) is observed along the direction of arrow Yb1. Figure 2 (a) is an enlarged view of the end face of the optical film material 110 shown in the figure, which shows the cross-sectional structure of the optical film material 110.

[0097] The optical film material 110 is generally a quadrilateral that is longer in the transverse direction (along the x-axis), with one side having a rounded curve. This optical film material 110 is processed to form the optical film 120 (described later) as a finished product. Figure 8 The optical film 120, as a product, is, for example, an optical film used in the LCD panel of an automotive device. This optical film has at least one of the following functions: anti-reflective, impact-resistant, anti-fingerprint, UV-shielding, and anti-glass-splash. Figure 8 The shape of the optical film 120 shown as the product is as follows: Figure 2(a) shows the shape and dimensions of the optical film material 110 along the cutting line L1.

[0098] The optical film material 110, which is the material of the optical film 120, is elongated and has a thickness t1 of about 200 μm to 500 μm. Its length along the x-axis (the length in the transverse direction) Lx1 is 400 mm to 1500 mm, and the length of the longest part along the y-axis (the length of the longest part in the longitudinal direction) Ly1 is 100 mm to 500 mm. Figure 2 The length Lx1 of the optical film material 110 along the x-axis shown represents Figure 1 The length Lx1 of the laminate 100 along the x-axis and the length Ly1 of the longest portion of the optical film material 110 along the y-axis represent... Figure 1 The length of the longest portion of the laminate 100 shown along the y-axis.

[0099] It should be noted that the optical film material 110 is pre-cut into a size that is slightly larger than the size of the optical film 120 (the size along the cutting line L1) and close to the desired shape by stamping or other processes. However, it is not necessary to cut it into a shape close to the finished product size; it can also be cut into a rectangular or near-rectangular shape.

[0100] Cross-sectional structure of optical film material 110 in the thickness t1 direction (refer to) Figure 2 (b) For example, it includes: a substrate such as PET or TAC (triacetyl cellulose) (thickness t2 is about 80 μm) 111; an anti-reflective film layer 112 (thickness t3 is a few μm) and a protective film layer 113 (thickness t4 is tens of μm) on one side of the substrate 111; an adhesive layer 114 (thickness t5 is 20 μm) on the other side of the substrate 111; and a release paper layer 115 (thickness t6 is 50 μm). Figure 2 The shape and dimensions of the units of the optical film material 110 shown are merely an example; in practice, various shapes and sizes are possible, depending on the application. After stacking dozens to over a hundred layers of the optical film material 110 with such a structure before machining, a laminate 100 is formed (see reference). Figure 1 ).

[0101] Figure 3 This is a diagram of a cutting machine used in the manufacture of the synthetic resin film according to this embodiment, wherein... Figure 3 (a) is a top view. Figure 3 (b) is observed along the y-axis in the direction of arrow Yb1. Figure 3 (a) diagram, Figure 3 (c) is observed along the x-axis in the direction of arrow Xa2. Figure 3 (b) is the diagram.

[0102] The laminate 100 exists on the xy-plane of a three-dimensional orthogonal coordinate system, with its sides (first side 101 to fourth side 104) vertically aligned along the z-axis of the x-axis, y-axis, and z-axis. Specifically, assuming a base 240 for a cutting machine exists on the xy-plane of the three-dimensional orthogonal coordinate system, the laminate 100 is fixed to the base 240 with its sides (first side 101 to fourth side 104) vertically aligned along the z-axis. The length (lateral) direction of the laminate 100 is aligned along the x-axis.

[0103] The cutting machine includes: two end mills, a first end mill 310 and a second end mill 320, which are multiple end mills; a first pad 210 that fixes the upper surface 105 of the laminate 100 within a range slightly narrower than the area enclosed by the cutting line L1 set on the laminate 100; a second pad 220 that fixes the lower surface 106 of the laminate 100 within a range slightly narrower than the area enclosed by the cutting line L1 set on the laminate 100; a first pad pressing body 230 that applies a pressing force along the z-axis from top to bottom to the first pad 210; and a second pad pressing body 240 that applies a pressing force along the z-axis from bottom to top to the second pad 220. The base of the cutting machine functions as the second pad pressing body 240. Therefore, Figure 3 The second pad pressing body 240 shown can also be considered the base of the machining machine. This will be discussed later. Figure 6 and Figure 7 The same applies to China.

[0104] The upper surface 105 of the laminate 100 is pressed by a first pad 210 within the area surrounded by the cutting line L1, and the lower surface 106 is pressed by a second pad 220 within the area surrounded by the cutting line L1. These first pads 210 and second pads 220 can be of the same shape and size, but their size is slightly smaller than the area of ​​the laminate 100 surrounded by the cutting line L1. In other words, the first pads 210 and second pads 220 clamp and fix the laminate 100 within a slightly narrower area than the area surrounded by the cutting line L1. Here, the predetermined length of the first pads 210 and second pads 220 along the x-axis is defined as Lx2, and the length along the y-axis is defined as Ly2.

[0105] The first pad pressing body 230 is arranged along the x-axis in the length direction. As described above, a pressing force is applied to the first pad 210 from the upper side to the lower side. The length of the first pad pressing body 230 along the x-axis is set to be greater than Lx2 of the length of the first pad 210 along the x-axis (refer to...). Figure 3 (a) and Figure 3(b) is longer, thus enabling the first pad 210 to be pressed along the entire x-axis. Furthermore, the length Lx1 of the laminate 100 along the x-axis (refer to...) Figure 2 The first pad pressing body 230 is set to be longer. Furthermore, the first pad pressing body 230 is configured to extend further outward than one end (third side 103) and the other end (fourth side 104) of the laminate 100 along the x-axis. In this way, the first pad pressing body 230 can apply pressure uniformly to the first pad 210 from one end 210a to the other end 210b along the x-axis.

[0106] The length Ly3 of the first pad pressing body 230 along the y-axis is set to be the same as or slightly shorter than the length Ly2 of the first pad 210 along the y-axis. Furthermore, the length Ly3 of the first pad pressing body 230 along the y-axis is set to be slightly shorter than the length Ly2 of the second pad 210 along the y-axis.

