Sheet-like member cutting method and sheet-like member manufacturing method

Abstract

Provided is a method for cutting a sheet-like member, the method being capable of suppressing the occurrence of cracks in an end surface. A method for cutting an end surface of a laminate (9) comprising a plurality of sheet-like members using a rotary cutter (5) having a rotary shaft (51), an installation surface (54) extending in a direction perpendicular to the rotary shaft (51), and a cutting blade (8) provided on the installation surface (54), the cutting blade (8) being configured so that when viewed from the direction perpendicular to the installation surface (54), the cutting blade (8) extends in the direction perpendicular to the installation surface (54), and the cutting blade (8) is positioned on the installation surface (54). At least one of the cutting blades (83) is inclined in the direction opposite to the rotation direction of the rotary cutter (5) with respect to an imaginary straight line passing through the rotation axis (51) and the end of the cutting blade (83) on the side of the rotation axis (51), and the rotary cutter (5) is rotated so that chips are discharged in the radial direction of the installation surface (54). The end surface of the laminated body (9) is cut in a region (S1) on the upper side of a horizontal virtual reference line (F1) passing through the rotating shaft (51) in the setting surface (54).

Description

Technical Field

[0001] The present invention relates to a method for cutting an end surface of a sheet-like component and a method for manufacturing a sheet-like component having a cut end surface. Background Art

[0002] For example, sheet components for optical applications such as those incorporated into liquid crystal displays may require high-precision end surface processing. In such cases, a plurality of sheet components are stacked to form a laminate, and the end surfaces of the laminate are cut using a rotary cutter.

[0003] For example, Patent Document 1 discloses a cutter for processing the end surface of a film. The cutter comprises a rotating body and a plurality of cutting portions provided on a mounting surface perpendicular to the rotational axis of the rotating body and having cutting blades. The cutting blades are inclined in the rotational direction of the rotational axis by an angle of not less than 20 degrees and not more than 35 degrees, relative to a straight line passing through the end of the cutting blade on the rotational axis and the rotational axis, when the cutting blades are viewed from a direction perpendicular to the mounting surface. Patent Document 1 discloses that, in a sheet region including a horizontal plane passing through the rotational axis of the cutter, the end surface of the film is cut by bringing the cutting blades of the rotating cutter into contact with the lower surface of the film, such that the difference between the exit angle at which the cutting blades contact the lower surface of the film and the intrusion angle at which the cutting blades contact the upper surface of the film is not more than 45 degrees.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2011-93086 Summary of the Invention

[0007] The end surface machining cutter disclosed in Patent Document 1 discharges chips inward (toward the rotation axis). On the other hand, using a cutter that discharges chips outward improves chip removal. Patent Document 1 does not disclose a method for cutting the end surface of a laminate while suppressing the occurrence of large cracks using a cutter that discharges chips outward.

[0008] Technical solutions to technical problems

[0009] An object of the present invention is to provide a cutting method for a sheet-like member, which can suppress the occurrence of large cracks on the end surface when cutting the end surface of a laminated body while discharging chips to the outside.

[0010] A first embodiment of a method for cutting a sheet component is a method for cutting an end surface of a stacked body formed by stacking a plurality of sheet components using a rotary cutter for end surface processing, the rotary cutter comprising a rotation axis, a setting surface extending in a direction perpendicular to the rotation axis, and a cutting blade provided on the setting surface, wherein a plurality of cutting blades are provided on the setting surface, and when viewed from a direction perpendicular to the setting surface, at least one of the cutting blades is inclined in a direction opposite to the rotation direction of the rotary cutter relative to an end portion on the rotation axis side of the cutting blade and a virtual straight line passing through the rotation axis, so that the rotary cutter rotates , so that the chips generated from the end face of the stack by the cutting of the inclined cutting blade are discharged in the radial outward direction of the setting surface, and when the cutting blade invades from the upper surface side of the sheet component on the cutting travel side of the rotary cutter, the end face of the stack is cut in an area of the setting surface that is above the horizontal virtual reference line passing through the rotation axis, and when the cutting blade invades from the lower surface side of the sheet component on the cutting travel side of the rotary cutter, the end face of the stack is cut in an area of the setting surface that is below the horizontal virtual reference line passing through the rotation axis.

[0011] A second aspect of the cutting method for a sheet member is the cutting method of the first aspect, wherein an angle of the inclined cutting blade relative to the virtual straight line is 30 degrees or less.

[0012] A third aspect of the sheet member cutting method is the cutting method of the first or second aspect, wherein the end surface of the stacked body is cut at an intrusion angle of the inclined cutting blade relative to the upper or lower surface of the sheet member within a range of 10 to 50 degrees.

[0013] The fourth method for cutting a sheet-like component is, in any one of the cutting methods of the first to third methods mentioned above, the upper area or the lower area is an area sandwiched by a horizontal line passing through a position half the distance from the end of the inclined rotation axis side of the cutting blade to the rotation axis and the virtual reference line.

[0014] According to another aspect of the present invention, a manufacturing apparatus for a sheet member is provided.

[0015] The method for manufacturing a sheet member includes the step of cutting the end surface of the sheet member by performing any one of the cutting methods described in the first to fourth aspects.

[0016] Effects of the Invention

[0017] According to the cutting method of the present invention, it is possible to suppress the occurrence of relatively large cracks when cutting the end surface of a stacked body. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a side view showing an example of the layer structure of a sheet member.

[0019] Figure 2 It is a side view showing another layer structure example of the sheet member.

