Method for manufacturing film sheet

Abstract

Provided is a method for producing a film pellet, which is capable of producing a film pellet in which a plurality of light release layers are laminated and in which the occurrence of cracks and the upwarp of the light release layers are suppressed. A method for manufacturing a film pellet according to an embodiment of the present invention includes a step of cutting a single sheet into a product portion and an outer product portion by a cutting blade. The single sheet is provided with a laminated film having a laminated structure of five or more layers, and a plurality of light release layers adhered to the laminated film. The plurality of light release layers include a first light release layer disposed on the outermost layer, and a second light release layer on which the first light release layer is laminated. The angle of a tool nose of the cut-off tool ranges from 20 degrees to 40 degrees.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a membrane chip. Background Art

[0002] Film chips, having a structure tailored to their intended use, are widely used in various industrial products. A method for producing such film chips has been proposed, for example, by unwinding a strip of sheet material from a roll of raw film, attaching a single sheet to the sheet material, and then cutting the single sheet and sheet material together to produce film chips (see, for example, Patent Document 1).

[0003] A light release layer may be provided on the outermost layer of such a film small piece to protect the surface of the film small piece during the production process and the transportation process of the film small piece.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2005-298208 Summary of the Invention

[0007] Problems to be solved by the invention

[0008] In recent years, there has been a desire to inspect film sheets with a light release layer on their outermost layer without removing the release layer. However, when film sheets with a light release layer on their outermost layer are subjected to various inspections, it is sometimes impossible to accurately inspect the film sheets due to scratches on the release layer caused during the manufacture and / or transportation of the film sheets.

[0009] To this end, we have explored stacking multiple peeling layers and removing the outermost peeling layer immediately before inspecting a film sheet. This removes the outermost peeling layer, which is prone to scratches, and thus reduces false detections caused by scratches in the peeling layer during film sheet inspection. Furthermore, since even after removing one peeling layer, some peeling layer remains on the film sheet, allowing the sheet to be transported while protecting its surface after inspection.

[0010] As a method for producing such a film small piece having multiple light release layers, for example, the method described in Patent Document 1 discusses a technique of using a single sheet having multiple light release layers laminated thereon, laminating the single sheet to a sheet-like object, and then cutting the sheet.

[0011] However, the method described in Patent Document 1 uses a single sheet having a plurality of light release layers laminated thereon. This may cause cracks in the film pieces when the single sheet or sheet-like object is cut, or may cause warping (peeling) of the light release layers.

[0012] A main object of the present invention is to provide a method for producing a small film piece, which is a method for producing a small film piece in which a plurality of light release layers are laminated and in which cracking and warping of the light release layers are suppressed.

[0013] Solutions to the Problem

[0014] [1] A method for manufacturing a film sheet according to an embodiment of the present invention includes the step of cutting a single sheet into a product portion and a product-external portion using a cutting blade. The single sheet comprises a laminated film having a laminated structure of five or more layers and a plurality of light release layers. The plurality of light release layers are adhered to the laminated film. The plurality of light release layers include a first light release layer disposed as the outermost layer and a second light release layer laminated with the first light release layer. The cutting blade has a tip angle of 20° to 40°.

[0015] [2] In the method for producing a small film sheet described in [1] above, in the step of cutting the single sheet, the single sheet arranged on a movable carrier sheet may be cut.

[0016] [3] In the method for manufacturing a film sheet described in [1] or [2] above, the cutting blade may be provided on a cylindrical reel to form a rotary cutter. Among the angles of the cutting blade tip, a first angle on the product outer portion side relative to a reference line may be at least 1.5 times a second angle on the product portion side relative to the reference line, the reference line being along the radial direction of the rotary cutter and passing through the front end of the cutting blade.

[0017] [4] In the method for producing a small film piece according to any one of [1] to [3] above, the rotary cutter may further include a buffer material that contacts the cutting blade.

[0018] [5] In the method for manufacturing a small film sheet described in [4] above, in the process of cutting the single sheet, the cushioning material can be sandwiched between the rotary cutter and the single sheet and contact the product portion and the outer portion of the product.

[0019] [6] In the method for manufacturing a film sheet described in [4] or [5], the hardness of the cushioning material may be 30° to 60°. Before the step of cutting the single sheet, the thickness of the cushioning material may be 0.8 to 2 times the length of the cutting blade in the radial direction of the rotary cutter.

[0020] [7] In the method for producing a small film sheet according to any one of [1] to [6] above, the thickness of the single sheet may be 300 μm or greater.

[0021] [8] In the method for producing a small film piece according to any one of [1] to [7] above, the laminated film may include a polarizing plate.

[0022] Effects of the Invention

[0023] According to the embodiment of the present invention, a small film piece can be manufactured in which a plurality of light release layers are laminated and in which the occurrence of cracks and the warping of the light release layers are suppressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 The diagram schematically shows the structure of a film chip production line capable of implementing a film chip production method according to an embodiment of the present invention.

[0025] Figure 2 Is configured in Figure 1 A schematic top view of a single sheet on a carrier sheet cut into a rectangular product portion and a product outer portion.

[0026] Figure 3 yes Figure 2 A schematic cross-sectional view of a single sheet is shown.

[0027] Figure 4 yes Figure 1 A schematic cross-sectional view of the rotary cutter is shown.

[0028] Figure 5 yes Figure 4 The schematic cross-sectional view of the cutting blade of the rotary cutter is shown.

[0029] Figure 6 yes Figure 4 Schematic cross-sectional view of the die sheet and cushioning material shown.

[0030] Figure 7 yes Figure 6 The schematic cross-sectional view shows a state in which the cushioning material is compressed by being sandwiched between the die sheet and the single sheet.

[0031] Figure 8 It is used to Figure 1 The diagram is a diagram illustrating the process of cutting a single sheet into a hexagonal product portion and a product outer portion, in which the upstream end of the product portion is approximately parallel to a side in a direction perpendicular to the moving direction of the carrier sheet.

[0032] Figure 9 It is used to Figure 1 The diagram is a diagram for explaining the process of cutting a single sheet into a hexagonal product portion and a product outer portion, in which the upstream end of the product portion is a corner.

[0033] Explanation of symbols

[0034] 1 slide

[0035] 2 single sheets

[0036] 2a Product part

[0037] 2b External part of the product

[0038] 21 light peeling layers

[0039] 21a 1st light peeling layer

[0040] 21b Second light peeling layer

[0041] 22-layer laminated film

[0042] 221 polarizer

[0043] 31 Rotary cutter

[0044] 311 reel

[0045] 313 cutting knife

[0046] 314 cushioning material DETAILED DESCRIPTION

[0047] Hereinafter, representative embodiments of the present invention will be described, but the present invention is not limited to these embodiments. In addition, in order to more clearly illustrate the drawings, the width, thickness, shape, etc. of each part are sometimes schematically shown compared with the embodiments, but this is only an example and does not limit the interpretation of the present invention.

[0048] A. Overview of the Film Chip Manufacturing Method

[0049] Figure 1 1 is a schematic diagram of the structure of a film chip manufacturing line capable of implementing a method for manufacturing a film chip according to an embodiment of the present invention; Figure 2 Is configured in Figure 1 A schematic top view of a single sheet on a carrier sheet cut into a rectangular product portion and a portion outside the product; Figure 3 yes Figure 2 A schematic cross-sectional view of a single sheet is shown.

[0050] A method for producing a film sheet according to one embodiment of the present invention includes a cutting step. In this step, a cutting blade cuts a single sheet 2 into a product portion 2a and a non-product portion 2b. The single sheet 2 comprises a laminated film 22 having a laminated structure of five or more layers and a plurality of light release layers 21 adhered to the laminated film 22.

[0051] like Figure 3 As shown, the plurality of light release layers 21 include a first light release layer 21a and a second light release layer 21b. The first light release layer 21a is disposed on the outermost layer of the sheet 2. Typically, the second light release layer 21b is disposed between the first light release layer 21a and the laminate film 22. The first light release layer 21a is laminated on the second light release layer 21b.

[0052] The cutting blade used in the cutting step has a blade tip angle of 20° to 40°, preferably 25° to 35°.