[0107] On the other hand, as described above, the second pad pressing body 240 applies a pressing force from the lower side to the upper side to the second pad 220. The second pad 220 is substantially subjected to a pressing force from the lower side to the upper side by the first pad pressing body 230 pressing the first pad 210 and receiving the pressing force.

[0108] The length of the second pad pressing body 240 along the y-axis is set to be greater than the length Ly2 of the second pad 220 along the y-axis (refer to...). Figure 3 (a) and Figure 3 (c) is longer, thus enabling it to press the second pad 220 along the entire y-axis, and the length Ly1 of the longest portion of the laminate 100 along the y-axis (refer to) Figure 2 The second pad press body 240 is configured to extend further outward than one end (first side 101) and the other end (second side 102) of the laminate 100 along the y-axis. In this way, the second pad press body 240 can extend from one end 220a (refer to) of the second pad 220 along the y-axis direction. Figure 3 (c) to the other end 220b (refer to) Figure 3 (c) Apply pressure evenly.

[0109] The length Lx3 of the second pad pressing body 240 along the x-axis is set to be the same as or slightly shorter than the length Lx2 of the second pad 220 along the x-axis. Here, the length Lx3 of the second pad pressing body 240 along the x-axis is set to be slightly shorter than the length Lx2 of the second pad 220 along the x-axis.

[0110] The first pad pressing body 230 and the second pad pressing body 240 are arranged in a cross configuration, sandwiching the first pad 210, the laminate 100, and the second pad 220. At this time, the intersection area Cr of the first pad pressing body 230 and the second pad pressing body 240 (refer to...) Figure 4 It is categorized within the area enclosed by the cutting line L1 of the laminate 100.

[0111] Figure 4 This is a diagram used to illustrate the intersection area Cr of the first pad pressing body 230 and the second pad pressing body 240. (See diagram below.) Figure 4 As shown, the first pad pressing body 230 and the second pad pressing body 240 are arranged in an intersecting manner in the area where the laminate 100 is fixed to the base (the second pad pressing body 240), and the intersecting area Cr (in Figure 4 The area (represented in gray) is categorized within the area enclosed by the cutting line L1 of the laminate 100.

[0112] return Figure 3 The first end mill 310 and the second end mill 320 will be described. Both the first end mill 310 and the second end mill 320 are driven by NC (Numerical Control) programs and are capable of moving up and down along the z-axis, moving along the x-axis, moving along the y-axis, and moving in any direction in the xy-plane. When moving the first end mill 310 and the second end mill 320 along the x-axis and y-axis, they can perform not only linear movement but also curved movement, i.e., moving while drawing a curve.

[0113] First, the first end mill 310 will be described. The first end mill 310 has a cutting edge 311 and a drive unit 312 that drives the cutting edge 311. Figure 3 (a) shows the circumferential section of the cutting edge 311.

[0114] When the first end mill 310 is rising along the z-axis, as follows: Figure 3 As shown by the dashed line in (b), the tip e1 of the cutting edge 311 of the first end mill 310 is located higher than the first pad pressing body 230. Specifically, when the first end mill 310 is rising along the z-axis, there is a predetermined interval d1 between the tip e1 of the cutting edge 311 of the first end mill 310 and the upper surface (upper surface 230a) of the first pad pressing body 230. In this state, the first end mill 310 does not abut against the upper surface 230a of the first pad pressing body 230 and can move in any direction in the xy plane.

[0115] When the first end mill 310 is descending along the z-axis, as follows: Figure 3As shown by the solid line in (b), the side of the cutting edge 311 of the first end mill 310 is positioned opposite to the side of the laminate 100 (e.g., the first side 101). At this time, the first end mill 310 remains at a position where the tip e1 of the cutting edge 311 does not contact the upper surface (upper surface 240a) of the second pad pressing body 240, and a predetermined interval d2 exists between the tip e1 of the first end mill 310 and the upper surface 240a of the second pad pressing body 240. Figure 3 ).

[0116] In this way, when the first end mill 310 is in a descending state along the z-axis, the first end mill 310 can move along the x-axis in the xy-plane. Therefore, the first end mill 310 can cut the first side 101 of the laminate 100 along the x-axis.

[0117] That is, the cutting edge 311 of the first end mill 310 can completely cover the thickness t0 of the laminate 100 along the z-axis (refer to...). Figure 1 (a)) In this state, the first end mill 310 moves along the x-axis, and can perform uniform cutting in the vertical direction (thickness t0 direction of the stacked body 100) of the first side 101 of the stacked body 100 while moving along the x-axis.

[0118] Specifically, the first end mill 310 passes along... Figure 3 (a) and Figure 3 The direction of the x-axis shown in (b) is ( Figure 3 (a) and Figure 3 (b) to the right of the attached diagram), and along Figure 3 (c) shows the direction of the x-axis. Figure 3 (c) The first end mill 310 moves from the surface perpendicular to the drawing towards the back side to cut the first side 101 of the laminate 100. When moving along the x-axis, the first end mill 310 can move not only in a straight line, but also while drawing various curves.

[0119] As the first end mill 310 moves along the x-axis, the tip e1 of the cutting edge 311 of the first end mill 310 is spaced apart by a distance d2 from the upper surface 240a of the second pad pressing body 240. Therefore, the tip e1 of the first end mill 310 will not contact the upper surface 240a of the second pad pressing body 240. The first end mill 310 can cut not only the first side 101 along the x-axis, but also the second side 102 along the x-axis, which will be explained later.

[0120] Next, the second end mill 320 will be described. The second end mill 320 is identical to the first end mill 310, having a cutting edge 321 and a drive unit 322 for driving the cutting edge 321. Figure 3(a) shows the circumferential section of the cutting edge 321.

[0121] When the second end mill 320 is descending along the z-axis, as follows: Figure 3 As shown by the dashed line in (b), the tip e2 of the cutting edge 321 of the second end mill 320 is located below the second pad pressing body 240. Specifically, when the second end mill 320 is descending along the z-axis, there is a predetermined gap d1 between the tip e2 of the cutting edge 321 of the second end mill 320 and the lower surface 240b of the second pad pressing body 240. In this state, the second end mill 320 does not abut against the lower surface 240a of the second pad pressing body 240 and can move in any direction in the xy plane.