[0020] Figure 3 It is a side view showing another layer structure example of the sheet member.

[0021] Figure 4 It is a side view showing an example of a cutting machine.

[0022] Figure 5 It means from Figure 4 A top view of the cutting machine viewed in the direction of arrow V.

[0023] Figure 6 It is from Figure 5 An enlarged front view of the first rotary cutter when viewed in the direction of arrow VI.

[0024] Figure 7 It is from Figure 5 An enlarged front view of the second rotary cutter when viewed in the direction of arrow VII.

[0025] Figure 8 This is an enlarged front view of a rotary cutter showing another arrangement example of cutting blades.

[0026] Figure 9 This is an enlarged front view of the first rotary cutter during cutting, viewed from a direction perpendicular to the installation surface.

[0027] Figure 10 This is a reference front view used to illustrate the intrusion angle.

[0028] Figure 11 This is an enlarged front view of a first rotary cutter according to another embodiment, when viewed from a direction perpendicular to the installation surface.

[0029] Figure 12 is an enlarged front view of a first rotary cutter used in the embodiment.

[0030] Figure 13 This is an enlarged front view showing the state during cutting for reference in the embodiment.

[0031] Figure 14 This is a graph showing the results of Example 1.

[0032] Figure 15 This is a graph showing the results of Example 2. DETAILED DESCRIPTION

[0033] [Sheet parts]

[0034] From the perspective of its top view shape, the sheet member is a single piece. Furthermore, the top view shape refers to the shape of the sheet member when viewed from a direction perpendicular to its top surface (i.e., the shape when viewed from above). For example, the top view shape of the sheet member is a rectangular shape such as a substantially rectangular or substantially square.

[0035] From the perspective of layer composition, the sheet member may have a single-layer structure or a multi-layer structure. When the sheet member has a multi-layer structure, the number of layers is 2 or more, and the upper limit is not particularly limited, but is generally 10 or less. The following cutting method can suppress the generation of relatively large cracks, so it is effective to apply this method to sheet members with a multi-layer structure.

[0036] From a functional perspective, the sheet member may include a layer having an optical function (hereinafter referred to as an "optical function layer") or a layer not having an optical function (hereinafter referred to as a "layer other than the optical function layer").

[0037] The thickness of the sheet member is not particularly limited, and is, for example, 10 μm or more and 2 mm or less.

[0038] Figures 1 to 3 The layer structure of the sheet member 1 is exemplified.

[0039] Figure 1 The sheet member 1 shown has, for example, a three-layer structure including, in order from the upper side of the paper, a first constituent layer 11 , a second constituent layer 12 , and a third constituent layer 13 .

[0040] Figure 2 The sheet member 1 shown has a five-layer structure including, in order from the upper side of the paper, a fourth constituent layer 14 , a fifth constituent layer 15 , a sixth constituent layer 16 , a seventh constituent layer 17 , and an eighth constituent layer 18 .

[0041] Figure 3 The sheet-like member 1 shown has a single-layer structure. The single-layer structure includes a ninth constituent layer 19 .

[0042] Each constituent layer is not particularly limited, and examples thereof include any appropriate layer such as an optical functional layer, a surface protective layer, a release liner, a pressure-sensitive adhesive layer, an adhesive layer, and a top coat layer.

[0043] If we list a few examples, for example, in a sheet member 1 of one example, Figure 1 The first constituent layer 11 shown is a surface protection layer, the second constituent layer 12 is an adhesive layer, and the third constituent layer 13 is an optical function layer. Figure 1The first constituent layer 11 shown is a surface protection layer, the second constituent layer 12 is an optical functional layer, and the third constituent layer 13 is a layer other than the optical functional layer. Figure 1 The first constituent layer 11 shown is a layer other than the optical functional layer, the second constituent layer 12 is a pressure-sensitive adhesive layer, and the third constituent layer 13 is a layer other than the optical functional layer.

[0044] In another example of the sheet member 1, Figure 2 The fourth constituent layer 14 is a surface protective layer, the fifth constituent layer 15 is an adhesive layer, the sixth constituent layer 16 is an optical functional layer, the seventh constituent layer 17 is an adhesive layer, and the eighth constituent layer 18 is a release liner. Figure 2 The fourth constituent layer 14 is a surface protective layer, the fifth constituent layer 15 is an adhesive layer, the sixth constituent layer 16 is an optical functional layer, the seventh constituent layer 17 is an adhesive layer or a pressure-sensitive adhesive layer, and the eighth constituent layer 18 is a surface protective layer.

[0045] In addition, another example of the sheet member 1 Figure 3 The ninth constituent layer 19 shown is an optical functional layer.

[0046] However, the number of layers of the sheet member and the specific types of the constituent layers are not limited to Figures 1 to 3 .

[0047] The optically functional layer includes, for example, a polarizing layer, a phase difference layer, an antireflection layer, a light diffusion layer, a brightness enhancement layer, and a light reflection layer. The polarizing layer is a layer that transmits light vibrating in a specific direction (polarized light) and blocks light vibrating in other directions. The phase difference layer is a layer that exhibits optical anisotropy, and representative examples include stretched films of acrylic resins, cycloolefin resins, and cellulose resins. The optically functional layer may be composed of only one selected from the polarizing layer, phase difference layer, and the like, or may be a laminated film of two or more selected from the polarizing layer, phase difference layer, and the like.