[0053] According to this method, since the cutting blade angle is within the above-mentioned range, even when a single sheet comprising multiple light release layers is cut, cracks in the laminated film can be suppressed, and localized lifting (peeling) of the first light release layer from the second light release layer can be suppressed. Therefore, as a product, a small film sheet can be manufactured in which multiple light release layers are laminated and cracks and lifting of the light release layers are suppressed.

[0054] like Figure 2 As shown, in one embodiment, the method for manufacturing a film sheet further includes a configuration step. The configuration step is implemented before the cutting step. In the configuration step, typically, a single sheet 2 (a laminated film 22 with multiple light peeling layers 21 attached thereto) is configured on a movable carrier 1. The carrier 1 can move intermittently or continuously. The carrier 1 preferably moves continuously. Therefore, in the cutting step, the single sheet 2 (a laminated film 22 with multiple light peeling layers 21 attached thereto) configured on the movable carrier 1 is cut.

[0055] In the arrangement step, a plurality of sheets 2 are typically arranged on a carrier sheet 1 in parallel in the moving direction of the carrier sheet 1. The plurality of sheets 2 are arranged at intervals from one another on the carrier sheet 1. Preferably, all intervals between adjacent sheets 2 in the plurality of sheets 2 are substantially the same.

[0056] In the cutting step, the single sheet may be cut by a continuous process such as a rotary process or an intermittent process such as a press process.

[0057] As long as the blade edge angle is within the above range, the shape of the cutting blade is not particularly limited and may be double-edged or single-edged. Examples of the cutting blade include a PINNACLE (registered trademark) knife, a sealing knife, a Thomson knife, and a carving knife.

[0058] In one embodiment, the cutting step is carried out by continuous processing. Figure 4 and Figure 5 As shown, the cutting blade 313 cuts the single sheet 2 carried by the carrier sheet 1. In the example shown in the figure, the cutting blade 313 is provided on the cylindrical roll 311 to constitute the rotary cutter 31. Typically, the rotary cutter 31 includes the cylindrical roll 311 and a knife die sheet 312 including the cutting blade 313. It should be noted that Figure 4 and Figure 5 It is a cross-sectional view, but the hatching is omitted for convenience.

[0059] The cylindrical drum 311 is configured to rotate by receiving a driving force from the outside.

[0060] The die sheet 312 includes a sheet body 315 and a cutting blade 313. The sheet body 315 is flexible. The cutting blade 313 has any appropriate pattern shape corresponding to the outer shape of the product portion 2a. The cutting blade 313 protrudes from the sheet body 315 in the thickness direction.

[0061] The die sheet 312 is wound around and fixed to the circumference of the drum 311. When the die sheet 312 is fixed to the circumference of the drum 311, the cutting blade 313 protrudes outward in the radial direction of the drum 311.

[0062] The length of the cutting blade 313 in the radial direction of the rotary cutter 31 (hereinafter referred to as the height of the cutting blade 313 ) is, for example, 0.5 mm to 3.0 mm, or 0.6 mm to 1.5 mm, or 0.6 mm to 0.8 mm.

[0063] like Figure 5 As shown, the cross-section of the cutting blade 313 is substantially wedge-shaped. The cutting blade tip angle of the cutting blade 313 is divided into a first angle θ1 on the product outer portion 2b side and a second angle θ2 on the product portion 2a side, along a reference line L passing through the tip of the cutting blade 313 along the radial direction of the rotary cutter 31 (more specifically, the reel 311).

[0064] The first angle θ1 on the product outer portion 2b side is, for example, 1.0 times or greater, preferably 1.5 times or greater, and more preferably 2.0 times or greater, relative to the second angle θ2 on the product portion 2a side. When the first angle θ1 is at such a ratio relative to the second angle θ2, cracking in the product portion can be stably suppressed, and lifting (peeling) of the light peeling layer during single sheet cutting can be stably suppressed.

[0065] The first angle θ1 on the product outer portion 2 b side is, for example, 0° to 30°, preferably 15° to 30°, and more preferably 18° to 30°.

[0066] The second angle θ2 on the product portion 2 a side is, for example, 0° to 30°, preferably 0° to 15°, and more preferably 0° to 12°.

[0067] like Figure 4 As shown, in one embodiment, the rotary cutter 31 includes a flexible cushioning material 314 in addition to the roll 311 and the die sheet 312 .

[0068] Typically, the cushioning material 314 is located on the opposite side of the die sheet 312 from the roll 311. In the illustrated example, the cushioning material 314 is fixed to the sheet body 315. The cushioning material 314 is in contact with the cutting blade 313.

[0069] like Figure 6 As shown, the cushioning material 314 has a slit 314a at a portion corresponding to the cutting blade 313. The slit 314a penetrates the cushioning material 314 in the radial direction of the reel 311. The cutting blade 313 is disposed in the slit 314a and contacts the inner surface of the slit 314a.

[0070] It should be noted that in Figure 6 and Figure 7 In the drawing, for convenience, the die sheet 312 and the cushioning material 314 are shown as extending linearly in the left-right direction of the paper, but in fact, the die sheet 312 and the cushioning material 314 extend in an arc shape along the outer peripheral surface of the roll 311.

[0071] like Figure 7 As shown, during the cutting process, the cushioning material 314 is compressed between the main sheet 315 of the die sheet 312 and the individual sheets 2, contacting the product portion 2a and the outer portion 2b. This cushioning material prevents unintended movement of the product and outer portions during the cutting process. This prevents rubbing of the cutting blade against the product and / or the outer portion of the product. Consequently, cracks in the product can be more reliably suppressed.

[0072] Note that the cushioning material 314 may be partially provided on the rotary cutter 31 so as to be in contact with the product portion 2 a and not in contact with the product outer portion 2 b during the cutting step.

[0073] The hardness of the cushioning material 314 is, for example, 10° to 80°, preferably 30° to 60°. The hardness of the cushioning material can be measured using a hardness meter, for example.

[0074] If the hardness of the buffer material is within this range, the buffer material can appropriately press the product part and the outer part of the product during the cutting process, thereby stably suppressing the movement of the product part and the outer part of the product during the cutting process and suppressing the formation of dents in the product part.

[0075] Before the cutting process, the thickness of the cushioning material 314 (i.e., the thickness of the cushioning material 314 in an uncompressed state) is, for example, 1 to 5 times, preferably 0.8 to 2 times, the height of the cutting blade 313. Before the cutting process, the thickness of the cushioning material 314 is, for example, 0.4 mm to 8.0 mm, preferably 1.0 mm to 6.0 mm.

[0076] During the cutting process, the cushioning material 314 is compressed as described above. The compression rate of the cushioning material during the cutting process is, for example, 70% or less, preferably 60% or less, and more preferably 50% or less. Meanwhile, the compression rate of the cushioning material during the cutting process is, for example, 20% or more, preferably 35% or more. The compression rate of the cushioning material can be calculated, for example, using the following formula.

[0077] Compression ratio = (thickness of the cushioning material in the compressed state / thickness of the cushioning material before compression) × 100

[0078] If the compression rate of the cushioning material is within this range, the pressing force of the cushioning material against the product and the outer portion of the product can be appropriately adjusted, thereby more stably suppressing the movement of the product and the outer portion of the product and more stably suppressing the formation of dents in the product.

[0079] The moving speed of the individual sheets 2 during the cutting process is, for example, 10 m / min or less, preferably 5 m / min or less. Alternatively, the moving speed of the individual sheets 2 during the cutting process is, for example, 1 m / min or greater. If the rotary cutter cuts the individual sheets moving at such a moving speed during the cutting process, the arrangement process and the cutting process can be fully integrated, allowing these processes to be performed continuously and smoothly.

[0080] like Figure 1 As shown, in the cutting process, the rotary cutter 31 typically rotates so as to feed the cut single sheet 2 to the downstream side in the moving direction of the carrier sheet 1. In the example shown, the rotary cutter 31 rotates counterclockwise when viewed from the front side of the paper.