[0122] When the second end mill 310 is rising along the z-axis, as follows: Figure 3 As shown by the solid line in (b), the side of the cutting edge 321 of the second end mill 320 is positioned opposite to the side of the laminate 100 (e.g., the third side 103). At this time, the second end mill 320 remains at a position where the tip e2 of the cutting edge 321 does not contact the lower surface 230b of the first pad pressing body 230, and a predetermined interval d2 exists between the tip e2 of the second end mill 320 and the lower surface 230b of the first pad pressing body 230 (refer to...). Figure 3 (b)).

[0123] Thus, when the second end mill 320 is in the rising state along the z-axis, it can move along the y-axis in the xy plane. Therefore, the second end mill 320 can cut the third side 103 of the laminate 100 along the y-axis.

[0124] That is, the cutting edge 321 of the second end mill 320 can cover the thickness t0 along the z-axis of the laminate 100 (refer to...). Figure 1 (a)) In this state, when the second end mill 320 moves along the y-axis, it can uniformly cut and machine the third side surface 103 of the laminate 100 in the vertical direction (the thickness t0 direction of the laminate 100) while moving along the y-axis.

[0125] Specifically, in Figure 3 In (a), it is possible to follow the direction of the y-axis shown in the figure ( Figure 3 (a) The upper direction of the attached figure is moved, in Figure 3 In (b), it is possible to follow the direction of the y-axis shown in the figure (from the direction of the y-axis Figure 3 (b) The orthogonal surfaces in the attached diagram move towards the back side, in Figure 3 In (c), it is possible to follow the direction of the y-axis shown in the figure (from the direction of the y-axis Figure 3(c) The second end mill 320 moves to the right of the attached diagram. When moving along the y-axis, it can move not only in a straight line, but also while tracing various curves.

[0126] As the second end mill moves along the y-axis, the tip e2 of the cutting edge 321 of the second end mill 320 is spaced apart by a distance d2 from the lower surface 230b of the first pad pressing body 230. Therefore, the tip e2 of the second end mill 310 will not contact the lower surface 230b of the first pad pressing body 230. The second end mill 320 can cut not only the third side 103 along the y-axis, but also the fourth side 104 along the y-axis, which will be explained later.

[0127] Next, the cutting process in the method for manufacturing the synthetic resin film according to the embodiments will be described.

[0128] Figure 5 This is a flowchart illustrating the manufacturing process of the synthetic resin film according to the embodiments. The manufacturing process for manufacturing the synthetic resin film according to the embodiments is as follows: Figure 5 As shown, it includes: a laminate forming process (step S1) to form a laminate 100 formed by stacking multiple thin plate-shaped optical film materials 110; and a cutting process (step S2) to cut the sides (first side 101 to fourth side 104) of the laminate 100 using multiple end mills (first end mill 310 and second end mill 320) to make the optical film material, which is a synthetic resin film material, into the desired shape and size.

[0129] Multiple end mills (first end mill 310 and second end mill 320) are assigned cutting areas on the circumferential side of the stack 100 of each end mill (first end mill 310 and second end mill 320). The cutting process (step S2) performs cutting on the cutting areas assigned to each end mill (first end mill 310 and second end mill 320) along an imaginary cutting line L1 set on the stack 100.

[0130] In the method for manufacturing the synthetic resin film according to the embodiment, the cutting area assigned to the first end mill 310 is located on the side of the laminate 100 along the x-axis of the first pad pressing body 230 (the side where the first side 101 is located) and on the other side of the laminate 100 along the x-axis of the first pad pressing body 230 (the side where the second side 102 is located). On the other hand, the cutting area assigned to the second end mill 320 is located on the side of the laminate 100 along the y-axis of the second pad pressing body 240 (the side where the third side 103 is located) and on the other side of the laminate 100 along the y-axis of the second pad pressing body 240 (the side where the fourth side 104 exists).

[0131] exist Figure 5 The cutting process (step S2) shown includes: a first step, in which the first end mill 310, in a lowered state, performs cutting machining on the side surface of the laminate 100 (the side surface where the first side surface 101 is located) on one side of the first pad pressing body 230 along the x-axis; a second step, after the first step, moving and lowering the end mill 310 in a manner that sweeps over the surface (upper surface 230a) above the first pad pressing body 230; and a third step, in the lowered state of the first end mill 310, performing cutting machining on the side surface of the laminate 100 (the side surface where the second side surface 102 is located) on the other side of the first pad pressing body 230 along the x-axis. The specific grinding processes of the first to third steps will be described later.

[0132] Furthermore, in Figure 5 The cutting process (step S2) shown further includes: a fourth step, in which the second end mill 320, in its raised state, performs cutting machining on the side surface (the side surface where the third side surface is located) of the laminate 100 located on one side of the second pad pressing body 240 along the y-axis; a fifth step, after performing the fourth step, in which the second end mill 320 descends and moves laterally across the lower side surface (lower surface 240b) of the second pad pressing body 240 before rising; and a sixth step, in which the second end mill 320, in its raised state, performs cutting machining on the side surface (the side surface where the fourth side surface is located) of the laminate 100 located on the other side of the second pad pressing body 240 along the y-axis. The specific grinding processes of the fourth to sixth steps will be described later.

[0133] When the first end mill 310 and the second end mill 320 perform cutting on the laminate 100, they repeatedly perform the machining process to achieve the desired size and shape. In this embodiment, the first end mill 310 and the second end mill 320 each perform one roughing and one finishing machining operation. The cutting amount for roughing is 0.2 mm, and for finishing is 0.1 mm; however, this is just an example, and the cutting amount can be set arbitrarily. The number of roughing and finishing operations is not limited to one each. During roughing and finishing, not only the cutting amount but also the rotational speed and travel speed of each end mill can be set to values ​​suitable for roughing and finishing, respectively.