[0048] Examples of the surface protective layer include a substantially isotropic, colorless, and transparent layer. Examples of the substantially isotropic, colorless, and transparent layer include resin films primarily composed of polyester resins such as polyethylene terephthalate and polyethylene naphthalate; cellulose resins such as triacetylcellulose; polycarbonate resins; acrylic resins such as polymethyl methacrylate; styrene resins such as polystyrene; olefin resins such as polyethylene and polyolefins having a cyclic or norbornene structure; vinyl chloride resins; amide resins such as nylon 6; imide resins; sulfone resins; vinyl alcohol resins; vinylidene chloride resins; vinyl butyral resins; arylate resins; and polyoxymethylene resins.

[0049] The release liner is a layer used to cover the adhesive force of the adhesive layer. The release liner has a release property for the adhesive layer and is usually peeled off during use. There are no particular restrictions on the release liner, and it is usually used for layers other than the optical functional layer.

[0050] The adhesive layer has adhesive properties at room temperature, and its adhesive properties last for a long time. The adhesive layer is composed of a known adhesive. The adhesive is colorless and transparent, and examples thereof include acrylic adhesives, rubber adhesives, silicone adhesives, polyurethane adhesives, vinyl alkyl ether adhesives, polyvinyl pyrrolidone adhesives, polyacrylamide adhesives, and cellulose adhesives. The adhesive layer firmly joins the two layers in a manner that is not easily peeled off.

[0051] [Laminated body]

[0052] A laminate is an object to be machined. It is composed of multiple sheet-like components, formed by stacking these components in the thickness direction. The top view of the laminate is identical to the top view of the sheet-like components. The end faces of the laminate are composed of a collection of the end faces of the sheet-like components. Furthermore, an end face is a surface along the thickness direction (thickness surface). If the laminate (sheet-like component) is rectangular in top view, there are four end faces of the laminate. The thickness of the laminate is calculated by multiplying the thickness of the sheet-like components by the number of sheet-like components. By setting the number of stacked sheet-like components, the thickness of the laminate can be appropriately set.

[0053] [Cutting Machine]

[0054] The cutting method is performed using a cutting machine. Figure 4 is a side view of an exemplary cutting machine 2, Figure 5 It is a plan view of the cutting machine 2 viewed from above toward below.

[0055] The cutting machine 2 includes a work table 21 , a pair of support columns 22 , 22 provided on the work table 21 , a frame 23 mounted on the pair of support columns 22 , a holding device 3 for holding the stacked body 9 , and a pair of rotary cutters 5 , 5 for end surface processing.

[0056] The holding device 3 includes a rotating table 31 installed on the workbench 21; a clamp 32 mounted on the frame 23 so as to be movable along the frame 23; a lower clamping plate 33 mounted on the rotating table 31 via a vertical movement mechanism 35; and an upper clamping plate 34 mounted on the clamp 32 via a vertical movement mechanism 36. As the vertical movement mechanisms 35 and 36, for example, cylinders or the like can be used.

[0057] By raising the lower clamping plate 33 by using the vertical movement mechanism 35 and / or lowering the upper clamping plate 34 by using the vertical movement mechanism 36, the stacked body 9 can be clamped and fixed between the lower clamping plate 33 and the upper clamping plate 34. Figure 5 As shown by the hollow arrow in FIG, the rotating table 31 can rotate within the surface (horizontal plane) of the workbench 21. By rotating the rotating table 31, the direction of the end face of the sandwiched stack 9 can be changed within the horizontal plane. Figure 4 and Figure 5 As shown by the hollow arrows, the holding device 3 including the rotating table 31 and the clamp 32 can slide synchronously along the frame 23. By sliding the holding device 3 on the surface of the work table 21, the end face of the clamped laminate 9 can be moved along the longitudinal direction of the end face while in contact with the rotating cutter 5, thereby cutting the end face.

[0058] Although not specifically shown, the holding device 3 may be immobile, while the mounting portion 53 including the pair of rotary cutters 5 is movable. In this case, by sliding the rotary cutters 5, the rotary cutters 5 can be moved while contacting the end faces of the sandwiched laminate 9 in the longitudinal direction, thereby cutting the end faces. Alternatively, the holding device 3 and the pair of rotary cutters 5 may be configured to be movable relative to each other.

[0059] A pair of rotary cutters 5 are provided facing each other in order to simultaneously cut the opposing end surfaces of the laminate 9. Hereinafter, one rotary cutter 5 will be referred to as the "first rotary cutter 6," and the other rotary cutter 5 will be referred to as the "second rotary cutter 7." When referring to both rotary cutters collectively, they will be simply referred to as the "rotary cutter 5."

[0060] The rotary shaft 51 of the rotary cutter 5 is connected to a driving device 52 such as a motor, and the driving device 52 is installed on the workbench 21 via a mounting portion 53. Figure 5 As shown by the hollow arrow in FIG, the mounting portion 53 can be moved along the rotation axis 51. By moving the mounting portion 53, the interval between the first rotary cutter 6 and the second rotary cutter 7 can be appropriately adjusted. In addition, the rotation axis 51 of the first rotary cutter 6 and the rotation axis 51 of the second rotary cutter 7 are Figure 4 That is, the rotation axis 51 of the second rotary cutter 7 exists on the extension line of the rotation axis 51 of the first rotary cutter 6.

[0061] <First Rotary Cutter>

[0062] Figure 6 It is an enlarged front view of the first rotary cutter 6 as viewed from the installation surface side in a direction perpendicular to the installation surface.

