Method for manufacturing laminate and apparatus for manufacturing laminate

Abstract

This method for manufacturing a laminate comprises: a first step for pressing a laminate film, which has a base film and an inorganic layer laminated on the base film, against a first intermediate point between a first end and a second end of a substrate using a pressing member, and pressing the pressing member against the laminate film while pressing the laminate film against a second intermediate point between the first end and the second end of the substrate; one side of the pressing part moves from the first middle point to the first end; a second step of moving the pressing member to a second intermediate point between the first end and the second end without pushing the pressing member against the laminated film; and a third step of moving the pressing member from the second intermediate point toward the second end while pushing the pressing member against the laminated film.

Description

Technical Field

[0001] The present invention relates to a method for producing a laminate and an apparatus for producing a laminate. This application claims priority over the contents described in Japanese Patent Application No. 2022-163216 filed in Japan on October 11, 2022. Background Art

[0002] Anti-reflection films are used in various applications. For example, anti-reflection films are bonded to display glass of vehicle-mounted liquid crystal panels. Anti-reflection films are bonded to substrates such as glass.

[0003] For example, Patent Document 1 describes a bonding device for bonding a sheet member to a long film member.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2018-185505 Summary of the invention

[0007] Problems to be solved by the invention

[0008] When a laminated film including an inorganic layer is bonded to a substrate, cracks may occur in the laminated film when a pressing member reaches an end of the substrate.

[0009] The present disclosure has been made in view of the above-mentioned problems, and aims to provide a method for manufacturing a laminated body and an apparatus for manufacturing a laminated body that can suppress the occurrence of cracks during bonding.

[0010] Solutions for solving problems

[0011] In order to solve the above problems, the present invention proposes the following solutions.

[0012] (1) The method for manufacturing a stacked body of the first scheme comprises: a first step of using a pressing member to push a stacked film having a base film and an inorganic layer stacked on the base film against a first midpoint between a first end and a second end of a substrate, and moving the pressing member from the first midpoint toward the first end while pushing the pressing member against the stacked film; a second step of moving the pressing member toward a second midpoint between the first end and the second end without pushing the pressing member against the stacked film; and a third step of pushing the pressing member against the stacked film and moving the pressing member from the second midpoint toward the second end.

[0013] (2) In the method for manufacturing a laminated body according to the above aspect, the second midpoint may coincide with the first midpoint.

[0014] (3) In the method for manufacturing a laminated body according to the above aspect, the second midpoint may be located closer to the first end than the first midpoint.

[0015] (4) In the method for producing a laminated body according to the above aspect, the second midpoint may be located closer to the second end than the first midpoint.

[0016] (5) In the method for manufacturing a laminated body according to the above aspect, regarding the lamination pressure per unit time between the laminated film and the substrate, the lamination pressure at the first intermediate point may be greater than the lamination pressure at the first end.

[0017] (6) In the method for manufacturing a laminated body according to the above aspect, regarding the lamination pressure per unit time between the laminated film and the substrate, the lamination pressure at the second intermediate point may be greater than the lamination pressure at the second end.

[0018] (7) In the method for manufacturing a stacked body of the above scheme, the width of the substrate in a second direction orthogonal to the first direction connecting the first end and the second end may not be fixed, the width of the first portion in the second direction may be narrower than the width of the second portion in the second direction, and regarding the bonding pressure per unit time between the stacked film and the substrate, the bonding pressure in the first portion may be smaller than the bonding pressure in the second portion.

[0019] (8) In the method for producing a laminated body according to the above aspect, the pressing tool may include a first roller in contact with the laminated film and a second roller in contact with the substrate.

[0020] (9) In the method for manufacturing a laminated body according to the above aspect, in the first step and the third step, a bonding pressure for bonding the laminated film and the substrate by the pressing member may be 0.1 MPa or more and 0.5 MPa or less.

[0021] (10) The manufacturing device of the stacked body of the second scheme comprises: a pressing member, which pushes a stacked film having a base film and an inorganic layer stacked on the base film against a substrate; and a control unit, which controls the relative position of the pressing member and the substrate, and the control unit performs the following actions: a first action, using the pressing member to push against a first midpoint between the first end and the second end of the substrate, while pushing the pressing member against the stacked film, the pressing member is moved from the first midpoint toward the first end; a second action, without pushing the pressing member against the stacked film, the pressing member is moved toward the second midpoint between the first end and the second end; and a third action, while pushing the pressing member against the stacked film, the pressing member is moved from the second midpoint toward the second end.