[0081] The peripheral speed of the rotary cutter 31 during the cutting process is, for example, ±1.0 m / min of the moving speed of the sheet 2, preferably ±0.5 m / min of the moving speed of the sheet 2. The peripheral speed of the rotary cutter 31 is, for example, 1 m / min to 10 m / min, preferably 1 m / min to 5 m / min. When the peripheral speed of the rotary cutter is within this range, the moving sheet can be cut with good accuracy during the cutting process.

[0082] In one embodiment, the method for producing film sheets further includes a beat difference absorbing step. In this beat difference absorbing step, the carrier sheet 1 is guided through a buffer roller 73 between the placement step and the cutting step. This absorbs the beat time difference between the placement step and the cutting step, allowing the individual sheets to be fed to the rotary cutter at the appropriate time.

[0083] In one embodiment, the buffer roller 73 is movable in a direction intersecting the direction in which the axis of the rotary cutter 31 extends. During the cutting process, when the rotary cutter 31 cuts the sheet 2 as described above, the sheet 2 and the carrier sheet 1 may be pulled by the rotation of the rotary cutter 31. In this case, the buffer roller 73 receives a force from the carrier sheet 1 drawn around it, causing it to move toward the rotary cutter 31.

[0084] During the beat error absorption process, the position of the buffer roller 73 can be detected. If the buffer roller 73 is closer to the rotary cutter 31 than a predetermined position during the beat error absorption process, there is a risk that the individual sheets 2 and carrier sheets 1 will be stretched beyond their permitted limits due to the rotation of the rotary cutter 31. Therefore, the cutting of the individual sheets 2 by the rotary cutter 31 is stopped. This prevents the occurrence of defective product parts and improves the yield rate of film sheets.

[0085] In one embodiment, the method for producing a small film piece further includes a separation step. In the separation step, the product outer portion 2b is peeled off from the product portion 2a after the cutting step.

[0086] Furthermore, when multiple individual sheets 2 are arranged on the carrier sheet 1 during the arrangement step, the film sheet manufacturing method may further include a bonding step. In the bonding step, between the arrangement step and the separation step, the product outer portions 2b of adjacent individual sheets 2 in the multiple individual sheets 2 are bonded together using a bonding material 63. In the illustrated example, the bonding step is performed between the arrangement step and the beat difference absorbing step.

[0087] According to such a method, the plurality of product external portions are connected by the connecting material, and therefore the plurality of product external portions can be continuously separated from the product portion in the separation step.

[0088] like Figure 2 As shown, the connecting material 63 is typically a long strip of connecting tape 63a. The connecting tape 63a can have any suitable structure. The connecting tape 63a is affixed to the product outer portions 2b of adjacent single sheets 2 at one time so as not to overlap with the product portions 2a of the single sheets 2.

[0089] In one embodiment, a connecting tape 63a is simultaneously attached to the widthwise ends (orthogonal to the direction of movement of the carrier 1) of multiple individual sheets 2 arranged side by side in the direction of movement of the carrier 1. This allows the outer product portions of three or more individual sheets to be connected by a single connecting tape. In the illustrated example, both widthwise ends of the individual sheets 2 are connected together by the connecting tape 63a.

[0090] like Figure 1As shown, in one embodiment, the method for manufacturing a small film piece further includes an image recognition process. In the image recognition process, image recognition is performed on the product portion 2a. The image recognition process is implemented at least after the cutting process. In the example shown in the figure, it is implemented after the separation process. In the case of continuous processing using a rotary cutter in the cutting process, the vibration of the single sheet during cutting can be reduced compared to the case of cutting the single sheet by intermittent processing (such as pressurization). Therefore, even if the image recognition process is implemented after the cutting process, the image recognition of the small film piece can be performed with good accuracy.

[0091] In the image recognition step, the product part 2a is typically image-recognized to obtain information about the product part 2a. Examples of the obtained information about the product part 2a include the outer shape of the product part, detection of defect marks, and confirmation of the position of product marks.

[0092] B. Details of a single film

[0093] Next, refer to Figure 3 The details of the single sheet used in the method for producing the small film sheet will be described.

[0094] The single sheet 2 is a mother sheet from which at least one product portion 2a can be punched. The shape and size of the single sheet 2 are not particularly limited as long as the product portion 2a can be punched out. In other words, during the cutting process, one or more product portions 2a can be cut from a single single sheet 2. The number of product portions 2a that can be cut from a single single sheet 2 ranges from 1 to 6, or 15 to 30, for example.

[0095] The thickness of the sheet 2 is, for example, 250 μm or more, preferably 300 μm or more. On the other hand, the thickness of the sheet 2 is, for example, 700 μm or less, preferably 500 μm or less.

[0096] The sheet 2 has a laminated structure of seven or more layers. The number of layers in the sheet 2, excluding non-self-supporting layers such as adhesive layers (adhesive layers and pressure-sensitive adhesive layers) and surface treatment layers, is seven or more, preferably eight or more. On the other hand, the number of layers in the sheet 2, excluding non-self-supporting layers such as adhesive layers (adhesive layers and pressure-sensitive adhesive layers) and surface treatment layers, is typically ten or less.

[0097] In the illustrated example, the single sheet 2 includes a laminate film 22 and a plurality of light release layers 21 .

[0098] B-1. Laminated film

[0099] The laminated film 22 has a laminated structure of 5 or more layers. The number of layers of the laminated film 22, excluding non-self-supporting layers such as adhesive layers (adhesive layers and pressure-sensitive adhesive layers) and surface treatment layers, is 5 or more, preferably 6 or more. On the other hand, the number of layers of the laminated film 22, excluding non-self-supporting layers such as adhesive layers (adhesive layers and pressure-sensitive adhesive layers) and surface treatment layers, is typically 8 or less.

[0100] In the illustrated example, the laminated film 22 includes a polarizing plate 221 , a retardation film 226 , and an optical functional film 222 .

[0101] The polarizing plate 221 typically includes a polarizer 221a. According to one embodiment, even if the laminated film includes a polarizer, it is possible to stably suppress the occurrence of cracks in the polarizer during the cutting process.

[0102] Any appropriate polarizer can be adopted as the polarizer 221a. The polarizer may be composed of, for example, a single-layer resin film or a laminated body of two or more layers.

[0103] Specific examples of polarizers composed of a single-layer resin film include those obtained by dyeing a hydrophilic polymer film such as a polyvinyl alcohol (PVA) resin film, a partially formalized PVA resin film, or a partially saponified ethylene-vinyl acetate copolymer film with a dichroic substance such as iodine or a dichroic dye and then stretching it; and polyene-based oriented films such as a dehydrated PVA film or a dehydrochlorinated polyvinyl chloride film. Polarizers obtained by dyeing a PVA resin film with iodine and then uniaxially stretching it are preferably used due to their excellent optical properties.

[0104] As a specific example of a polarizer obtained using a laminate, there can be mentioned a laminate using a resin substrate and a PVA-type resin layer (PVA-type resin film) laminated on the resin substrate, or a polarizer obtained using a laminate using a resin substrate and a PVA-type resin layer formed by coating the resin substrate. The polarizer obtained using a laminate using a resin substrate and a PVA-type resin layer formed by coating the resin substrate can be made, for example, by the following method: a PVA-type resin solution is applied to a resin substrate, dried to form a PVA-type resin layer on the resin substrate, thereby obtaining a laminate of the resin substrate and the PVA-type resin layer; the laminate is stretched and dyed to make the PVA-type resin layer into a polarizer. In one embodiment, a polyvinyl alcohol-type resin layer containing a halide and a polyvinyl alcohol-type resin is preferably formed on one side of the resin substrate. Stretching typically includes immersing the laminate in a boric acid aqueous solution for stretching. In addition, stretching can further include stretching the laminate in a gas atmosphere at a high temperature (for example, above 95°C) before stretching in a boric acid aqueous solution as needed. Furthermore, in one embodiment of the present invention, the laminate is preferably subjected to a drying and shrinking treatment in which the laminate is heated while being transported in the longitudinal direction, thereby shrinking the laminate by at least 2% in the width direction. Typically, the manufacturing method of this embodiment includes sequentially subjecting the laminate to an auxiliary stretching treatment in a gas atmosphere, a dyeing treatment, an aqueous solution stretching treatment, and a drying and shrinking treatment. By introducing the auxiliary stretching treatment, the crystallinity of the PVA can be improved, even when PVA is coated on a thermoplastic resin, enabling high optical properties to be achieved. Furthermore, by simultaneously improving the orientation of the PVA beforehand, problems such as a decrease in orientation and dissolution of the PVA during immersion in water during the subsequent dyeing and stretching steps can be prevented, thereby achieving high optical properties. Furthermore, when the PVA-based resin layer is immersed in a liquid, the orientation disorder and decrease in orientation of the polyvinyl alcohol molecules can be suppressed compared to a case where the PVA-based resin layer does not contain a halide. This improves the optical properties of the polarizer obtained by immersing the laminate in a liquid, such as through dyeing and aqueous solution stretching. Furthermore, by utilizing a drying shrinkage treatment to shrink the laminate in the width direction, the optical properties can be improved. The resulting resin substrate / polarizer laminate can be used directly (i.e., the resin substrate can be used as a protective layer for the polarizer), or the resin substrate can be peeled from the resin substrate / polarizer laminate and any appropriate protective layer corresponding to the purpose can be laminated on the peeled surface for use. Details of the method for manufacturing such a polarizer are described, for example, in Japanese Patent Application Publication No. 2012-73580 and Japanese Patent No. 6470455. The entire contents of these publications are incorporated herein by reference.