[0134] Figure 6 This is a diagram illustrating the specific cutting operations of the first end mill 310, in which... Figure 6 (a) is related to Figure 3 (a) The corresponding diagram, in Figure 6 (a) in relation to Figure 3 (a) The same structural elements are assigned the same symbols. Figure 6(b) is related to Figure 3 (c) The corresponding diagram is in Figure 6 (b) in relation to Figure 3 (c) Identical structural elements are assigned the same symbols. Furthermore, Figure 6 The white circle in (a) indicates the position of the cutting edge 311 of the first end mill 310.

[0135] Reference Figure 6 As previously explained Figures 1-5 To illustrate the specific cutting process of the first end mill 310. Before cutting begins, the first end mill 310... Figure 3 As shown by the dashed line in (b), the first end mill 310 is in an ascending state, which is taken as its initial state. Starting from this initial state, the first end mill 310 descends along the z-axis and reaches position P1 (refer to...). Figure 6 (a)) is the starting point for cutting. Position P1 is located near the first pad pressing body 230 on the first corner C1 of the laminate 100.

[0136] The first end mill 310, starting from position P1, performs cutting machining on the side surface of the laminate 100 (the side surface where the first side surface 101 exists) along the x-axis of the first pad pressing body 230 (first operation). Specifically, the first end mill 310, starting from position P1, moves towards... Figure 6 In the diagram in (a), the side of the curved first corner C1, the side of the arc-shaped first corner C1, and the side of the curved second corner C2 are cut along the cutting line L1 until they are about to contact the first pad pressing body 230 at position P2.

[0137] Then, at position P2, the first end mill 310 is as follows: Figure 6 (b) is shown by the dashed line. When the first end mill 310 rises to position P2, there is a gap d1 between the tip e1 of the cutting edge 311 and the upper surface 230a of the first pad pressing body 230 (refer to...). Figure 6 (b) At this time, when the first end mill 310 rises at position P2, it moves in the direction of arrow y1 by laterally sweeping over the upper side surface (upper surface 230a) of the first pad pressing body 230, and then immediately descends at position P3 (second process). At this time, position P3 is located near the first pad pressing body 230 on the triangular portion C3 of the laminate 100.

[0138] "Moving in the direction of arrow y1 by laterally sweeping across the surface (upper surface 230a) above the first pad pressing body 230" means that the first end mill 310 is moved in the direction of arrow y1 while maintaining the distance d1 between the tip e1 of the cutting edge 311 of the first end mill 310 and the surface (upper surface 230a) above the first pad pressing body 230. Figure 6 (a) Move in the direction of arrow y1.

[0139] Then, with the first end mill 310 in the lowered state at position P3, starting from position P3, it performs cutting machining on the side surface (the side surface where the second side surface is located) of the laminate 100 located on the other side of the first pad pressing body 230 along the x-axis (third step). Specifically, the first end mill 310 starts from position P3 and moves towards... Figure 6 In diagram (a), the first end mill 310 moves to the left (arrow x1 direction) and cuts along the cutting line L1 to the side of the curved third corner C3, the straight second side 102, and the curved fourth corner C4 until it is about to abut against the first pad pressing body 230 at position P4. Then, at position P4, the first end mill 310 rises.

[0140] The cutting process of the first end mill 310 described above, namely the cutting process of the side of the laminate 100 on one side of the first pad pressing body 230 along the x-axis and the cutting process of the side of the laminate 100 on the other side of the first pad pressing body 230 along the x-axis, are both rough cutting processes with a cutting amount of 0.2 mm.

[0141] Next, the cutting process of the second end mill 320 will be explained.

[0142] Figure 7 This is a diagram illustrating the specific cutting operations of the second end mill 320, in which... Figure 7 (a) is related to Figure 3 (a) Corresponding diagram, in Figure 7 (a) in relation to Figure 3 In (a), structural elements that are identical are assigned the same symbol. Figure 7 b is with Figure 3 The diagram corresponding to b is in Figure 7 In b, regarding Figure 3 Elements in b that are identical are given the same symbol. Figure 7 The white circle in (a) indicates the position of the cutting edge 321 of the second end mill 320.

[0143] Reference Figure 7 As previously explained Figures 1-5 This describes the specific cutting operation of the second end mill 320. Before cutting begins, the second end mill 320... Figure 3As shown by the dashed line in (b), the second end mill 320 is in a descending state, which is taken as its initial state. From this initial state, the second end mill 320 rises along the z-axis, with reference position P5 ( Figure 7 (a)) is the starting point for cutting. Position P5 is located near the second pad pressing body 240 on the third corner C3 of the laminate 100.

[0144] The second end mill 320, starting from position P5, performs cutting machining (fourth operation) on the side surface of the laminate 100 (the side surface 101 located on the third side surface 101) along the y-axis of the second pad pressing body 240. Specifically, the second end mill 320, starting from position P5, moves towards... Figure 7 As shown in (a), the side of the curved triangular portion C3, the straight third side 103, and the side of the curved second corner portion C2 are cut along the cutting line L1 in the direction of arrow y2 until they are about to abut against the second pad pressing body 240 at position P6.

[0145] Then, at position P6, the second end mill 320... Figure 7 (b) shows the descent as indicated by the dashed line. At this time, when the second end mill 320 descends to position P6, there is a gap d1 between the tip e2 of the cutting edge 321 and the lower surface 240b of the second pad pressing body 240 (refer to...). Figure 7 (b)).

[0146] When the second end mill 320 descends at position P6, it moves in the direction of arrow x2 by laterally sweeping across the lower side surface (lower surface 240b) of the second pad pressing body 240, and then rises at position P7 (fifth process). At this time, position P7 is located near the second pad pressing body 240 on the first corner C1 of the laminate 100.

[0147] "Moving laterally across the lower side (lower surface 240b) of the second pad pressing body 240 in the direction of arrow x2" means that the second end mill 320 is moved towards the lower side (lower surface 240b) of the second pad pressing body 240 while maintaining the distance d1 between the tip e2 of the cutting edge 321 of the second end mill 320 and the lower side (lower surface 240b) of the second pad pressing body 240. Figure 6 (a) Move in the direction of arrow x1.