[0022] Effects of the Invention

[0023] The method for producing a laminate and the apparatus for producing a laminate according to the present embodiment can suppress the occurrence of cracks during bonding. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a cross-sectional view of the laminated film according to the present embodiment.

[0025] Figure 2 It is a cross-sectional view for explaining the first step in the method for producing a laminated body according to the present embodiment.

[0026] Figure 3 It is a plan view for explaining the first step in the method for producing a laminated body according to the present embodiment.

[0027] Figure 4 It is a cross-sectional view for explaining the second step in the method for producing a laminated body according to the present embodiment.

[0028] Figure 5 It is a cross-sectional view for explaining the third step in the method for producing a laminated body according to the present embodiment.

[0029] Figure 6 It is a plan view for explaining the third step in the method for producing the laminated body according to the present embodiment.

[0030] Figure 7 It is a plan view for explaining another example of the third step in the method for producing the laminated body according to the present embodiment.

[0031] Figure 8 It is a plan view for explaining another example of the third step in the method for producing the laminated body according to the present embodiment. DETAILED DESCRIPTION

[0032] Hereinafter, the present embodiment will be described in detail with reference to the accompanying drawings as appropriate. In the drawings used in the following description, in order to facilitate understanding of the features of the present disclosure, the features are sometimes enlarged for convenience, and the dimensional ratios of the components are sometimes different from the actual ones. The materials, dimensions, etc. illustrated in the following description are examples, and the present disclosure is not limited thereto, and can be implemented with appropriate changes within the scope of achieving its effects.

[0033] First, the direction is defined. The moving direction of the pressing member 30 is referred to as the first direction. The x direction is an example of the first direction. In addition, in the plane in which the substrate 20 extends, the direction orthogonal to the first direction is referred to as the second direction. The y direction is an example of the second direction. The z direction is a direction orthogonal to the x direction and the y direction. The z direction is consistent with the direction of application of pressure when the laminated film 10 and the substrate 20 are bonded together, for example.

[0034] "Method for producing a laminate"

[0035] The method for producing a laminated body of the present embodiment includes a first step, a second step, and a third step. In the method for producing a laminated body of the present embodiment, the laminated film 10 is bonded to the substrate 20 to produce a laminated body including the laminated film 10 and the substrate 20 .

[0036] The substrate 20 is, for example, glass, plastic, etc. The bonding surface 20S of the substrate 20 to which the laminated film 10 is bonded may be flat or curved. When the bonding surface 20S is curved, the bonding surface 20S is, for example, curved in the z direction relative to the x direction. For example, in the xz cross section, the bonding surface 20S is convexly curved in the +z direction or -z direction at the center of the x direction. In addition, the top view shape of the bonding surface 20S is not particularly limited and may be an irregular shape.

[0037] The laminate film 10 is, for example, slightly larger than the bonding surface 20S of the substrate 20. After the laminate film 10 is bonded to the substrate 20, an excess portion of the laminate film 10 is left around the substrate 20. The excess portion of the laminate film 10 is cut and removed in a subsequent step.

[0038] The laminated film 10 includes a base film and an inorganic layer laminated on the base film. Figure 1 It is a cross-sectional view of the laminated film 10 according to the present embodiment. Figure 1 The laminated film 10 shown has, for example, a release layer 1, an adhesive layer 2, a base film 3, a hard coat layer 4, an optical function layer 5, an antifouling layer 6, and a protective layer 7. The optical function layer 5 is an example of an inorganic layer.

[0039] The release layer 1 is a layer that protects the adhesive layer 2. The release layer 1 is peeled off at the time of lamination, and the adhesive layer 2 exposed by peeling off the release layer 1 is bonded to the substrate 20. The release layer 1 is, for example, paper or film coated with a release agent. The thickness of the release layer 1 is, for example, 70 μm or more and 80 μm or less.

[0040] The adhesive layer 2 is a layer bonded to the substrate 20. The adhesive layer 2 includes, for example, an acrylic adhesive, a silicone adhesive, or a urethane adhesive. The thickness of the adhesive layer 2 is, for example, 10 μm to 50 μm, preferably 20 μm to 30 μm.

[0041] The substrate film 3 is, for example, a plastic film. The constituent material of the plastic film is, for example, a polyester resin, an acetate resin, a polyethersulfone resin, a polycarbonate resin, a polyamide resin, a polyimide resin, a polyolefin resin, a (meth)acrylic resin, a polyvinyl chloride resin, a polyvinylidene chloride resin, a polystyrene resin, a polyvinyl alcohol resin, a polyarylate resin, or a polyphenylene sulfide resin.