[0105] The dyeing of the above-mentioned utilization of iodine can be carried out by, for example, immersing the PVA type resin film in an iodine aqueous solution. The stretching ratio of the above-mentioned uniaxial stretching is preferably 3 to 7 times. Stretching can be carried out after the dyeing process, or while dyeing. In addition, it is also possible to dye after the stretching. The PVA type resin film can be subjected to swelling treatment, cross-linking treatment, cleaning treatment, drying treatment, etc. as required. For example, by immersing the PVA type resin film in water and washing it before dyeing, not only can dirt and anti-blocking agents on the PVA type resin film surface be cleaned, but also the PVA type resin film can be swollen and suppressed from dyeing unevenly.

[0106] The thickness of the polarizer 221 a is, for example, 1 μm to 80 μm, preferably 1 μm to 15 μm, more preferably 1 μm to 12 μm, and even more preferably 3 μm to 12 μm.

[0107] Typically, the polarizer 221a exhibits absorption dichroism at any wavelength within the range of 380 nm to 780 nm. The single-unit transmittance of the polarizer 221a is, for example, 41.5% to 46.0%, preferably 43.0% to 46.0%, and more preferably 44.5% to 46.0%. The polarization degree of the polarizer 221a is preferably 97.0% or higher, more preferably 99.0% or higher, and even more preferably 99.9% or higher.

[0108] In addition to the polarizer 221a, the polarizing plate 221 may also include a protective layer 221b. The protective layer 221b is provided on at least one side of the polarizer 221a. Specifically, the protective layer 221b may be provided on only one side of the polarizer 221a or on both sides. In the illustrated example, the protective layer 221b is provided on both sides of the polarizer 221a. Typically, the protective layer 221b is adhered to the polarizer 221a via any suitable adhesive layer (not shown).

[0109] The protective layer can be formed of any appropriate film that can be used as a protective layer for a polarizer. As the material that becomes the main component of the film, representative examples include transparent resins, specifically, cycloolefin (COP) resins such as polynorbornene; polyester resins such as polyethylene terephthalate (PET); cellulose resins such as cellulose triacetate (TAC); polycarbonate (PC) resins; (meth) acrylic resins; polyvinyl alcohol resins; polyamide resins; polyimide resins; polyethersulfone resins; polysulfone resins; polystyrene resins; polyolefin resins; acetate resins. In addition, thermosetting resins or ultraviolet curing resins such as (meth) acrylic acid, urethane, (meth) acrylic urethane, epoxy, and silicone can also be mentioned. It should be noted that in this specification, "(meth) acrylic acid" includes acrylic acid and methacrylic acid. In addition, glassy polymers such as siloxane polymers can also be mentioned. In addition, the polymer film described in Japanese Patent Application Laid-Open No. 2001-343529 (WO01 / 37007) can also be used. As the material of this film, for example, a resin composition containing a thermoplastic resin having a substituted or unsubstituted imide group in the side chain and a thermoplastic resin having a substituted or unsubstituted phenyl and nitrile group in the side chain can be used, for example: a resin composition having an alternating copolymer formed by isobutylene and N-methylmaleimide and an acrylonitrile-styrene copolymer. This polymer film can be, for example, an extrusion molding of the above-mentioned resin composition. The material of the resin film can be used alone or in combination.

[0110] The thickness of the protective layer 221 b is typically 5 mm or less, preferably 1 mm or less, more preferably 1 μm to 500 μm, and even more preferably 5 μm to 150 μm.

[0111] Furthermore, a surface treatment layer 221c may be provided on the surface of the protective layer 221b as needed. In the illustrated example, the surface treatment layer 221c is provided on the surface of the protective layer 221b on the side of the optical functional film 222. Examples of the surface treatment layer 221c include a hard coating layer, an anti-reflection layer, an anti-blocking layer, and an anti-glare treatment layer, with a hard coating layer being preferred.

[0112] The thickness of the surface treatment layer 221 c can be arbitrarily and appropriately set. For example, the thickness of the surface treatment layer 221 c is 1 μm to 10 μm.

[0113] Typically, the retardation film 226 is bonded to the polarizing plate 221 via the first adhesive layer 223. In the illustrated example, the retardation film 226 is bonded to the surface treatment layer 221c via the first adhesive layer 223.

[0114] Any appropriate material may be used as the material of the retardation film 226. In one embodiment, the retardation film 226 is formed of a stretched film of a polymer film.

[0115] Any suitable resin can be used as the resin forming the polymer film. Specific examples include resins that form positive birefringence films, such as norbornene resins, polycarbonate resins, cellulose resins, polyvinyl alcohol resins, and polysulfone resins. Among these materials for the phase difference film 226, polycarbonate resins are preferably used.

[0116] The optical functional film 222 can impart any appropriate performance to the film piece 10. In one embodiment, the optical functional film 222 is disposed on the opposite side of the retardation film 226 from the polarizer 221. In the illustrated example, the optical functional film 222 is attached to the retardation film 226 via a second adhesive layer 224.

[0117] The optical functional film 222 includes a base material 222a and a functional layer 222b.

[0118] The substrate 222a is a resin film that supports the functional layer 222b. The substrate 222a can be made of any appropriate material. Examples of the material of the substrate 222a include the above-mentioned transparent resins.

[0119] The thickness of the substrate 222a is, for example, 20 μm or more, or preferably 30 μm or more. On the other hand, the thickness of the substrate 222a is, for example, 80 μm or less, or preferably 50 μm or less.

[0120] Typically, the functional layer 222b is disposed on the surface of the substrate 222a opposite to the polarizer 221. Examples of the functional layer 222b include a hard coat layer, an anti-reflection layer, an anti-blocking layer, and an anti-glare layer. The functional layer 222b may also have a laminated structure of two or more layers. Among the functional layers 222b, an anti-reflection layer may preferably be included.

[0121] The thickness of the functional layer 222b can be arbitrarily and appropriately set. For example, the thickness of the functional layer 222b is 0.05 μm to 15 μm, or 1 μm to 8 μm.

[0122] In the example shown in the figure, the laminated film 22 further includes a third adhesive layer 225. The third adhesive layer 225 is located on the side of the polarizing plate 221 opposite to the retardation film 226. In the example shown in the figure, the third adhesive layer 225 is laminated on the protective layer 221b of the polarizing plate 221.

[0123] The first adhesive layer 223, the second adhesive layer 224, and the third adhesive layer 225 can each be composed of any appropriate adhesive. Examples of adhesives include (meth) acrylic adhesives, rubber adhesives, silicone adhesives, polyester adhesives, urethane adhesives, epoxy adhesives, and polyether adhesives. By adjusting the type, quantity, combination, and mixing ratio of the monomers forming the base resin of the adhesive, as well as the amount of the cross-linking agent, the reaction temperature, the reaction time, etc., an adhesive having desired properties corresponding to the purpose can be prepared. The base resin of the adhesive can be used alone or in combination of two or more.