[0148] Then, with the second end mill 320 in the raised state at position P7, it performs cutting machining (sixth step) on the side of the laminate 100 (the side where the fourth side is located) on the other side of the second pad pressing body 240 along the y-axis, starting from position P7. Specifically, the second end mill 320 starts from position P7 and moves towards... Figure 7As shown in (a), the second end mill 320 moves along the cutting line L1 in the direction of arrow y3 to cut the side of the curved first corner C1, the straight fourth side 104, and the side of the curved fourth corner C4 until it is about to abut against the second pad pressing body 240 at position P8. Then, at position P8, the second end mill 320 descends.

[0149] The cutting operations performed using the second end mill 320 described above, namely the cutting operations on the side of the laminate 100 on one side of the second pad pressing body 240 along the y-axis and the cutting operations on the side of the laminate 100 on the other side of the second pad pressing body 240 along the y-axis, are both rough cutting operations with a cutting amount of 0.2 mm.

[0150] Next, while performing finish machining on the side surface of the laminate 100 on one side of the first pad pressing body 230 along the x-axis using the first end mill 310, and simultaneously performing finish machining on the side surface of the laminate 100 on the other side of the first pad pressing body 230 along the x-axis using the second end mill 320, finish machining on the side surface of the laminate 100 on one side of the second pad pressing body 240 along the y-axis, and simultaneously performing finish machining on the side surface of the laminate 100 on the other side of the second pad pressing body 240 along the y-axis using the second end mill 320. These finish machining operations can also be performed in the same manner as the roughing operations described above, therefore their description is omitted. The cutting amount during the finish machining using the first end mill 310 and the second end mill 320 is, for example, 0.1 mm.

[0151] When performing cutting operations with the first end mill 310 and the second end mill 320, if curved surfaces are formed at the corners of the laminate, repeated cutting operations are performed using the first end mill 310 and the second end mill 320. For example, as with the laminate 100, if curved surfaces are formed at each corner (first corner C1, fourth corner C4), repeated cutting operations are performed at each corner using the first end mill 310 and the second end mill 320.

[0152] For example, in Figure 6 and Figure 7In this process, focusing on the second corner C2 of the stack 100, the first end mill 310 moves in the x1 direction while cutting the curved surface of the second corner C2 until it is about to abut against the first pad pressing body 230. On the other hand, the second end mill 320 moves in the y2 direction while cutting the curved surface of the second corner C2 until it is about to abut against the second pad pressing body 240. Therefore, in this second corner C2, repeated cutting is performed by the first end mill 310 and the second end mill 320. This is also done in other corners (first corner C1, third corner C3, and fourth corner C4). In this way, by repeatedly cutting with the first end mill 310 and the second end mill 320 in each corner (first corner C1 and fourth corner C4), the cutting of each corner can be reliably performed.

[0153] As described above, in the method for manufacturing a synthetic resin film according to this embodiment, two end mills (first end mill 310 and second end mill 320) are each assigned a cutting area in the circumferential direction on the side surface of the laminate 100.

[0154] Specifically, the cutting area assigned to the first end mill 310 is located on the side of the laminate 100 along the x-axis of the first pad pressing body 230 (the side where the first side 101 is located) and on the other side of the laminate 100 along the x-axis of the first pad pressing body 230 (the side where the second side 102 is located). On the other hand, the cutting area assigned to the second end mill 320 is located on the side of the laminate 100 along the y-axis of the second pad pressing body 240 (the side where the third side 103 is located) and on the other side of the laminate 100 along the y-axis of the second pad pressing body 240 (the side where the fourth side is located).

[0155] In its raised state, the first end mill 310 can move in any direction along the xy-plane formed by the x-axis and y-axis of the raised state; in its lowered state, it can move along the x-axis of the lowered state (including curved movement). Conversely, in its lowered state, the second end mill 320 can move in any direction along the xy-plane of the lowered state; in its raised state, it can move along the y-axis of the raised state (including curved movement).

[0156] When the first end mill 310 and the second end mill 320 perform such actions, making it impossible to fix the laminated body in a way that allows the end mills to continuously circumferentially surround the side of the laminated body, for example, as... Figure 3As shown, the first pad pressing body 230 can be machined along the entire circumference of the side surface of the laminate 100, even when configured to extend further outward than one end (first side surface 101) and the other end (second side surface 102) of the laminate 100 along the x-axis. In this case, the side surface of the laminate 100 along the x-axis (e.g., the first side surface 101 and the second side surface 102) can be machined by the first end mill 310, and the side surface of the laminate 100 along the y-axis (e.g., the third side surface 103 and the fourth side surface 104) can be machined by the second end mill 320.

[0157] Specifically, after machining the first side surface 101 of the laminate 100 along the x-axis, the first end mill 310 moves laterally across the upper side surface (upper surface 230a) of the first pad pressing body 230 and then machines the second side surface 102 of the laminate 100 along the x-axis. On the other hand, after machining the third side surface 103 of the laminate 100 along the y-axis, the second end mill 320 moves laterally across the lower side surface (lower surface 240b) of the second pad pressing body 240 and then machines the fourth side surface 104 of the laminate 100 along the y-axis.

[0158] like Figure 4 As shown, since the first pad pressing body 230 and the second pad pressing body 240 are configured such that the intersection area Cr of the first pad pressing body 230 and the second pad pressing body 240 is contained within the area surrounded by the cutting line L1 of the laminate 100, the first end mill 310 and the second end mill 320 will not come into contact with the first pad pressing body 230 and the second pad pressing body 240 when cutting with the first end mill 310 and the second end mill 320.

[0159] Thus, according to the synthetic resin film manufacturing method of this embodiment, it is possible to efficiently cut and process a laminate 100 formed by stacking multiple optical films 110, which are materials used to manufacture elongated optical films or optical films with complex curves. In this way, elongated optical films or optical films with complex curves can be manufactured efficiently.

[0160] Figure 8 This is an example diagram of an optical film 120 manufactured by the synthetic resin film manufacturing method according to this embodiment. Figure 8 The optical film 120 shown is from the optical film 120 through ... Figure 6 and Figure 7 A top view of the laminate 100 cut by the cutting process described in the text is taken out. That is to say, Figure 8 The optical film 120 shown has in Figure 2 The outline of the optical film material (optical film material before cutting) 110 shown along the cutting line L1.