[0042] The substrate film 3 is, for example, a polyester resin, an acetate resin, a polycarbonate resin, or a polyolefin resin. For example, a polyethylene terephthalate (PET) substrate or a triacetyl cellulose (TAC) substrate is preferably used as the substrate film 3 .

[0043] The thickness of the substrate film 3 is, for example, 60 μm or more. If the thickness of the substrate film 3 is thin, the bending of the film may cause cracks in the laminated film 10. The thickness of the substrate film 3 is, for example, 1 mm or less, preferably 500 μm or less, and more preferably 300 μm or less. If the thickness of the substrate film 3 is too thick, the transparency of the substrate film 3 is reduced, and the rigidity is increased, and it is easy to break.

[0044] One side of the substrate film 3 may be subjected to etching treatment and / or primer treatment such as sputtering, corona discharge, ultraviolet irradiation, electron beam irradiation, chemical conversion, oxidation, etc. By performing these treatments in advance, the adhesion of the hard coating layer 4 formed on the substrate film 3 is improved.

[0045] The hard coating layer 4 is formed on one side of the substrate film 3. The hard coating layer 4 is not particularly limited, and a known material can be used. The hard coating layer 4 can contain, for example, a binder resin and a filler. In addition, the hard coating layer 4 can also contain a leveling agent.

[0046] The binder resin is preferably transparent, and may be, for example, a resin that is cured by ultraviolet rays or electron beams, an ionizing radiation curable resin, a thermoplastic resin, a thermosetting resin, or the like.

[0047] An example of an ionizing radiation curable resin as a binder resin is ethyl (meth)acrylate, ethylhexyl (meth)acrylate, styrene, methylstyrene, N-vinylpyrrolidone, etc. In addition, the ionizing radiation curable resin may also be a compound having two or more unsaturated bonds. Ionizing radiation curable resins having two or more unsaturated bonds include, for example, trimethylolpropane tri(meth)acrylate, tripropylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, 1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, di(trimethylolpropane) tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate. The present invention relates to a binder resin comprising a plurality of functional compounds, such as trimethoxymethyl acrylate, tripentaerythritol octamethoxymethyl acrylate, tetrapentaerythritol decamethoxymethyl acrylate, isocyanuric acid trimethoxymethyl acrylate, isocyanuric acid dimethoxymethyl acrylate, polyester trimethoxymethyl acrylate, polyester dimethoxymethyl acrylate, bisphenol dimethoxymethyl acrylate, diglycerol tetramethoxymethyl acrylate, adamantyl dimethoxymethyl acrylate, isobornyl dimethoxymethyl acrylate, dicyclopentyl dimethoxymethyl acrylate, tricyclodecyl dimethoxymethyl acrylate, di(trimethylolpropane) tetramethoxymethyl acrylate, etc. Among them, pentaerythritol triacrylate (PETA), dipentaerythritol hexamethoxymethyl acrylate (DPHA) and pentaerythritol tetramethoxymethyl acrylate (PETTA) are particularly preferably used as binder resins. It should be noted that "(meth)acrylate" refers to methacrylate and acrylate. Furthermore, as the ionizing radiation curable resin, the above compounds may be modified with PO (propylene oxide), EO (ethylene oxide), CL (caprolactone), etc. The ionizing radiation curable resin is preferably an acrylic ultraviolet curable resin composition.

[0048] In addition, an example of a thermoplastic resin as a binder resin is a styrene resin, (meth) acrylic resin, vinyl acetate resin, vinyl ether resin, halogen-containing resin, alicyclic olefin resin, polycarbonate resin, polyester resin, polyamide resin, cellulose derivative, silicone resin, rubber or elastomer, etc. The above-mentioned thermoplastic resin is non-crystalline and soluble in an organic solvent (especially a common solvent that can dissolve a variety of polymers and curable compounds). In particular, from the viewpoint of transparency and weather resistance, the binder resin is preferably a styrene resin, (meth) acrylic resin, alicyclic olefin resin, polyester resin, cellulose derivative (cellulose esters, etc.), etc.

[0049] Thermosetting resins used as binder resins may be, for example, phenolic resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, unsaturated polyester resins, polyurethane resins, epoxy resins, aminoalkyd resins, melamine-urea co-condensation resins, silicone resins, polysiloxane resins (including so-called cage-shaped, ladder-shaped, etc. silsesquioxanes, etc.), etc.