[0124] Among the pressure-sensitive adhesives, preferably, a (meth)acrylic pressure-sensitive adhesive is used.

[0125] The shear storage modulus of each of the first adhesive layer 223, the second adhesive layer 224, and the third adhesive layer 225 is, for example, 10 kPa to 300 kPa, preferably 50 kPa to 300 kPa at 25°C. If the storage modulus of each adhesive layer is lower than the above lower limit, there is a tendency for poor peeling to occur. It should be noted that the shear storage modulus can be measured, for example, using a dynamic viscoelasticity device (product name: ARES Rheometric Scientific) at a heating rate of 5°C / min, a frequency of 1 Hz, and a measurement temperature range of -40°C to 100°C.

[0126] The thickness of each of the first adhesive layer 223 , the second adhesive layer 224 , and the third adhesive layer 225 is, for example, 3 μm to 30 μm, or 5 μm to 20 μm.

[0127] As described above, the laminated film 22 shown in the figure includes, in order, an optical functional film 222, a second adhesive layer 224, a phase difference film 226, a first adhesive layer 223, a protective layer 221b, a polarizer 221a, a protective layer 221b, and a third adhesive layer 225. In other words, the laminated film 22 shown in the figure has a five-layer laminated structure excluding the adhesive layer (adhesive layer and adhesive layer).

[0128] Although not shown, the laminated film 22 may further include another retardation film as needed. The other retardation film is typically disposed between the retardation film 226 and the optical functional film 222. The other retardation film may have any appropriate retardation according to the application of the film piece 10.

[0129] B-2. Light peeling layer

[0130] The plurality of light release layers 21 are attached to the laminated film 22. In the illustrated example, the plurality of light release layers 21 are laminated on the optical functional film 222.

[0131] Although not shown in the drawings, each of the plurality of light release layers 21 includes a base film and an adhesive layer.

[0132] The base film can be made of any suitable material. Examples of base film materials include polyester resins such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and polybutylene terephthalate (PBT); cellulose resins such as cellulose diacetate and cellulose triacetate; polycarbonate resins; (meth)acrylic resins such as polymethyl methacrylate; and cycloolefin resins such as polynorbornene. These resins can be used alone or in combination.

[0133] The thickness of the base film is, for example, 20 μm to 70 μm, and preferably 30 μm to 60 μm.

[0134] The adhesive layer included in the light release layer 21 can be described in the same manner as the first adhesive layer 223 described above.

[0135] The thickness of the light release layer 21 is, for example, 30 μm to 80 μm, or preferably 40 μm to 70 μm.

[0136] As described above, the plurality of light release layers 21 include the first light release layer 21a and the second light release layer 21b. Typically, the first light release layer 21a is bonded to the second light release layer 21b.

[0137] The peel force of the first light release layer 21a relative to the second light release layer 21b is, for example, 0.15 N / 50 mm or less, preferably 0.10 N / 50 mm or less. On the other hand, the peel force of the first light release layer 21a relative to the second light release layer 21b is typically 0.05 N / 50 mm or greater. The peel force can be measured, for example, by a peel force test using an Autograph.

[0138] In the illustrated example, the plurality of light release layers 21 further includes a third light release layer 21c. The third light release layer 21c is positioned between the second light release layer 21b and the laminate film 22. In other words, the first light release layer 21a, the second light release layer 21b, and the third light release layer 21c are stacked in this order. Typically, the second light release layer 21b is attached to the third light release layer 21c.

[0139] The peeling force of the second light release layer 21b relative to the third light release layer 21c is, for example, 0.11 N / 50 mm or more, preferably 0.15 N / 50 mm or more.

[0140] In the illustrated example, the third light release layer 21c is attached to the optical functional film 222. The range of the release force of the third light release layer 21c with respect to the optical functional film 222 is, for example, the same as the range of the release force of the first light release layer 21a described above.

[0141] The plurality of light release layers 21 do not need to include the third light release layer 21c. In this case, the second light release layer 21b is bonded to the optical functional film 222 with the above-mentioned release force.

[0142] B-3. Release liner

[0143] The sheet 2 may further include a release liner 23. In one embodiment, the release liner 23 is temporarily attached to the surface of the third adhesive layer 225 opposite to the polarizer 221. In the illustrated example, the release liner 23 is located on the outermost layer of the sheet 2 opposite to the first light release layer 21a.

[0144] The release liner 23 can be made of any suitable plastic film. Specific examples of plastic films include polyethylene terephthalate (PET) film, polyethylene film, and polypropylene film. Although not shown, the surface of the release liner 23 facing the third adhesive layer 225 can be treated with any suitable release agent (e.g., a silicone release agent) as needed.

[0145] The thickness of the release liner 23 is, for example, 20 μm to 100 μm, or 30 μm to 50 μm.

[0146] As described above, the sheet 2 of the illustrated example includes, in this order, the first light release layer 21a, the second light release layer 21b, the third light release layer 21c, the optical functional film 222, the second adhesive layer 224, the retardation film 226, the first adhesive layer 223, the protective layer 221b, the polarizer 221a, the protective layer 221b, the third adhesive layer 225, and the release liner 23. In other words, excluding the adhesive layers (the adhesive layer and the adhesive layer), the sheet 2 of the illustrated example has a nine-layer laminated structure.

[0147] C. Membrane chip manufacturing line

[0148] Next, refer to Figure 1 A film chip production line 100 capable of implementing the above-described film chip production method will be described.

[0149] The film chip production line 100 is a continuous line capable of producing film chips 10. In one embodiment, the film chip production line 100 includes a carrier sheet conveying unit 7, a sheet supply unit 5, a tape laminating unit 6, a cutting device 3, a separator 8, an image recognition unit 4, and a chip collecting unit 9.

[0150] C-1. Slide transport department

[0151] In the illustrated example, the carrier sheet conveying section 7 includes a carrier sheet continuous feeding roller 71 (hereinafter referred to as the CS continuous feeding roller 71 ), a carrier sheet take-up roller 72 (hereinafter referred to as the CS take-up roller 72 ), the aforementioned buffer roller 73 , and a plurality of guide rollers 74 .

[0152] A long carrier sheet 1 is wound in a roll on the CS continuous feed roller 71. The CS take-up roller 72 is driven by an external force to rotate and take up the carrier sheet 1 drawn from the CS continuous feed roller 71. This allows the carrier sheet 1 to move from the CS continuous feed roller 71 toward the CS take-up roller 72.

[0153] The buffer roller 73 is located between the CS continuous unwinding roller 71 and the CS winding roller 72. The buffer roller 73 is a dancer roller. In the illustrated example, the carrier sheet 1 is bent between the tape laminating section 6 and the cutting device 3 and guided around the buffer roller 73.

[0154] The plurality of guide rollers 74 are arbitrarily and appropriately arranged to guide the movement of the carrier sheet 1. In the illustrated example, the plurality of guide rollers 74 include two first guide rollers 74a located between the tape laminating unit 6 and the cutting device 3. The two first guide rollers 74a guide the carrier sheet 1 so that it passes around the buffer roller 73. The two first guide rollers 74a are located at intervals in the horizontal direction and are located above the buffer roller 73.

[0155] C-2. Sheet supply unit

[0156] The sheet supply unit 5 can supply the single sheet 2 onto the carrier sheet 1 moved by the carrier sheet conveying unit 7. In the illustrated example, the sheet supply unit 5 includes a sheet tray 51, a table 52, a conveyor 53, two first pinch rollers 55, and a pickup device 54.

[0157] The sheet tray 51 can accommodate a plurality of individual sheets 2. Typically, the plurality of individual sheets 2 are accommodated in the sheet tray 51 in a state of being overlapped in the thickness direction.

[0158] The stage 52 has a substantially flat plate shape extending in the horizontal direction.

[0159] The conveyor 53 can transport the sheet 2 placed on the conveyor 53 in a horizontal direction. The conveyor 53 can be operated intermittently or continuously. The conveyor 53 preferably operates continuously. The conveyor 53 can have any appropriate structure. A representative example of the conveyor 53 is a roller conveyor.