[0063] The first rotary cutter 6 includes a rotary shaft 51 , a mounting surface 54 extending in a direction perpendicular to the rotary shaft 51 , and a cutting blade 8 mounted on the mounting surface 54 .

[0064] Specifically, the setting surface 54 is a surface on which the cutting blade 8 is set, for example, Figure 6 The figure shows one surface of a disk that is substantially circular when viewed from the front. A rotating shaft 51 is fixed to the surface opposite to the installation surface 54. The installation surface 54 (disc) can be rotated by rotating the rotating shaft 51 using a driving device 52. Figure 5 as well as Figure 6 The thin arrow indicates the rotation direction of the first rotary cutter 6 .

[0065] A plurality of cutting blades 8 are provided on the installation surface 54. The cutting blades 8 are formed in a portion of the cutting portion 89. The cutting blades 8 protrude from the installation surface 54. When the cutting portion 89 is viewed from a direction perpendicular to the installation surface 54, the cutting portion 89 is, for example, rectangular in shape. The cutting blades 8 are formed on one side of the rectangular cutting portion 89. Figure 6 In the figure, for easier understanding, the cutting blade 8 is indicated by double lines. However, the cutting portion 89 is not limited to a rectangular shape and may also be a polygonal shape such as a triangle, a straight line, or the like. Furthermore, the straight cutting portion 89 is composed solely of the cutting blade 8 (i.e., the straight cutting portion itself constitutes the cutting blade 8). The material of the cutting blade 8 is not particularly limited; examples thereof include diamond, CBN sintered body, ceramics, alloys such as high-speed steel, and other metals.

[0066] A plurality of cutting blades 8 are provided in the circumferential and / or radial directions of the installation surface 54. In the illustrated example, three cutting blades 8 are provided as one group, and another group of cutting blades 8 is provided at positions 180 degrees rotationally symmetrical with the axis O of the rotation axis 51 as the center point. In the aforementioned group, the three (or more) cutting blades 8 are arranged at equal intervals in the radial direction. Figure 6In the figure, to facilitate understanding of the differences in the radial positions of the cutting blades 8, portions of concentric circles of varying radii are indicated by small dashed lines. Hereinafter, from the outside of the mounting surface 54 toward the inside, these are sometimes referred to as the "first cutting blade 81," the "second cutting blade 82," and the "third cutting blade 83." "Outside" refers to the side away from the axis O of the rotation axis 51, and "inside" refers to the side closer to the axis O of the rotation axis 51. The first cutting blade 81 is farthest from the axis O of the rotation axis 51, while the third cutting blade 83 is closest to the axis O of the rotation axis 51. The second cutting blade 82 is located between the first and third cutting blades 81 and 83. The second cutting blade 82 is positioned at a predetermined interval in the direction opposite to the direction of rotation, relative to the position where the first cutting blade 81 is positioned. The third cutting blade 83 is positioned at a predetermined interval in the direction opposite to the direction of rotation, relative to the position where the second cutting blade 82 is positioned. Typically, the circumferential spacing between the second cutting blade 82 and the first cutting blade 81 is the same as the circumferential spacing between the third cutting blade 83 and the second cutting blade 82, but these spacings may be different. Furthermore, a plurality of cutting blades 8 may be arranged radially (in this case, the circumferential spacing between the cutting blades 8 is zero).

[0067] The radius of the setting surface 54 of the first rotary cutter 6 can be appropriately set, for example, 70mm to 300mm, preferably 80mm to 200mm. In addition, the position where the first cutting blade 81 is set is slightly inside the outer edge of the setting surface 54, and the radius of the setting surface 54 is approximately equal to the cutting radius.

[0068] The first cutting blade 81 protrudes less than the second cutting blade 82, and the second cutting blade 82 protrudes less than the third cutting blade 83. The first cutting blade 81 is a so-called rough cutting blade, the second cutting blade 82 is a so-called intermediate cutting blade, and the third cutting blade 83 is a so-called finish cutting blade.

[0069] like Figure 6 As shown, when viewed from a direction perpendicular to the setting surface 54, the first cutting blade 81 is arranged on a virtual straight line R1 passing through the end 81a of the first cutting blade 81 on the side of the rotation axis 51 and the axis O of the rotation axis 51. In addition, the virtual straight line passing through the end of the cutting blade 8 on the side of the rotation axis 51 and the axis O of the rotation axis 51 is synonymous with the radius line of the setting surface 54. Hereinafter, the end of the cutting blade 8 on the side of the rotation axis 51 is referred to as the "inner end". As for the second cutting blade 82, it is also arranged on a virtual straight line R2 passing through the inner end 82a of the second cutting blade 82 and the axis O of the rotation axis 51. On the other hand, as Figure 6As shown, when viewed from a direction perpendicular to the installation surface 54, the third cutting blade 83 is inclined in a direction opposite to the rotation direction of the first rotary cutter 6 relative to a virtual straight line R3 passing through the inner end 83a of the third cutting blade 83 and the axis O of the rotation shaft 51. Preferably, the third cutting blade 83 is inclined at an acute angle in a direction opposite to the rotation direction of the first rotary cutter 6 relative to the virtual straight line R3. Figure 6 , each virtual straight line R1, R2, and R3 is represented by a single-dot chain line. The inclination angle A3 of the third cutting blade 83 can be set appropriately, but from the perspective of fully achieving the effects of the present invention, it is preferably 45 degrees or less, preferably 40 degrees or less, and more preferably 30 degrees or less. The lower limit of the inclination angle A3 of the third cutting blade 83 is theoretically greater than zero, but if it is too small, the purpose of inclining the cutting blade 8 is lost. Therefore, for example, it is set to 3 degrees or more, preferably 5 degrees or more, and more preferably 7 degrees or more. The inclination angle refers to the angle of the inclined cutting blade 8 (e.g., the third cutting blade 83) relative to the virtual straight line. Hereinafter, a cutting blade that is inclined relative to the virtual straight line in a direction opposite to the direction of rotation of the rotary cutter 5 is sometimes referred to as an "inclined cutting blade."