[0050] The hard coat layer 4 may include an organic resin and an inorganic material, or may be an organic-inorganic hybrid material. As an example, a material formed by a sol-gel method may be cited. As an inorganic material, for example, silicon dioxide, aluminum oxide, zirconium oxide, and titanium dioxide may be cited. As an organic material, for example, an acrylic resin may be cited.

[0051] The filler may be composed of an organic substance, an inorganic substance, or both. The filler contained in the hard coat layer 4 may be selected from various fillers according to the purpose of the laminated film 10 from the perspectives of anti-glare, adhesion with the optical functional layer 5 described later, and anti-blocking properties. Specifically, as the filler, for example, known fillers such as silica (Si oxide) particles, alumina particles, and organic microparticles may be used.

[0052] When the filler is silica particles and / or alumina particles, the average particle size of the filler is, for example, 800 nm or less, preferably 100 nm or less, more preferably 40 nm or more and 70 nm or less. When the filler is organic fine particles, the average particle size of the organic fine particles is, for example, 10 μm or less, preferably 5 μm or less, more preferably 3 μm or less.

[0053] The thickness of the hard coat layer 4 is preferably 0.5 μm or more, and more preferably 1 μm or more, for example. The thickness of the hard coat layer 4 is preferably 100 μm or less. The hard coat layer 4 may be composed of a single layer or a plurality of layers stacked together.

[0054] The optical function layer 5 is a layer that exhibits an optical function. The optical function refers to a function of controlling reflection, transmission, and refraction, which are properties of light, and examples thereof include an antireflection function, a selective reflection function, an antiglare function, and a lens function.

[0055] The optical functional layer 5 is, for example, a laminated film in which a high refractive index layer and a low refractive index layer are alternately laminated sequentially from the hard coat layer 4 side. The refractive index of the high refractive index layer is higher than that of the low refractive index layer. The refractive index of each high refractive index layer may be the same or different. The refractive index of each low refractive index layer may be the same or different.

[0056] The total number of stacked low refractive index layers and high refractive index layers in the optical functional layer 5 is not particularly limited. Figure 1As shown, the number of laminations of each layer can be 4 layers, can be less than 3 layers, and can be more than 5 layers. The total number of laminations of the low refractive index layer and the high refractive index layer in the optical functional layer 5 is preferably more than 4 layers and less than 10 layers, more preferably more than 4 layers and less than 6 layers, and most preferably 4 layers. When the number of laminations of the optical functional layer 5 is 4 layers, the number of laminations is small and the thickness is thin, so compared with the case where the number of laminations is more than 5 layers, the productivity is excellent.

[0057] The optical function layer 5 exhibits an antireflection function by causing interference of reflected light reflected at the interface of a laminated body formed by alternately laminating high refractive index layers and low refractive index layers and by diffusing light incident from the antifouling layer 6 side.

[0058] The total thickness of the optical function layer 5 is, for example, 100 μm or more and 800 μm or less.

[0059] Hereinafter, the optical functional layer 5 is described as an example in which a laminate of four layers, namely, a first high refractive index layer 5A, a first low refractive index layer 5B, a second high refractive index layer 5C, and a second low refractive index layer 5D, is sequentially stacked from the side close to the hard coat layer 4. The refractive indexes of the first high refractive index layer 5A and the second high refractive index layer 5C are respectively higher than those of the first low refractive index layer 5B and the second low refractive index layer 5D.

[0060] The refractive index of the first high refractive index layer 5A and the second high refractive index layer 5C is, for example, 2.00 to 2.60, or preferably 2.10 to 2.45. The refractive indexes of the first high refractive index layer 5A and the second high refractive index layer 5C may be the same or different.

[0061] As the material of the first high refractive index layer 5A and the second high refractive index layer 5C, for example, niobium pentoxide (Nb2O5, refractive index 2.33), titanium dioxide (TiO2, refractive index 2.33-2.55), tungsten oxide (WO3, refractive index 2.2), cerium oxide (CeO2, refractive index 2.2), tantalum pentoxide (Ta2O5, refractive index 2.16), zinc oxide (ZnO, refractive index 2.1), indium tin oxide (ITO, refractive index 2.06), zirconium oxide (ZrO2, refractive index 2.2), etc. The first high refractive index layer 5A and the second high refractive index layer 5C are preferably niobium pentoxide. The materials constituting the first high refractive index layer 5A and the second high refractive index layer 5C may be the same or different.