[0160] The two first pinch rollers 55 are arranged on the downstream side of the conveyor 53 in the transport direction of the conveyor 53. Typically, the two first pinch rollers 55 face each other in the vertical direction. The carrier sheet 1 passes between the two first pinch rollers 55.

[0161] The pickup device 54 can pick up the individual sheets 2 stored in the sheet tray 51 one by one and can move while holding the individual sheets 2. The pickup device 54 can have any appropriate structure. A typical example of the pickup device 54 is a vacuum suction type pickup device.

[0162] C-3. Belt fitting area

[0163] The tape laminating section 6 can adhere the aforementioned connecting tape 63a to the plurality of sheets 2 arranged on the carrier sheet 1. In the illustrated example, the tape laminating section 6 includes a tape continuous feeding roller 61 and two second nip rollers 62.

[0164] A long connecting tape 63a is wound in a roll shape on the continuous tape feeding roller 61. The connecting tape 63a drawn out from the continuous tape feeding roller 61 is fed between the two second pinch rollers 62.

[0165] The two second pinch rollers 62 are located downstream of the first pinch roller 55 in the direction of movement of the carrier sheet 1. In the illustrated example, they are located between the first pinch roller 55 and the buffer roller 73. Typically, the two second pinch rollers 62 face each other in the vertical direction. The carrier sheet 1 passes between the two second pinch rollers 62.

[0166] C-4. Cutting device

[0167] The cutting device 3 is capable of cutting a single sheet 2 positioned on the carrier sheet 1. The cutting device 3 is located downstream of the buffer roller 73 in the direction of movement of the carrier sheet 1. In the illustrated example, the cutting device 3 is a rotary processing device comprising the aforementioned rotary cutter 31 and the opposing roller 32. Typically, the rotary cutter 31 and the opposing roller 32 face each other in the vertical direction. The carrier sheet 1 passes between the rotary cutter 31 and the opposing roller 32.

[0168] It should be noted that the cutting device 3 is not limited to the configuration including the rotary cutter 31. The cutting device 3 may also be a press working device.

[0169] Furthermore, among the plurality of guide rollers 74, the guide roller 74 located between the cutting device 3 and the separation unit 8 can also function as a peeling roller 74b. The peeling roller 74b peels the cut sheet 2 from the carrier sheet 1. Thus, the cut sheet 2 is transferred from the carrier sheet 1 to the separation unit 8 (typically, the conveyor 83).

[0170] C-5. Separation section

[0171] The separation unit 8 is configured to separate the product outer portion 2b from the product portion 2a after being cut in the cutting device 3. The separation unit 8 is located on the side of the cutting device 3 opposite the buffer roller 73. In the illustrated example, the separation unit 8 includes a conveyor 83, a separation roller 81, and a take-up roller 82. It should be noted that the separation unit 8 may also be a component having a more acute angle, such as a separation rod.

[0172] The conveyor 83 can transport the single sheet 2 transferred from the carrier sheet 1 in a horizontal direction. The conveyor 83 can be operated intermittently or continuously. The conveyor 83 preferably operates continuously. The conveyor 83 can have any appropriate structure. As a representative example of the conveyor 83, a belt conveyor can be cited.

[0173] The separation roller 81 is arranged slightly above the conveyor 83. The separation roller 81 can separate the product outer portion 2b from the product portion 2a when the sheet 2 conveyed by the conveyor 83 passes between the separation roller 81 and the conveyor 83.

[0174] The winding roller 82 can wind up the product outer portion 2 b separated by the separation roller 81 .

[0175] C-6. Image Recognition Unit

[0176] The image recognition unit 4 can perform image recognition on the product portion 2a. More specifically, by performing image recognition on the product portion 2a, the image recognition unit 4 can perform functions such as defect mark detection, center of gravity detection, IJP printing position detection, printing defect detection, outer diameter measurement, printing detection, and defect detection.

[0177] In the example shown in the figure, the image recognition unit 4 performs image recognition on the product portion 2a separated from the product outer portion 2b.

[0178] The image recognition unit 4 is located on the downstream side of the separation roller 81 in the conveying direction of the conveyor 83. The image recognition unit 4 is arranged at a distance above the conveyor 83. The image recognition unit 4 performs image recognition on the information of the product part 2a that reaches the bottom of the image recognition unit 4. When the image recognition unit 4 performs image recognition, the conveyor 83 can be stopped or maintained in the conveying state. When the conveyor 83 maintains the conveying state, the image recognition unit 4 performs image recognition on the information of the above-mentioned product part 2a when the product part 2a transported by the conveyor 83 passes under the image recognition unit 4. In this way, the image recognition of the product part 2a can be implemented efficiently. On the other hand, there is a hidden danger that the vibration caused by the drive of the conveyor 83 affects the image recognition unit 4.

[0179] Examples of the image recognition unit 4 include a camera, a light source, a monitor, and an image processing unit.

[0180] C-7. Small Flakes Recycling Department

[0181] The small piece collecting unit 9 can collect the product part 2a. In the illustrated example, the small piece collecting unit 9 can collect the product part 2a after image recognition by the image recognition unit 4. The small piece collecting unit 9 includes a pickup device 91, a good product tray 92, and a bad product tray 93.

[0182] The pickup device 91 can pick up the product parts 2a on the conveyor 83 one by one and can move while holding the product parts 2a. The pickup device 91 can have any appropriate structure. As a representative example of the pickup device 91, a vacuum suction type pickup device can be cited.

[0183] The conforming product tray 92 can store the product parts 2a determined as conforming products based on the information of the product parts 2a obtained by image recognition by the image recognition unit 4 as film pieces 10. Typically, the film pieces 10 are stored in the conforming product tray 92 in a stacked state in the thickness direction.

[0184] The defective product tray 93 can accommodate the product parts 2 a determined to be defective based on the information of the product parts 2 a obtained by image recognition by the image recognition unit 4 .

[0185] D. Details of the membrane chip manufacturing method

[0186] Next, refer to Figure 1 The details of the method for manufacturing the small film piece 10 will be described.

[0187] In the illustrated example, the above-described arrangement step, connection step, beat difference absorption step, cutting step, separation step, and image recognition step are continuously performed.

[0188] D-1. Configuration process

[0189] In the placement step, the single sheet 2 is placed on the carrier sheet 1 as described above. At this time, the first light release layer 21a is located on the opposite side of the carrier sheet 1. When the single sheet 2 includes the laminate film 22, the plurality of light release layers 21, and the release liner 23, the release liner 23 is in contact with the carrier sheet 1.

[0190] In the illustrated example, a sheet 2 stored in a sheet tray 51 is temporarily removed by a pickup device 54 and placed on a table 52. Next, at a predetermined timing, the sheet 2 is transported from the table 52 to a conveyor 53 by the pickup device 54. In one embodiment, the sheet 2 is intermittently placed on the continuously operating conveyor 53. The sheet 2 is then transported by the conveyor 53 toward between two first pinch rollers 55. While passing between the two first pinch rollers 55, the sheet 2 is placed on the carrier sheet 1 and appropriately pressed by the first pinch rollers 55.

[0191] Thus, the single sheet 2 is transferred from the conveyor 53 to the carrier sheet 1 and arranged on the carrier sheet 1. By repeating this arrangement process, a plurality of single sheets 2 are arranged on the carrier sheet 1 in parallel in the moving direction of the carrier sheet 1.

[0192] D-2. Joining process

[0193] In the connecting step, as described above, mutually adjacent individual sheets 2 among the plurality of individual sheets 2 are connected by the long connecting tape 63 a .

[0194] In the illustrated example, the connecting tape 63a is continuously fed from the continuous tape feed roller 61 to between the two second pinch rollers 62. As the sheet 2 passes between the two second pinch rollers 62 along with the movement of the carrier sheet 1, the connecting tape 63a is attached to the widthwise end of the sheet 2. As the next sheet 2 passes between the two second pinch rollers 62, the connecting tape 63a is attached to the widthwise end of the sheet 2.