[0161] Since the optical film 120 is manufactured in this way, it is not obtained by cutting the optical film material through a stamping machine or other means. Therefore, it will not have defects such as tapered shearing surfaces, cracks, or missing adhesive, and is a high-quality optical film.

[0162] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be implemented without departing from the spirit of the invention. For example, the following modifications are also possible.

[0163] (1) Although not mentioned in the above embodiments, a chip removal section (not shown) for removing chips generated by cutting can also be provided on the grinding machine. By providing such a chip removal section, it is possible to prevent chips from remaining attached to the laminate 100, thereby enabling each optical film after cutting to have high quality.

[0164] The chip removal unit has a gas ejection section capable of ejecting gas for blowing out chips. The gas ejected from the gas ejection section can be room temperature air, but preferably a cooling gas capable of cooling at least one of the cutting edges of each end mill (cutting edge 311 of the first end mill 310 and cutting edge 321 of the second end mill 320) and the cutting area of ​​the laminate 100. For example, the cooling gas can be air at a temperature much lower than room temperature, or carbon dioxide or nitrogen gas with a temperature below freezing point.

[0165] Then, when machining the first side surface 101 of the laminate 100 using the first end mill 310, cooling gas from the gas ejector is blown towards the cutting edge 311 of the first end mill 310 and the first side surface 101 of the laminate 100 while machining. Similarly, when machining the second side surface 102 of the laminate 100, cooling gas is blown towards the cutting edge 311 of the first end mill 310 and the second side surface 101 of the laminate 100 while machining.

[0166] When machining the third side 103 of the laminate 100 using the second end mill 320, cooling gas from the gas ejector is blown onto the cutting edge 321 of the second end mill 320 and the third side 103 of the laminate 100 while machining. Similarly, when machining the fourth side 104 of the laminate 100, cooling gas is sprayed from the gas ejector onto the cutting edge 321 of the second end mill 320 and the fourth side 104 of the laminate 100 while machining.

[0167] In this way, during cutting, by blowing cooling gas onto the cutting edges 311, 321 of the first end mill 310 and the second end mill 320 and the cutting area of ​​the laminate 100, cutting chips generated during cutting can be blown away. In particular, various effects can be obtained by using cooling gas ejected through the gas ejection section.

[0168] That is, by using a cooling gas ejected from the gas ejector, it is possible to prevent the adhesive of the optical film material 110 from dissolving, overflowing, and falling off (the aforementioned "insufficient adhesive"). By preventing adhesive overflow, it is possible to prevent cutting chips from adhering to the dissolved and overflowed adhesive, thus preventing the cutting chips from becoming difficult to detach from the laminate 100. Therefore, cutting chips can be easily blown out, thereby efficiently removing them.

[0169] By using the gas ejected from the gas ejection section as cooling gas, the cutting edge 311 of the first end mill 310, the cutting edge 321 of the second end mill 320, and the laminate 100 can be prevented from being heated due to friction, thereby enabling high-quality cutting operations.

[0170] The above description describes a case where cooling gas from the gas ejector is sprayed onto the cutting edges 311 of the first end mill 310, the cutting edges 321 of the second end mill 320, and the cutting area of ​​the laminate 100 while machining. However, it is also possible to pre-cool the cutting edges of each end mill (the cutting edges 311 of the first end mill 310 and the cutting edges 321 of the second end mill 320) and the cutting area of ​​the laminate 100. Furthermore, after pre-cooling, it is also possible to further blow cooling gas from the gas ejector onto the cutting edges 311 of the first end mill 310, the cutting edges 321 of the second end mill 320, and the cutting area of ​​the laminate 100 while machining.

[0171] The chip removal function of the chip removal unit can remove chips in a way that allows for chip removal. Figure 5 This is performed as a cutting operation (step S2) involving multiple end mills in the flowchart. In this case, chip removal can be performed simultaneously with the cutting process, or it can be performed after the cutting process is completed.

[0172] The chip removal unit may also include a chip dust collection unit for collecting chip dust. By having such a chip dust collection unit, the blown-away chips can be prevented from scattering into the surrounding environment.

[0173] (2) In the above embodiment, although the planar shape of the laminate 100, which is the object of cutting, is as follows: Figure 1The image shown is a long, narrow quadrilateral with one side curved, but it is not limited to this shape. For example, even those with a shape like... Figure 9 The planar stack 100 shown can also be machined.

[0174] Figure 9 This is another example of a laminate composed of multiple long strips of optical film material, in which... Figure 9 (a) Showing the planar shape of a laminate 100A made of multiple strips of optical film material with one long side bent in the middle. Figure 9 (b) Demonstrates a laminate 100B composed of multiple strips of optical film material with two semicircles side by side on one long side. Figure 9 (c) A laminate 100C is shown, consisting of multiple sheets of elongated optical film material that are integrally elongated elliptical in shape. The cutting process performed on the sides of these laminates 100A to 100C can be carried out in the same manner as the cutting process described in the above embodiments.

[0175] The method for manufacturing the optical film of the present invention can be applied even if the laminate is not a long strip, but a planar shape such as a circle or a quadrilateral that is close to a square.

[0176] Figure 10 This is an example diagram of a laminate composed of multiple optical film materials with planar shapes that are close to circular or square. Figure 10 (a) Displaying a 100D laminate made of multiple planar circular optical film materials. Figure 10 (b) A laminate 100E is shown, consisting of multiple sheets of optical film material with a planar shape that is close to square. The cutting process for machining the sides of these laminates can be performed in the same way as the cutting process described in Embodiment 1 above.

[0177] It should be noted that, Figure 9 and Figure 10 The planar shape of the laminate shown is only one example. The method for manufacturing synthetic resin films according to the present invention can cut and process laminates of various planar shapes, and thus can manufacture synthetic resin films with various planar shapes.