[0062] The refractive index of the first low refractive index layer 5B and the second low refractive index layer 5D is, for example, 1.20 to 1.60, or preferably 1.30 to 1.50. The refractive indexes of the first low refractive index layer 5B and the second low refractive index layer 5D may be the same or different.

[0063] The first low refractive index layer 5B and the second low refractive index layer 5D contain, for example, oxides of Si. The first low refractive index layer 5B and the second low refractive index layer 5D are, for example, layers with SiO2 (oxides of Si) as the main component. Oxides of Si are easy to obtain and cost-effective. The SiO2 monolayer film is colorless and transparent. In this embodiment, the main component refers to the component that accounts for more than 50% by mass of the components contained in the layer. The refractive indexes of the first low refractive index layer 5B and the second low refractive index layer 5D may be the same or different.

[0064] The first low refractive index layer 5B and the second low refractive index layer 5D may also contain other elements less than 50% by mass when the oxide of Si is used as the main component. The content of the element different from the oxide of Si is preferably less than 10%. Other elements are, for example, Na, Zr, Al, and N. Na can improve the durability of the first low refractive index layer 5B and the second low refractive index layer 5D. Zr, Al, and N can improve the hardness of the first low refractive index layer 5B and the second low refractive index layer 5D and improve their alkali resistance.

[0065] The antifouling layer 6 is in contact with the surface of the optical functional layer 5 opposite to the surface in contact with the hard coating layer 4. The antifouling layer 6 can prevent contamination of the optical functional layer 5. In addition, the antifouling layer 6 can suppress the loss of the optical functional layer 5 due to pen sliding when applied to a touch panel or the like.

[0066] The antifouling layer 6 is, for example, a fluorine-based organic compound. The fluorine-based organic compound is, for example, a compound containing a fluorine-modified organic group and a reactive silane group (e.g., alkoxysilane). Commercially available products that can be used in the antifouling layer 6 include Optool DSX (manufactured by Daikin Co., Ltd.) and KY-100 series (manufactured by Shin-Etsu Chemical Co., Ltd.).

[0067] The thickness of the antifouling layer 6 is, for example, 1 nm or more and 20 nm or less, preferably 3 nm or more and 10 nm or less. When the thickness of the antifouling layer 6 is 1 nm or more, when the laminate is applied to a touch panel, etc., the wear resistance can be fully ensured. In addition, when the thickness of the antifouling layer 6 is 20 nm or less, the time required for vapor deposition can be completed in a short time, and efficient manufacturing can be achieved.

[0068] If necessary, the antifouling layer 6 may contain additives such as a light stabilizer, an ultraviolet absorber, a colorant, an antistatic agent, a lubricant, a leveling agent, a defoaming agent, an antioxidant, a flame retardant, an infrared absorber, and a surfactant.

[0069] The protective layer 7 is a layer that protects the film during transportation and storage. Examples of the protective layer 7 include a protective layer having a base material of polypropylene, polyethylene, polyethylene terephthalate, etc. and having an adhesive layer having natural rubber, synthetic rubber, acrylic resin, etc. as a main component.

[0070] Figure 2 It is a cross-sectional view for explaining the first step in the method for producing a laminated body according to the present embodiment. Figure 3 It is a plan view for explaining the first step in the method for producing a laminated body according to the present embodiment.

[0071] In the first step, the laminated film 10 is first pushed against the first middle point 23 of the substrate 20 using the pressing member 30. The first middle point 23 is located between the first end 21 and the second end 22 of the substrate 20 in the x direction. The first end 21 and the second end 22 are both ends of the substrate 20 in the x direction. The operation of the pressing member 30 is controlled by, for example, the control unit 40. The control unit 40 includes, for example, an operating mechanism that moves the pressing member 30 relative to the substrate 20 and a processor that instructs the operation of the operating mechanism.

[0072] The pressing member 30 is not particularly limited as long as it can apply pressure in the thickness direction of the laminate film 10 and the substrate 20. The pressing member 30 is, for example, a roller whose width in the y direction is wider than the substrate 20. The pressing member 30 moves along the x direction. The pressing member 30 is, for example, a bonding roller having a first roller 31 and a second roller 32. The first roller 31 is in contact with the laminate film 10 when pressing. The second roller 32 is in contact with the substrate 20 when pressing. Neither the first roller 31 nor the second roller 32 may be present. If the bonding roller has the first roller 31 and the second roller 32, even when the bonding surface 20S of the substrate 20 is bent, the laminate film 10 can be firmly bonded to the substrate 20 by moving the bonding roller along the bonding surface 20S.