[0070] In addition, although the first cutting blade 81 and the second cutting blade 82 are positioned on the virtual straight lines R1 and R2 in the above description, they may be positioned on the virtual straight lines R1 and R2, for example. Figure 8 As shown, the first cutting blade 81 and the second cutting blade 82 are inclined in a direction opposite to the rotation direction of the first rotary cutter 6 relative to virtual straight lines R1 and R2, respectively, passing through the inner ends 81a and 82a of each cutting blade 8 and the axis O of the rotation axis 51. In other words, all cutting blades 8 may be inclined cutting blades. In this case, the inclination angle A1 of the first cutting blade 81, the inclination angle A2 of the second cutting blade 82, and the inclination angle A3 of the third cutting blade 83 may be the same or different. Furthermore, although not specifically shown, either the first cutting blade 81 or the second cutting blade 82 may be an inclined cutting blade. It suffices that at least one of the multiple cutting blades 8 be an inclined cutting blade. Preferably, at least the cutting blade 8 closest to the rotation axis 51 (the finishing cutting blade 8) is an inclined cutting blade.

[0071] The specific structure of each cutting blade 8 of the first rotary cutter 6 and the method of mounting it to the installation surface 54 may adopt the structure and mounting method described in

[0035] and

[0036] of Patent Document 1, for example, or other conventionally known structures.

[0072] <Second Rotary Cutter>

[0073] Figure 7 It is an enlarged front view of the second rotary cutter 7 when viewed from the installation surface 54 side in a direction perpendicular to the installation surface 54.

[0074] The second rotary cutter 7 has the same structure as the first rotary cutter 6 except that it is in a mirror image relationship with the first rotary cutter 6. Figure 6 " is replaced by "second rotary cutter 7" and " Figure 7 " to explain it.

[0075] [Cutting method]

[0076] like Figure 4 and Figure 5 As shown, the stacked body 9 is held between the clamping plates of the holding device 3. By sliding the holding device 3 holding the stacked body 9 toward the side of a pair of rotary cutters 5, one end face 9a of the stacked body 9 contacts the first rotary cutter 6 and is cut, and the other end face 9b opposite to the end face 9a contacts the second rotary cutter 7 and is cut. In addition, the first rotary cutter 6 and the second rotary cutter 7 can be moved along the end face of the stacked body 9, or the rotary cutter 5 and the holding device 3 can be moved separately. The rotation speed of the rotary cutter 5 can be appropriately set, for example, to 3000rpm~7000rpm. In addition, the moving speed of the stacked body 9 can be appropriately set, for example, to 200mm / min~1000mm / min. However, as mentioned above, when cutting, it is sufficient to move the stacked body 9 and the rotary cutter 5 relative to each other, so the moving speed of the stacked body 9 refers to the relative moving speed.

[0077] On the cutting path of the rotary cutter 5, the outermost cutting blades 8 contact the end faces 9a and 9b of the stack 9, performing the initial cutting. As the stack 9 moves, the innermost cutting blades 8 contact the end faces of the stack 9, performing a predetermined amount of cutting. For example, the outermost first cutting blade 81 cuts the end face by approximately 200 to 700 μm, the second cutting blade 82 cuts the end face by approximately 100 to 500 μm, and the innermost third cutting blade 83 cuts the end face by approximately 50 to 300 μm. On the cutting path, each cutting blade 8 continuously cuts the end face, completing the cutting of both end faces 9a and 9b of the stack 9. Next, the holding device 3 is slid back to its original position. After rotating the rotary table 31 90 degrees, the holding device 3 is again slid toward the pair of rotary cutters 5, allowing the remaining two uncut end faces to be similarly cut.

[0078] The rotary cutter 5 rotates so as to discharge chips generated from the end surface of the stacked body 9 during cutting with the inclined cutting blades radially outward (outward) of the installation surface 54. By discharging the chips outward, the chips are removed more effectively.

[0079] like Figure 6 As shown, by rotating the first rotary cutter 6 clockwise, the third cutting blade 83 as an inclined cutting blade cuts the end surface of the stacked body 9, and the chips are discharged radially outward (outward) of the installation surface 54. Figure 7 As shown, by rotating the second rotary cutter 7 counterclockwise, the third cutting blade 83, which is an inclined cutting blade, cuts the end surface of the stacked body 9, and the resulting chips are discharged outward (radially outward) of the installation surface 54. In the illustrated example, the first rotary cutter 6 and the second rotary cutter 7 are both arranged so that the cutting blades 8 penetrate from the upper surface side of the stacked body 9 on the cutting travel side of the rotary cutter 5. "Penetration" is also referred to as "entry."

[0080] As described above, when the cutting blade 8 intrudes from the upper surface side of the sheet member (the upper surface side of the laminated body 9) on the cutting travel side of the rotary cutter 5, the end surface of the laminated body 9 is cut in an area above the horizontal virtual reference line passing through the axis O of the rotation shaft 51 on the installation surface 54. Furthermore, as described later in the "Other Embodiments" section, when the cutting blade 8 intrudes from the lower surface side of the sheet member (the lower surface side of the laminated body 9) on the cutting travel side of the rotary cutter 5, the end surface of the laminated body 9 is cut in an area below the horizontal virtual reference line passing through the axis O of the rotation shaft 51 on the installation surface 54.