[0178] (3) In the above embodiments, although optical film structures are illustrated... Figure 2The structure shown in (b) is merely an example and is not limited to this structure. For example, the substrate material is not limited to PET or TAC (triacetyl cellulose), but can also be PC (polycarbonate), AC (acrylic acid), PI (polyimide), COP (cyclic olefin polymer), COC (cyclic olefin copolymer), etc. As a coating, materials with functions such as AG (anti-glare), AR (anti-reflective), LR (low-reflective), AF (anti-fingerprint), HC (hard coating), and UV protection can also be used.

[0179] (4) In the above embodiments, it was explained that the synthetic resin film to be manufactured is an optical film used in liquid crystal panels of automotive devices, but it is not limited to liquid crystal panels; it may also be an optical film used in organic EL panels, μLED panels, etc. The method for manufacturing the synthetic resin film of the present invention is also applicable to the manufacture of synthetic resin films for purposes other than optical applications.

[0180] (5) In the above embodiment, although it is described that the outer periphery of the laminate 100 is machined by multiple end mills (first end mill 310 and second end mill 320) (first side 101 to fourth side 104), when a through hole is formed on the laminate 100, the inner wall surface of the through hole can also be machined as one of the sides of the laminate 100.

[0181] Figure 11 This is a plan view used to illustrate the case where a through hole 108 is formed on the laminate 100. For example... Figure 11 As shown, when a through hole 108 is formed on the laminate 100, the inner wall surface of the through hole 108 is sometimes machined to give the through hole 108 a desired size and a desired planar shape (hereinafter also referred to as a desired through hole). This desired through hole, when used as an optical film in an article, can be used for various applications, such as lens mounting parts for cameras, connector mounting parts for electronic devices, and rotating shaft passage parts for operating knobs. When the desired through hole is, for example, circular, its diameter is approximately 5 mm to 20 mm, but it is not limited to this. Figure 12 In the diagram, the dashed line L2 represents the cutting line, and it is assumed that the desired through hole is formed by machining to this cutting line L2.

[0182] As an example of a method for forming such a desired through hole, a laminate 100 made of a synthetic resin film material (optical film material) having through holes 108 smaller than the desired through hole is formed by cutting to the cutting line L2 using a first end mill 310. The desired through hole is not limited to a circular planar shape; it can also be various planar shapes such as ellipse or quadrilateral. When forming the desired through hole, the optimal end mill can be selected for cutting based on the shape and size of the desired through hole. Alternatively, a dedicated end mill for cutting the inner wall surface of the through hole can be used as a third end mill.

[0183] (6) Manufacturing steps of the synthetic resin film manufacturing method involved in the embodiments (refer to) Figure 5 The process following the cutting process (step S2) in the laminate 100 may further include a process of applying a coating agent to the side surface (the side surface after cutting) of the laminate 100 for purposes such as corrosion prevention, waterproofing, and light blocking.

[0184] Figure 12 It is a demonstration as Figure 5 The flowchart shown is a process following the cutting process (step S2), namely the process of applying a coating agent to the side after the cutting process. Figure 12 The coating agent application process (step S3) shown is a process of applying a coating agent with anti-corrosion, waterproof, and light-blocking effects to the sides after machining (the first side 101 to the fourth side 104 after machining). As a coating agent, paints with anti-corrosion, waterproof, and light-blocking effects can be exemplified, but are not limited to paints.

[0185] By applying such a coating agent, the end face of the manufactured optical film possesses anti-corrosion, waterproof, and light-blocking effects, thus maintaining the quality of the optical film over a long period. Ideally, the coating agent should possess all the effects of anti-corrosion, waterproof, and light-blocking. However, depending on the application, a coating agent that provides only waterproofing, only anti-corrosion, or only light-blocking can be used. Furthermore, a coating agent possessing two of these effects can also be used. Moreover, a coating agent with additional effects (such as impact resistance) is also possible.

[0186] like Figure 11 As shown, when a through hole 108 is formed in the laminate 100, and the through hole 108 is also machined by an end mill to form a desired through hole, it is preferable to also apply a coating agent to the inner wall surface of the desired through hole.

[0187] (7) Although the first pad 210 and the second pad 220 used in the above embodiment are elongated quadrilateral shapes (rectangular shapes), as long as they are shapes that fall within the range surrounded by the cutting line L1 of the laminate 100, pads of various shapes can be used according to the planar shape of the laminate that is being cut.

[0188] (8) Although the first pad 210 and the second pad 220 used in the above embodiments are plate-shaped, they are not limited to a plate shape. For example, the first pad 210 and the second pad 220 can be frame-shaped, or they can be a shape consisting of a frame and a separator separating the frame (e.g., a trapezoidal or grid-shaped shape). The same applies to the first pad pressing body 230.

[0189] By forming such a shape using the first pad 210, the second pad, and the first pad pressing body 230, even if a through hole is formed near the center of the laminate and the inner wall of the through hole is machined, as long as the position of the frame and the separator separating the frame is carefully considered, it can be ensured that the cutting edge of the end mill (the cutting edge 311 of the first end mill 310) can reach the space required for the through hole formed on the laminate, and thus the inner circumferential surface of the through hole can be machined.

[0190] [Symbol Explanation]

[0191] 100, 100A~100E…Laminated body; 101…First side surface; 102…Second side surface; 103…Third side surface; 104…Fourth side surface; 110…Optical film material (synthetic resin film material); 120…Optical film as an article; 210…First pad; 220…Second pad; 230…First pad pressing body; 230a…Upper surface of the first pad pressing body; 230b…Lower surface of the first pad pressing body; 240…Second pad pressing body (base); 2 40a… Upper surface of the second pad pressing body; 240b… Lower surface of the second pad pressing body; 310… First end mill; 311… Cutting edge of the first end mill; 312… Drive unit of the first end mill; 320… Second end mill; 321… Cutting edge of the second end mill; 322… Drive unit of the second end mill; e1… Front end of cutting edge 311 of the first end mill; e2… Front end of cutting edge 321 of the second end mill; C1… First corner; C2… Second corner; C3… Third corner Part; C4…Fourth corner; Cr…Intersection area; d1…The interval between the tip e1 of the cutting edge 311 and the upper side surface (upper surface 230a) of the first pad pressing body 230 and the interval between the tip e2 of the cutting edge 321 and the lower side surface (lower surface 240b) of the second pad pressing body 240; d2…The interval between the tip e1 of the cutting edge 311 and the upper side surface (upper surface 240a) of the second pad pressing body 240 and the interval between the tip e2 of the cutting edge 321 and the lower side surface (lower surface 240b) of the second pad pressing body 230 (see table below) The spacing between surfaces 240b); L1, L2…cutting lines; Lx1…length of the optical film material 110 (laminate 100) along the x-axis; Lx2…length of the first pad 210 and the second pad 220 along the x-axis; Lx3…length of the second pad pressing body 240 along the x-axis; Ly1…length of the longest portion of the optical film material 110 (laminate 100) along the y-axis; Ly2…length of the first pad 210 and the second pad 220 along the y-axis; Ly3…length of the first pad pressing body 230 along the y-axis.