[0073] In the first step, the lamination pressure of the pressing member 30 pressed against the laminated film 10 or the substrate 20 is, for example, 0.1 MPa to 0.5 MPa, or preferably 0.3 MPa to 0.4 MPa.

[0074] The pressing member 30 may also stop at the time point when it reaches the first end 21 from the first intermediate point 23. In addition, the pressing member 30 may also go beyond the first end 21 and move in the traveling direction (-x direction). When the pressing member 30 climbs the step between the laminated film 10 and the substrate 20, the laminated film 10 is prone to cracks, but it is not easy to crack when climbing down the step, and there is no problem even if the pressing member 30 goes beyond the first end 21 and moves in the traveling direction.

[0075] Regarding the lamination pressure per unit time of the laminated film 10 and the substrate 20, the lamination pressure at the first intermediate point 23 and the lamination pressure at the first end 21 may be different. The lamination pressure per unit time of the laminated film 10 and the substrate 20 is the pressure per unit time of pushing the pressing member 30 against the laminated film 10 or the substrate 20. For example, the lamination pressure per unit time at the first intermediate point 23 may be greater than the lamination pressure per unit time at the first end 21. By not applying a large pressure near the first end 21 where cracks are likely to occur, the generation of cracks in the laminated film 10 can be further suppressed.

[0076] In addition, when the width of the substrate 20 in the y direction is not constant, the lamination pressure per unit time between the laminated film 10 and the substrate 20 can be changed according to the width of the substrate 20 in the y direction. Figure 3 As shown in FIG. 1 , when the width of the substrate 20 in the y direction is not constant, the lamination pressure per unit time is changed between the first portion 25 and the second portion 26. The width W25 in the y direction of the first portion 25 is narrower than the width W26 in the y direction of the second portion 26. In this case, the lamination pressure per unit time at the first portion 25 is made smaller than the lamination pressure per unit time at the second portion 26. By changing the lamination pressure per unit time according to the shape of the substrate 20, it is possible to suppress the generation of cracks in the laminated film 10 due to the local application of a large pressure.

[0077] The laminating pressure per unit time can be controlled by the travel speed of the pressing member 30, the pressing pressure of the pressing member 30, etc. For example, when the pressing member 30 is a laminating roller, the travel speed and the pressing pressure of the pressing member 30 can be controlled by the gap between the first roller 31 and the second roller 32 and the rotation speed of the first roller 31 and the second roller 32.

[0078] Figure 4 It is a cross-sectional view for explaining the second step in the method for producing a laminated body according to the present embodiment.

[0079] In the second step, the pressing member 30 is moved to the second intermediate point 24 without pressing the pressing member 30 against the laminated film 10. The movement of the pressing member 30 is controlled by, for example, the control unit 40. The second intermediate point 24 is located between the first end 21 and the second end 22 in the x direction. The details of the second intermediate point 24 will be described later.

[0080] Not pushing the pressing member 30 against the laminated film 10 means that no laminating pressure is applied between the laminated film 10 and the substrate 20. Even if the pressing member 30 is in contact with the laminated film 10, if no laminating pressure is applied, it can be said that the pressing member 30 is not pushed against the laminated film 10. For example, in the second step, the pressing member 30 is separated from the laminated film 10 and the substrate 20. For example, the first roller 31 is moved away from the laminated film 10, and the second roller 32 is moved away from the substrate 20.

[0081] Figure 5 It is a cross-sectional view for explaining the third step in the method for producing a laminated body according to the present embodiment. Figure 6 It is a plan view for explaining the third step in the method for producing the laminated body according to the present embodiment.

[0082] In the third step, the pressing member 30 is pressed against the laminated film 10 again. The pressing member 30 is pressed against the second middle point 24 of the substrate 20. Then, in the third step, the pressing member 30 is moved from the second middle point 24 toward the second end 22. The movement of the pressing member 30 is controlled by the control unit 40, for example.

[0083] like Figure 6 As shown, the second intermediate point 24 may coincide with the first intermediate point 23. In this case, the position at which pressing is started in the first step coincides with the position at which pressing is started in the third step.

[0084] In addition, if Figure 7 and Figure 8 As shown, the second center point 24 may not coincide with the first center point 23 . Figure 7 and Figure 8 It is a plan view for explaining another example of the third step in the method for producing the laminated body according to the present embodiment.