[0081] Figure 9 This is an enlarged front view of the first rotary cutter 6 during cutting, as viewed from a direction perpendicular to the installation surface 54 . Figure 9 The thin arrow indicates the rotation direction of the first rotary cutter 6, the hollow arrow indicates the direction in which the stack 9 is slid, the portion marked with countless dots indicates the portion of the end face of the stack 9 where cutting has been completed by all the cutting blades 8, the portion marked with shadows indicates the portion of the end face of the stack 9 that is in the process of being cut, the double-dotted line indicates a virtual reference line, and the single-dotted line indicates a horizontal line.

[0082] like Figure 9As shown, on the cutting travel side P, the cutting blade 8 intrudes from the upper surface 9c of the stack 9 (sheet components). The end face of the stack 9 is cut in an area S1 above a horizontal imaginary reference line F1 passing through the axis O of the rotating shaft 51. Preferably, the end face of the stack 9 is cut within the upper area S1, in an area S11 sandwiched between a horizontal line F2 passing halfway between the inner end 83a of the third cutting blade 83 (the end of the inclined cutting blade on the rotation axis side) and the imaginary reference line F1. The horizontal line F2 passes through half the distance from the inner end 83a of the third cutting blade 83 (the end on the rotation axis side of the inclined cutting blade) to the axis O of the rotating shaft 51. The thickness of the stack 9 is determined by the thickness of the sheet components and the number of sheets. Therefore, the number of overlapping sheet components is set so that the thickness of the stack 9 falls within the aforementioned area S1 or area S11. The same applies to the second rotary cutter 7. The second rotary cutter 7 is a mirror image of the first rotary cutter 6, and its illustration and description are omitted here.

[0083] By cutting the end surface of the laminate 9 in the upper region S1 (preferably, the region S11 sandwiched between the virtual reference line F1 and the horizontal line F2 ) in this manner, the generation of relatively large cracks can be suppressed.

[0084] From another perspective, the end face of the stacked body 9 is preferably cut in the upper region S1 at an angle of penetration of the inclined cutting blade relative to the upper surface of the sheet member of 10 to 50 degrees, more preferably at an angle of penetration of 30 to 50 degrees.

[0085] Figure 10 This is a reference front view used to illustrate the penetration angle of the inclined cutting blade. In this specification, the penetration angle B relative to the upper surface 1c of the sheet member 1 refers to the angle formed between the inclined cutting blade and the upper surface 1c of the sheet member 1 when the inner end 83a of the inclined cutting blade (e.g., the third cutting blade 83) contacts the upper surface 1c of the sheet member 1.

[0086] like Figure 10As shown, when the inclined cutter (e.g., the third cutter 83) is located at a position corresponding to the center angle C1, the intrusion angle B of the inclined cutter is obtained by adding the intrusion angle A3 of the inclined cutter to the center angle C1. When the inclined cutter (e.g., the third cutter 83) is located at a position corresponding to the center angle C2, the intrusion angle B of the inclined cutter is obtained by adding the intrusion angle A3 of the inclined cutter to the center angle C2. When the inclined cutter (e.g., the third cutter 83) is located at a position corresponding to the center angle C3, the intrusion angle B of the inclined cutter is obtained by adding the intrusion angle A3 of the inclined cutter to the center angle C3. The center angles C1, C2, and C3 are the angles formed between the virtual straight line R3 of the inclined cutter at each position and the virtual reference line F1. The center angle can be calculated using a trigonometric function (sin) based on the distance from the end of the inclined cutting blade on the rotation axis side (e.g., the inner end 83a of the third cutting blade 83) to the axis O and the height of the end of the inclined cutting blade on the rotation axis side (e.g., the inner end 83a of the third cutting blade 83) located at a predetermined position.

[0087] [Other embodiments]

[0088] In the above embodiment, the rotary cutter 5 is rotated so that the cutting blade 8 enters from the upper surface side of the sheet member during cutting. However, the rotary cutter 5 may be rotated so that the cutting blade 8 enters from the lower surface side of the sheet member.

[0089] Figure 11 This is an enlarged front view of an example of a first rotary cutter 6 rotating with the cutting blades 8 protruding from the lower surface of the sheet member while cutting. By rotating the first rotary cutter 6 counterclockwise, each cutting blade 8 protrudes from the lower surface of the sheet member (the lower surface of the stacked body 9), cutting the end surface of the stacked body 9. Similarly to the above-described embodiment, the first rotary cutter 6 rotates with the cutting blades 8 protruding from the lower surface of the sheet member, with at least one cutting blade 8 being an inclined cutting blade. The cutter rotates so that chips are discharged radially outward from the mounting surface 54.

[0090] Furthermore, as in the present embodiment, when the cutting blade 8 intrudes from the lower surface side of the sheet member on the cutting advancing side, the end face of the laminated body 9 is cut in an area S2 below the horizontal virtual reference line F1 passing through the rotation axis 51. Preferably, the end face of the laminated body 9 is cut in the lower area S2, in an area S22 sandwiched between a horizontal line F3 passing through a position halfway between the inner end 83a of the third cutting blade 83 (the end of the inclined cutting blade on the rotation axis side) and the axis O of the rotation axis 51.