Claims

1. A method for manufacturing a synthetic resin film, comprising manufacturing a synthetic resin film having a desired shape and size by cutting the sides of a laminate of multiple thin-plate synthetic resin film materials using a cutting machine, characterized in that, Include: The cutting process utilizes multiple end mills to cut and machine the sides of the laminate, thereby processing the synthetic resin film material into the desired shape and size. The base of the cutting machine exists on the xy plane, which forms a three-dimensional orthogonal coordinate system consisting of the x-axis, y-axis, and z-axis. When the laminated body is fixed to the base with its side facing vertically along the z-axis, The cutting machine includes: two end mills, serving as a first end mill and a second end mill, representing a plurality of end mills; a first pad for fixing the upper surface of the laminate; a second pad for fixing the lower surface of the laminate; a first pad pressing body for applying a pressing force along the z-axis from the upper side to the lower side to the first pad; and a second pad pressing body for applying a pressing force along the z-axis from the lower side to the upper side to the second pad. The length of the first pad pressing body along the x-axis is set to be longer than the length of the laminate along the x-axis, and is configured to extend further outward than one end and the other end of the laminate along the x-axis. The length of the second pad pressing body along the y-axis is set to be slightly longer than the length of the laminate along the y-axis, and is configured to extend further outward than one end and the other end of the laminate along the y-axis. The cutting edge of the first end mill is positioned downward along the z-axis, and the cutting edge of the second end mill is positioned upward along the z-axis. The first and second end mills can each move up and down along the z-axis.

2. The method for manufacturing a synthetic resin film according to claim 1, characterized in that: in, Each of the plurality of end mills has a cutting area assigned to it in the circumferential direction on the side surface of the laminate. When the first end mill performs cutting, it descends along the z-axis from its rising state. In this descending state, the cutting edge of the first end mill abuts against the side of the laminate, thereby performing cutting on the cutting area allocated to the first end mill. When the second end mill is performing cutting, it rises along the z-axis from a descending state. In this rising state, the cutting edge of the second end mill abuts against the side of the laminate, thereby performing cutting on the cutting area allocated to the second end mill.

3. The method for manufacturing a synthetic resin film according to claim 2, characterized in that: in, The first pad has a predetermined length along the x-axis and a predetermined length along the y-axis, and fixes the upper surface of the laminate within a range narrower than the area enclosed by an imaginary cutting line defined on the laminate. The second pad has a specified length along the x-axis and a specified length along the y-axis, and fixes the lower surface of the laminate within a range narrower than the area enclosed by the imaginary cutting line set on the laminate. The length of the first pad pressing body along the y-axis is set to be the same as or shorter than the length of the first pad along the y-axis. The length of the second pad pressing body along the x-axis is set to be equal to or shorter than the length of the second pad along the x-axis.

4. The method for manufacturing a synthetic resin film according to claim 3, characterized in that: in, In the rising state, the tip of the cutting edge of the first end mill is located above the first pad pressing body. In this state, the cutting edge of the first end mill can move in any direction on the xy plane. In the falling state, the cutting edge of the first end mill can move along the x-axis in a straight line and a curve. In the descending state, the tip of the cutting edge of the second end mill is located below the second pad pressing body. In this state, the cutting edge of the second end mill can move in any direction on the xy plane. In the ascending state, the cutting edge of the second end mill can move along the y-axis in a straight line and a curve.

5. The method for manufacturing the synthetic resin film according to claim 4, Its features are: The cutting area allocated to the first end mill is: the side surface of the laminate on one side of the first pad pressing body along the x-axis and the side surface of the laminate on the other side of the first pad pressing body along the x-axis. The cutting area allocated to the second end mill is: the side surface of the laminate on one side of the second pad pressing body along the y-axis and the side surface of the laminate on the other side of the second pad pressing body along the y-axis. The cutting process includes: In the first step, with the first end mill in a lowered state, the side surface of the laminated body located on one side along the x-axis of the first pad pressing body is cut. In the second step, after the first step is performed, the first end mill rises and immediately descends after moving laterally across the surface above the first pad pressing body. as well as In the third step, with the first end mill in the lowered state, the side surface of the laminate located on the other side of the first pad pressing body along the x-axis is machined. The cutting step further includes: In the fourth step, with the second end mill in the raised state, the side of the laminated body located on one side along the y-axis of the second pad pressing body is cut. In the fifth step, after the fourth step, the second end mill descends and immediately rises after moving laterally across the surface below the second pad pressing body; and In the sixth step, with the second end mill in the raised state, the side surface of the laminate located on the other side of the second pad pressing body along the y-axis is machined.

6. The method for manufacturing a synthetic resin film according to claim 5, characterized in that: At the corners forming curved surfaces between the side surfaces of the laminate along the x-axis and the side surfaces of the laminate along the y-axis, the cutting operations of the first end mill and the second end mill are performed overlappingly.

7. The method for manufacturing a synthetic resin film according to any one of claims 3 to 6, characterized in that: in, The first pad pressing body and the second pad pressing body are cross-arranged in a manner that sandwiches the first pad, the stack body and the second pad, and the intersection area of ​​the first pad pressing body and the second pad pressing body is summarized within the area surrounded by the cutting line.

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