[0195] Thus, the connecting tape 63 a is continuously attached to the width direction ends of the sheets 2 that sequentially pass between the two second nip rollers 62 , and the plurality of sheets 2 are connected at once by the connecting tape 63 a .

[0196] D-3. Beat error absorption process

[0197] In the beat absorbing step, the carrier sheet 1 supporting the single sheet 2 is guided by two guide rollers 74 so as to pass around the buffer roller 73. It should be noted that in the beat absorbing step, the position of the buffer roller 73 can be detected as described above, and the operation of the rotary cutter 31 can be controlled based on the detected position of the buffer roller 73.

[0198] D-4. Cutting process

[0199] In the cutting process, as described above, the single sheet 2 on the carrier sheet 1 is cut into the product portion 2a and the product outer portion 2b by the cutting knife (refer to Figure 2 ).

[0200] In the illustrated example, as the sheet 2 passes between the rotary cutter 31 and the opposing roller 32 as the carrier sheet 1 moves, the sheet 2 is cut by the rotary cutter 31 into a product portion 2a and a non-product portion 2b. More specifically, the portion of the sheet 2 to which the connecting tape 63a is not attached (in the illustrated example, the portion between the two connecting tapes 63a of the sheet 2) is cut by the rotary cutter 31.

[0201] The product portion 2a may have any appropriate shape when viewed in the thickness direction of the sheet 2. Examples of the shape of the product portion 2a include a polygonal shape, a circular shape, and an elliptical shape.

[0202] like Figure 2 As shown, in one embodiment, the product portion 2a has a rectangular shape when viewed in the thickness direction of the single sheet 2. In the example shown in the figure, a plurality of rectangular product portions 2a are cut out from one single sheet 2.

[0203] In this embodiment, the long side of the product portion 2a is, for example, not less than 20 mm and not more than 450 mm, and the short side of the product portion 2a is, for example, not less than 20 mm and not more than 250 mm.

[0204] like Figure 8 and Figure 9 As shown, in another embodiment, the product portion 2a has a polygonal shape having more than one pentagon when viewed in the thickness direction of the sheet 2. In the example shown in the figure, a plurality of hexagonal product portions 2a are cut out from one sheet 2.

[0205] In this embodiment, when viewed from the thickness direction of the product portion 2a, the upstream end of the product portion 2a in the moving direction of the carrier 1 is substantially parallel to the side in the width direction perpendicular to the moving direction (see FIG. Figure 8 ), or corners (see Figure 9 It should be noted that the expression “substantially parallel” includes the case where the angle formed by the side located at the upstream end of the product portion 2a and the width direction perpendicular to the moving direction of the carrier 1 is 0°±3°.

[0206] When the upstream end of the product portion 2a is a corner, the angle of the corner is, for example, 120° or more, preferably 150° or more. On the other hand, the angle of the corner of the upstream end of the product portion 2a is, for example, less than 180°.

[0207] When the sheet is cut in this manner during the cutting process, even when a rotary cutter is used to cut a polygonal product portion having a pentagonal or larger shape, cracks in the product portion (particularly the polarizer) can be suppressed. Furthermore, even when the sheet has multiple light release layers, warping (peeling) of the light release layers can be stably suppressed.

[0208] In addition, when the product portion 2a has a polygonal shape larger than a pentagon, the downstream end of the product portion 2a in the moving direction of the carrier 1 is substantially parallel to the side in the width direction perpendicular to the moving direction (see FIG. Figure 8 ), or corners (see Figure 9 ), preferably a corner.

[0209] The angle of the corner at the downstream end of the product portion 2a is, for example, 45° or greater, preferably 60° or greater. On the other hand, the angle of the corner at the downstream end of the product portion 2a is, for example, 120° or less. If the angle of the corner at the downstream end of the product portion is within this range, even when a single sheet includes multiple light release layers, warping (peeling) of the light release layer can be stably suppressed.

[0210] D-5. Separation process

[0211] like Figure 1 As shown, in the separation step, the product outer portion 2b is peeled off from the product portion 2a as described above.

[0212] In the illustrated example, the single sheet 2, after passing through the cutting device 3, is peeled off from the carrier sheet 1 by the peeling roller 74b and transferred from the carrier sheet 1 to the conveyor 83. That is, between the cutting process and the separation process, the carrier sheet 1 is peeled off from the single sheet 2. Then, the single sheet 2 is transported by the conveyor 83 and passes between the separation roller 81 and the conveyor 83. At this time, the product outer portion 2b is separated from the product portion 2a by the separation roller 81. Then, the multiple product outer portions 2b connected by the connecting belt 63a are continuously wound by the winding roller 82. On the other hand, the product portion 2a is held on the conveyor 83.

[0213] D-6. Image recognition process

[0214] In the image recognition step, the image recognition unit 4 performs image recognition on the product portion 2 a as described above.

[0215] In the illustrated example, the image recognition unit 4 accurately recognizes the product portion 2a on the conveyor 83. The pickup device 91 then transports the product portion 2a, whose information on the product portion 2a obtained through image recognition by the image recognition unit 4 is within the permitted range, to the acceptable product tray 92 as a film small piece 10. On the other hand, the pickup device 91 transports the product portion 2a, whose information on the product portion 2a obtained through image recognition by the image recognition unit 4 is not within the permitted range, to the acceptable product tray 93 as a defective product.

[0216] By the above operation, a film piece 10 having desired properties can be continuously manufactured. In one embodiment, the film piece 10 comprises a plurality of light release layers 21, a laminated film 22, and a release liner 23 (see Figure 3 ).

[0217] Such a film sheet 10 can be subjected to various inspections (e.g., inspection for foreign matter or bubbles) after the first light release layer 21a, the outermost layer, has been removed. In other words, the film sheet can be inspected after the first light release layer, which is more susceptible to scratches during manufacture and / or transportation, has been removed. This prevents false detections caused by scratches on the light release layer during these inspections. Furthermore, even after the first light release layer is removed, the second light release layer remains as the outermost layer of the film sheet, allowing the sheet to be transported while protecting its surface after inspection.

[0218] Furthermore, the film piece 10 can be used in various applications, and is particularly suitable for optical applications. More specifically, after the release liner 23 is peeled off from the second adhesive layer 224, the film piece 10 can be attached to an optical component via the second adhesive layer 224 for optical applications. Examples of optical components include liquid crystal display panels and organic EL display panels.

[0219] Example

[0220] Hereinafter, the present invention will be described in detail with reference to Examples, but the present invention is not limited to these Examples. The measuring methods of various properties are as follows.

[0221] (1) Thickness measurement

[0222] The thickness of each layer in Examples and Comparative Examples was measured using a film thickness meter (HKT-1202 manufactured by Fujiwork Co., Ltd.).

[0223] (2) Cracks

[0224] The cracks in the polarizers of the film pieces obtained in Examples and Comparative Examples were observed by microscopic inspection and evaluated according to the following criteria. The results are shown in Table 1.

[0225] ○: The length of the crack in the plane direction of the polarizer is 0 μm or more and 500 μm or less

[0226] △: The length of the crack in the plane direction of the polarizer exceeds 500 μm and is 1000 μm or less

[0227] ×: The length of the crack in the plane direction of the polarizer exceeds 1000 μm

[0228] (3) Warping of the light peeling layer

[0229] The lift-off of the light release layer in the film pieces obtained in Examples and Comparative Examples was observed by microscopic reflection inspection and evaluated according to the following criteria. The results are shown in Table 1.

[0230] ○: The maximum depth of warping in the plane direction of the polarizer is 0 μm or more and 500 μm or less

[0231] △: The maximum depth of warping in the plane direction of the polarizer exceeds 500 μm and is 1000 μm or less

[0232] ×: The maximum depth of warping in the plane direction of the polarizer exceeds 1000 μm

[0233] <<Production Example 1>>

[0234] A 30 μm-thick polyvinyl alcohol-based resin film (PVA-based resin film manufactured by Kuraray Co., Ltd.) was dyed by immersing it in a dye bath at a temperature of 30°C for 30 seconds (dyeing step). The dye bath was prepared by dissolving iodine in water. The iodine concentration in the dye bath was 1.0% by mass.