[0091] Furthermore, the end face of the stacked body 9 is preferably cut in the lower region S2 at an angle of penetration of the inclined cutting blade relative to the lower surface of the sheet member within a range of 10 to 50 degrees, and more preferably within a range of 30 to 50 degrees. In this specification, the penetration angle relative to the lower surface of the sheet member refers to the angle formed between the inclined cutting blade and the lower surface of the sheet member when the inner end 83a of the inclined cutting blade (e.g., the third cutting blade 83) contacts the lower surface of the sheet member.

[0092] The same applies to the second rotary cutter 7. The second rotary cutter 7 is in a mirror image relationship with the first rotary cutter 6, and its illustration and description are omitted for other embodiments.

[0093] [Example]

[0094] Next, examples of the present invention will be described. However, the present invention is not limited to the following examples.

[0095] [Cutting object]

[0096] The object used in the examples was a laminate of 200 350 μm thick sheet members. Therefore, the thickness of the laminate was approximately 70 mm. The sheet member had a rectangular shape of 48 mm x 45 mm when viewed from above, and its layer structure consisted of surface protection film / antireflection film / adhesive layer / retardation film / adhesive layer / polarizing film layer / adhesive layer / release liner.

[0097] [Example 1]

[0098] <Preparation of Cutting Machine>

[0099] Prepare Figure 4 and Figure 5 In the embodiment 1, as the first rotary cutter 6, a cutting machine 2 having the structure shown in FIG. Figure 12The rotary cutter shown. Specifically, the first rotary cutter 6 is in the shape of a disk with a setting surface 54 having a radius of 250 mm. An inclined cutter 84 is provided on the setting surface 54, and another inclined cutter 84 is provided at a 180-degree rotationally symmetrical position. The inclined cutter is made of an ultra-hard PCD blade, and the blade width W of the inclined cutter 84 is 50 mm. The protrusion of the inclined cutter 84 from the setting surface 54 is set to 3.5 mm. The inclination angle A4 of the inclined cutter 84 relative to the virtual straight line R4 is set to 10 degrees. In addition, the inclined cutter 84 is installed at a position where the distance D from the axis O of the rotating shaft 51 to the inner end 84a of the inclined cutter 84 is 110 mm. Therefore, the position halfway between the inner end 84a of the inclined cutting blade 84 and the axis O of the rotating shaft 51 is 55 mm upward from the axis O. The region S11 is the area sandwiched between the horizontal line F2 passing through this position and the virtual reference line F1 (a horizontal straight line passing through the axis O). Since the second rotary cutter is a mirror image of the first rotary cutter, its illustration and description are omitted.

[0100] <Cutting>

[0101] like Figure 13 As shown, the stack 9 is aligned in such a manner that the center portion 91 in the thickness direction is roughly aligned with the virtual reference line F1, and under the following condition 1, the stack 9 is horizontally slid between a pair of rotary cutters (a first rotary cutter and a second rotary cutter), thereby cutting the two end faces of the stack 9. The cutting amount of the end face is set to about 500 μm. The direction of rotation of the rotary cutter is such that the chips generated by the cutting of the inclined cutting blade 84 are discharged in the radial direction of the rotary cutter, and the inclined cutting blade 84 intrudes from the upper surface side of the stack 9 (sheet component). In addition, in Figure 13 In the figure, the rotation direction of the first rotary cutter 6 is indicated by a thin arrow, the movement direction of the laminate 9 is indicated by a hollow arrow, and the portion of the end surface of the laminate 9 that has been cut by the cutting blade 84 is marked with a point. The laminate 9 moves so that its center portion 91 in the thickness direction follows the virtual reference line F1. Therefore, the end surface of the upper half of the laminate 9 (35 mm thick above the center portion 91) is cut in the area above the rotary cutter, and the end surface of the lower half of the laminate 9 (35 mm thick below the center portion 91) is cut in the area below the rotary cutter.

[0102] Condition 1: Rotation speed of the rotary cutter: 5500 rpm. Moving speed of the laminate: 600 mm / min.

[0103] After cutting, visually inspect the cutting condition of one of the two end faces to check for cracks. If cracks are present, measure the length of the cracks. Figure 13 ), the crack length was recorded for each partition. The results are shown in Table 1. It should be noted that the crack length in Table 1 represents the largest crack among the cracks measured in each partition (the same applies to Table 2).

[0104] Specifically, if Figure 13 As shown, the position of the center portion 91 of the laminate 9 in the thickness direction is set to zero, and the area 5 mm above it is divided into sections 0 to 5, the area 5 mm above it is divided into sections 5 to 10, and so on, and so on, every 5 mm. Similarly, the position of the center portion 91 of the laminate 9 in the thickness direction is set to zero, and the area 5 mm below it is divided into sections 0 to -5, the area 5 mm below it is divided into sections -5 to -10, and so on, every 5 mm. Then, the length of each crack generated in each section is measured.

[0105] In addition, the end face of the laminate was cut in the same manner as in Condition 1, except that the rotation speed of the rotary cutter and the moving speed of the laminate were changed as in Conditions 2 to 9 below. For Conditions 2 to 9, the length of the crack in each partition was measured in the same manner as in Condition 1 after the cutting was completed. These results are shown in Table 1. Figure 14 The results of Table 1 are also shown in the graph. Figure 14 The black circles represent the average crack lengths for each partition, the upper dashed line represents the maximum crack length for each partition, and the lower dashed line represents the minimum crack length for each partition. For each partition, the crack lengths measured under conditions 1 to 9 are contained between the upper and lower dashed lines.