[0085] exist Figure 7 In the example shown, the second intermediate point 24 is located closer to the first end 21 than the first intermediate point 23. In this case, the portion where the lamination pressure is applied in the first step partially overlaps with the portion where the lamination pressure is applied in the third step. If the portions where the lamination pressure is applied overlap in the first step and the third step, it is possible to further prevent bubbles from being mixed between the laminate film 10 and the substrate 20.

[0086] exist Figure 8In the example shown, the second midpoint 24 is located closer to the second end 22 than the first midpoint 23. That is, there is a gap between the first midpoint 23 and the second midpoint 24. No bonding pressure is applied to the area between the first midpoint 23 and the second midpoint 24 in both the first step and the third step. Even when no bonding pressure is applied to the area between the first midpoint 23 and the second midpoint 24, the area between them is naturally bonded by passing through the first step and the third step. In this case, even if the precision of the action of the pressing member 30 is low, it can be fully coped with, and the cost of the laminate manufacturing device can be reduced. The distance between the first midpoint 23 and the second midpoint 24 is, for example, less than 10 mm, preferably less than 3 mm.

[0087] In the third step, the lamination pressure of the pressing member 30 pressed against the laminated film 10 or the substrate 20 is, for example, 0.1 MPa to 0.5 MPa, or preferably 0.3 MPa to 0.4 MPa.

[0088] The pressing member 30 may also stop at the time point when it reaches the second end 22 from the second intermediate point 24. In addition, the pressing member 30 may also move in the traveling direction (+x direction) beyond the second end 22. When the pressing member 30 climbs the step between the laminated film 10 and the substrate 20, the laminated film 10 is prone to cracks, but it is not easy to crack when climbing down the step, and there is no problem even if the pressing member 30 moves in the traveling direction beyond the second end 22.

[0089] Regarding the lamination pressure per unit time of the laminated film 10 and the substrate 20, the lamination pressure at the second intermediate point 24 may be different from the lamination pressure at the second end 22. For example, the lamination pressure per unit time at the second intermediate point 24 may be greater than the lamination pressure per unit time at the second end 22. By not applying a large pressure near the second end 22 where cracks are likely to occur, the generation of cracks in the laminated film 10 can be further suppressed.

[0090] In addition, when the width of the substrate 20 in the y direction is not constant, the lamination pressure per unit time between the laminated film 10 and the substrate 20 can be changed according to the width of the substrate 20 in the y direction. Figure 6 to Figure 8 As shown in FIG. 1 , when the width of the substrate 20 in the y direction is not constant, the lamination pressure per unit time is changed between the first portion 28 and the second portion 27. The width W28 in the y direction of the first portion 28 is narrower than the width W27 in the y direction of the second portion 27. In this case, the lamination pressure per unit time at the first portion 28 is made smaller than the lamination pressure per unit time at the second portion 27. By changing the lamination pressure per unit time according to the shape of the substrate 20, it is possible to suppress the generation of cracks in the laminated film 10 due to the local application of a large pressure.

[0091] In the method for manufacturing a laminated body of the present embodiment, when the pressing member 30 climbs the step between the substrate 20 and the laminated film 10, no pressure is applied between the substrate 20 and the laminated film 10. When the pressing member 30 abuts against the laminated film 10, strain is generated in the organic layer represented by the base film 3, for example, and stress is applied to the inorganic layer represented by the optical functional layer 5 due to the strain, thereby generating cracks in the laminated film 10. When the pressing member 30 climbs the step between the substrate 20 and the laminated film 10, a large stress is generated in the laminated film 10. As described above, in the method for manufacturing a laminated body of the present embodiment, when the pressing member 30 climbs the step between the substrate 20 and the laminated film 10, no pressure is applied between the substrate 20 and the laminated film 10, so that cracks in the laminated film 10 can be suppressed.

[0092] "Laminate manufacturing device"

[0093] The manufacturing apparatus of the laminated body of the present embodiment includes a pressing member 30 and a control unit 40. Figure 3 An apparatus for producing a laminate will be described using this example.

[0094] The pressing member 30 presses the laminated film 10 against the substrate 20. The pressing member 30 is not particularly limited as long as it can apply pressure in the thickness direction of the laminated film 10 and the substrate 20.

[0095] The control unit 40 controls the relative position of the pressing member 30 and the substrate 20. The control unit 40 is, for example, a microprocessor. The control unit 40 controls the movement of the pressing member 30 based on a program stored in the microprocessor. The control unit 40 controls the pressing member 30, for example, so that the pressing member 30 performs the first movement, the second movement, and the third movement.