[0235] Next, the PVA resin film after the above-mentioned dyeing process is immersed in a cross-linking bath (a boric acid aqueous solution obtained by adding 5 parts by mass of boric acid to 100 parts by mass of water) at a liquid temperature of 60°C for 300 seconds, and is uniaxially stretched to a total stretching ratio of 6.0 times relative to the original length, and cross-linked using boric acid (stretching process).

[0236] Next, the PVA-based resin film after the stretching step was immersed in a cleaning bath (water) having a liquid temperature of 20° C. (cleaning treatment).

[0237] The PVA resin film after the washing step was then dried in a 60°C oven for 4 minutes to obtain a 12 μm thick polarizer. A triacetyl cellulose resin film (25 μm thick) was then attached to one side of the resulting polarizer via a UV-curable adhesive layer (1 μm thick). A hard coat layer (surface treatment layer, 7 μm thick) was provided on the surface of the triacetyl cellulose resin film opposite the polarizer.

[0238] Furthermore, a cycloolefin resin film (13 μm thick) was attached to the other side of the polarizer as a protective layer via an ultraviolet curable adhesive layer (1 μm thick), thereby obtaining a polarizing plate having a structure of protective layer / polarizer / protective layer.

[0239] Next, a first adhesive layer (thickness 15 μm) consisting of a (meth) acrylic adhesive was formed on the hard coat layer. Then, a phase difference film (ZT12, cycloolefin phase difference film, thickness 17 μm, manufactured by Japan Zeon Co., Ltd.) was attached to the hard coat layer via the first adhesive layer. Next, a second adhesive layer (thickness 15 μm) consisting of a (meth) acrylic adhesive was formed on the phase difference film. Then, the optical functional film was attached to the phase difference film via the second adhesive layer. The optical functional film comprises a substrate (thickness 40 μm) composed of an acrylic resin, and an anti-reflection layer (functional layer, thickness 4 μm). The anti-reflection layer is provided on the surface of the substrate opposite to the hard coat layer.

[0240] Next, a light release film was attached to the antireflection layer to prepare a second light release layer. The second light release layer included a base film (50 μm thick) made of a cycloolefin resin and a pressure-sensitive adhesive layer (10 μm thick) made of an acrylic pressure-sensitive adhesive.

[0241] Next, a light release film (E-MASK RP207, manufactured by Nitto Denko Corporation) was attached to the base film of the second light release layer to form the first light release layer. The first light release layer included a base film (38 μm thick) made of PET and an adhesive layer (10 μm thick) made of an acrylic adhesive.

[0242] A second adhesive layer (20 μm thick) made of a (meth)acrylic adhesive was formed on the cycloolefin resin film, and a release liner made of PET (manufactured by Mitsubishi Chemical Corporation, trade name: DIAFOIL MRV#50) was attached to the surface of the second adhesive layer.

[0243] Thus, a single sheet having the structure of first light release layer / second light release layer / optical functional film / second adhesive layer / retardation film / first adhesive layer / polarizer / second adhesive layer / release liner was obtained. The number of light release layers included in the single sheet is shown in Table 1.

[0244] <<Production Example 2>>

[0245] A single sheet was obtained in the same manner as in Production Example 1, except that the light release layer was changed to a single layer. Specifically, a light release film (manufactured by Nitto Denko Corporation, trade name: E-MASK RP207) was attached to the antireflection layer to form the first light release layer. This resulted in a single sheet having a structure of first light release layer / optical functional film / second adhesive layer / retardation film / first adhesive layer / polarizer / second adhesive layer / release liner.

[0246] <<Examples 1, 2 and Comparative Example 1>>

[0247] The single sheet of Manufacturing Example 1 was placed on Figure 1 The film sheet manufacturing line shown in FIG. In this film sheet manufacturing line, a single sheet is arranged on a carrier sheet as described above, and the single sheet on the carrier sheet is cut into a product portion and a product outer portion by a rotary cutter (cutting process). The rotary cutter has a cylindrical roll and a knife die sheet with multiple cutting knives. In the cutting process, the circumferential speed of the rotary cutter is 1 m / min, and the moving speed of the single sheet is 1 m / min. The details of the cutting knife (specifically, the blade tip angle, the first angle on the product outer portion side, the second angle on the product portion side, the first angle / second angle, and the height) are shown in Table 1.

[0248] Through the above operations, a small film piece as a product portion was manufactured.

[0249] <<Example 3>>

[0250] The rotary cutter was equipped with a cushioning material in addition to the roll and the die sheet, and the first and second angles of the cutting blade were changed to the values shown in Table 1. Film pieces, which served as product parts, were produced in the same manner as in Example 1. The hardness and thickness of the cushioning material are shown in Table 1.

[0251] <<Examples 4 and 5>>

[0252] Small film pieces as product parts were produced in the same manner as in Example 1, except that the rotary cutter was equipped with a cushioning material in addition to the roll and the die sheet.

[0253] <<Example 6>>

[0254] Small film pieces as product parts were produced in the same manner as in Example 2 except that the rotary cutter was equipped with a cushioning material in addition to the roll and the die sheet.

[0255] <<Example 7>>

[0256] A small film piece as a product was produced in the same manner as in Example 4 except that the thickness of the cushioning material was changed to 0.6 mm.

[0257] <<Reference Example 1>>

[0258] A small film piece as a product was produced in the same manner as in Comparative Example 1 except that the single sheet of Production Example 1 was changed to the single sheet of Production Example 2.

[0259]

[0260] [evaluate]

[0261] As clearly shown in Table 1, when the single sheet contained a single light release layer (Reference Example 1), cracking of the polarizer in the film small piece was suppressed, and warping (peeling) of the light release layer relative to the optically functional film was also suppressed, even when the cutting blade's tip angle exceeded 40°. However, when the single sheet contained two or more light release layers (Comparative Example 1), cracking of the polarizer and warping (peeling) of the light release layer were observed in the film small piece when the cutting blade's tip angle exceeded 40°.

[0262] As shown in Examples 1 to 7, even if there are two or more light release layers in a single sheet, if the cutting blade angle is 20° to 40°, both cracking of the polarizer and lifting (peeling) of the light release layer can be suppressed in the film sheet.

[0263] Industrial Applicability

[0264] The method for producing a small film piece according to the embodiment of the present invention can be suitably used for producing small film pieces to be used in various industrial products.

Claims

1. A method for manufacturing a membrane sheet, the method comprising: The process of cutting a single sheet into the product part and the outer part of the product by a cutting knife. The single sheet includes a laminate film having a laminate structure of five or more layers, and a plurality of light release layers adhered to the laminate film. The plurality of light release layers include a first light release layer disposed on the outermost layer and a second light release layer stacked with the first light release layer. The cutting knife has a tip angle of 20° to 40°.

2. The method for manufacturing a film chip according to claim 1, wherein: In the step of cutting the single sheet, the single sheet placed on a movable carrier sheet is cut.

3. The method for producing a film chip according to claim 1 or 2, wherein: The cutting blade is arranged on a cylindrical drum to form a rotary cutter. Among the angles of the cutting knife tip, the first angle on the outer part of the product relative to the baseline is more than 1.5 times the second angle on the product part relative to the baseline, and the baseline is along the radial direction of the rotating cutter and passes through the front end of the cutting knife.

4. The method for manufacturing a film chip according to claim 3, wherein: The rotary cutter further includes a buffer material that comes into contact with the cutting blade.

5. The method for manufacturing a film chip according to claim 4, wherein: In the step of cutting the single sheet, the cushioning material is sandwiched between the rotary cutter and the single sheet and comes into contact with the product portion and the product outer portion.

6. The method for manufacturing a film chip according to claim 4, wherein: The hardness of the buffer material is 30°~60°, Before the step of cutting the individual sheets, the thickness of the cushioning material is 0.8 to 2 times the length of the cutting blade in the radial direction of the rotary cutter.

7. The method for producing a film chip according to claim 1 or 2, wherein: The thickness of the single sheet is greater than 300 μm.

8. The method for producing a small film piece according to claim 1 or 2, wherein: The laminated film includes a polarizing plate.

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