[0106] Condition 2: Rotation speed of the rotary cutter: 5500 rpm. Moving speed of the laminate: 400 mm / min.

[0107] Condition 3: Rotation speed of the rotary cutter: 5500 rpm. Moving speed of the laminate: 800 mm / min.

[0108] Condition 4: Rotation speed of the rotary cutter: 6000 rpm. Moving speed of the laminate: 400 mm / min.

[0109] Condition 5: Rotation speed of the rotary cutter: 6000 rpm. Moving speed of the laminate: 600 mm / min.

[0110] Condition 6: Rotation speed of the rotary cutter: 6000 rpm. Moving speed of the laminate: 800 mm / min.

[0111] Condition 7: Rotation speed of the rotary cutter: 5000 rpm. Moving speed of the laminate: 400 mm / min.

[0112] Condition 8: Rotation speed of the rotary cutter: 5000 rpm. Moving speed of the laminate: 600 mm / min.

[0113] Condition 9: Rotation speed of the rotary cutter: 5000 rpm. Moving speed of the laminate: 800 mm / min.

[0114] [Table 1]

[0115]

[0116] Here, we will explain the observation method in Table 1. For example, let's take sections 30-35 as an example. In sections 30-35, when cutting under condition 1, the maximum crack length was 43 μm, when cutting under condition 2, the maximum crack length was 40 μm, and when cutting under condition 3, the maximum crack length was 36 μm. The same applies to conditions 9 and up. The average values in the table are, for example, the average of the maximum crack lengths obtained when cutting sections 30-35 under each condition. The maximum and minimum values represent the maximum and minimum values within sections 30-35. The same applies to sections 25-30 and beyond.

[0117] [Example 2]

[0118] In Example 2, the inclination angle A4 of the inclined cutting blade 84 was set to 30 degrees. The same cutting machine as in Example 1 was used except that the rotary cutter with the inclination angle A4 changed to 30 degrees was used. Using this machine, the end face of the laminate was cut under conditions 1 to 9 in the same manner as in Example 1. In Example 2, after each cutting under conditions 1 to 9 was completed, the length of the crack in each partition was measured. These results are shown in Table 2. Figure 15 The results of Table 2 are also shown in the graph.

[0119] [Table 2]

[0120]

[0121] [evaluate]

[0122] The results of Examples 1 and 2 show that cutting the end face of the laminate in the upper region of the rotary cutter reduces the length of the crack. This is presumably because, depending on the direction of movement of the laminate and the trajectory of the cutter, there are two types of cutting: so-called "meeting cutting" (cutting in the upper region), in which the cutter cuts the laminate in the direction of movement, and so-called "feed cutting" (cutting in the lower region), in which the cutter cuts the laminate in the direction of movement. However, the "meeting cutting" method makes it easier for the cutter to penetrate the laminate with a smaller load.

[0123] [Explanation of Reference Numerals]

[0124] 1 sheet component

[0125] 2Cutting machines

[0126] 5, 6, 7 Rotary cutters

[0127] 51 Rotation axis

[0128] 54 Setting surface

[0129] 8, 81, 82, 83, 84 cutting knives

[0130] 9-layer stack

[0131] Inclination angle of A1, A2, A3, A4 cutting blades

[0132] B. Cutting blade penetration angle

[0133] R1, R2, R3 virtual straight lines

[0134] F1 Virtual Baseline

[0135] F2, F3 horizontal lines

[0136] The area above S1

[0137] The area below S2

Claims

1. A method for cutting sheet components, wherein the method comprises cutting an end surface of a stacked body formed by stacking a plurality of sheet components using a rotary cutter for end surface processing, the rotary cutter comprising a rotation axis, a mounting surface extending in a direction perpendicular to the rotation axis, and a cutting blade mounted on the mounting surface, wherein: A plurality of cutting blades are provided on the installation surface, and when viewed from a direction perpendicular to the installation surface, at least one of the cutting blades is inclined in a direction opposite to the rotation direction of the rotary cutter relative to a virtual straight line passing through an end portion of the cutting blade on the rotation axis side and the rotation axis. The rotary cutter is rotated so that chips generated from the end surface of the stacked body by cutting with the inclined cutting blade are discharged radially outward from the installation surface. When the cutting blade intrudes from the upper surface side of the sheet member on the cutting travel side of the rotary cutter, the end surface of the stacked body is cut in an area above a horizontal virtual reference line passing through the rotation axis on the installation surface. When the cutting blade intrudes from the lower surface side of the sheet member on the cutting travel side of the rotary cutter, the end surface of the stacked body is cut in a region of the installation surface below a horizontal virtual reference line passing through the rotation axis.

2. The cutting method of a sheet member according to claim 1, wherein: The angle of the inclined cutting blade relative to the virtual straight line is 30 degrees or less.

3. The cutting method of a sheet member according to claim 1, wherein: The end surface of the stacked body is cut while the inclined cutting blade penetrates into the upper surface or the lower surface of the sheet member at an angle within a range of 10 to 50 degrees.

4. The cutting method of a sheet member according to claim 1, wherein: The upper region or the lower region is a region sandwiched between a horizontal line passing through a position halfway between the end of the inclined cutting blade on the rotation axis side and the rotation axis and the virtual reference line.

5. A method for manufacturing a sheet component, characterized in that: The method comprises the step of cutting the end surface of the stacked body by the method according to any one of claims 1 to 4.

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