[0096] The first operation corresponds to the first step described above. In the first operation, the pressing member 30 is pressed against the first intermediate point 23 of the substrate 20 , and the pressing member 30 is moved from the first intermediate point 23 toward the first end 21 while being pressed against the laminated film 10 .

[0097] The second operation is an operation corresponding to the second step described above. In the second operation, the pressing member 30 is moved to the second intermediate point 24 so as not to press the pressing member 30 against the laminated film 10. The second intermediate point 24 may or may not coincide with the first intermediate point 23.

[0098] The third operation corresponds to the third step described above. In the third operation, the pressing member 30 is moved from the second intermediate point 24 toward the second end 22 while being pressed against the laminated film 10 .

[0099] The manufacturing apparatus of the laminated body of the present embodiment can easily realize the manufacturing method of the laminated body described above. Therefore, when a laminated body composed of the laminated film 10 and the substrate 20 is manufactured using the manufacturing apparatus of the laminated body of the present embodiment, cracks are unlikely to occur in the laminated film 10 .

[0100] As mentioned above, although the preferred embodiment of the present invention is described in detail, the present invention is not limited to the specific embodiment, and various deformation|transformation and changes are possible within the scope of the summary of the present invention described in the means for solving the problem.

[0101] Description of Reference Numerals

[0102] 1: peeling layer; 2: adhesive layer; 3: base film; 4: hard coating layer; 5: optical functional layer; 5A: first high refractive index layer; 5B: first low refractive index layer; 5C: second high refractive index layer; 5D: second low refractive index layer; 6: antifouling layer; 7: protective layer; 10: laminated film; 20: substrate; 20S: bonding surface; 21: first end; 22: second end; 23: first midpoint; 24: second midpoint; 25, 28: first part; 26, 27: second part; 30: pressing piece; 31: first roller; 32: second roller; 40: control unit.

Claims

1. A method for producing a laminate, wherein: have: In a first step, a pressing member is used to push a laminated film having a base film and an inorganic layer laminated on the base film against a first midpoint between a first end and a second end of a substrate, and the pressing member is moved from the first midpoint toward the first end while the pressing member is pressed against the laminated film. a second step of moving the pressing member toward a second intermediate point between the first end and the second end in a manner that the pressing member is not pushed against the laminated film; as well as In a third step, the pressing member is moved from the second intermediate point toward the second end while pressing the pressing member against the laminated film.

2. The method for producing a laminate according to claim 1, wherein: The second midpoint coincides with the first midpoint.

3. The method for producing a laminate according to claim 1, wherein: The second middle point is located closer to the first end than the first middle point.

4. The method for producing a laminate according to claim 1, wherein: The second middle point is located closer to the second end than the first middle point.

5. The method for producing a laminate according to claim 1, wherein: Regarding the lamination pressure per unit time between the laminated film and the substrate, the lamination pressure at the first intermediate point is greater than the lamination pressure at the first end.

6. The method for producing a laminate according to claim 1, wherein: Regarding the lamination pressure per unit time between the laminated film and the substrate, the lamination pressure at the second intermediate point is greater than the lamination pressure at the second end.

7. The method for producing a laminate according to claim 1, wherein: The width of the substrate in a second direction orthogonal to the first direction connecting the first end and the second end is not constant, The width of the first portion in the second direction is narrower than the width of the second portion in the second direction, Regarding the lamination pressure per unit time between the laminated film and the substrate, the lamination pressure in the first portion is smaller than the lamination pressure in the second portion.

8. The method for producing a laminate according to claim 1, wherein: The pressing member includes a first roller in contact with the laminated film and a second roller in contact with the substrate.

9. The method for producing a laminate according to claim 1, wherein: In the first step and the third step, the lamination pressure of laminating the laminated film and the substrate by the pressing member is 0.1 MPa or more and 0.5 MPa or less.

10. A device for manufacturing a laminate, wherein: have: A pressing member that pushes a laminated film having a base film and an inorganic layer laminated on the base film against a substrate; and A control unit controls the relative position of the pressing member and the substrate, The control unit performs the following actions: A first action is to use the pressing member to press against a first middle point between the first end and the second end of the substrate, and to move the pressing member from the first middle point toward the first end while pressing the pressing member against the laminated film; a second action of moving the pressing member toward a second intermediate point between the first end and the second end in a manner that the pressing member is not pushed against the laminated film; as well as The third operation is to move the pressing member from the second intermediate point toward the second end while pressing the pressing member against the laminated film.

Images