Method for manufacturing sheet film

Abstract

To prevent an adhesive from stringing in pulling out and removing an unneeded portion after cutting a raw fabric having a first film, an adhesive layer, and a second film.SOLUTION: In a method for transporting a long, strip-shaped raw fabric 1 having a first film, an adhesive layer, and a second film downstream with respect to a longitudinal direction, cutting the raw fabric 1 with a cutting blade 51, and obtaining a plurality of sheet films 2, the raw fabric 1 is cut so as to partition the raw fabric 1 into the plurality of sheet films 2 and an unneeded portion 3 that has a reticulated shape in plan view remaining around the sheet films 2, and immediately after the cutting, the unneeded portion 3 is pulled out and removed.SELECTED DRAWING: Figure 12

Description

Technical Field

[0001] The present invention relates to a method for cutting a web including an adhesive layer to produce a plurality of sheet-like films.

Background Art

[0002] Conventionally, products having an adhesive layer between two films have been used for various applications. For example, an optical film having an adhesive layer is formed into a predetermined planar shape according to a screen of an image display device or the like, and is incorporated into the screen of an image display device or the like. In the present specification, a film formed into a predetermined shape is referred to as a "sheet-like film". The sheet-like film is generally obtained by cutting out from a long strip-shaped web having film / adhesive layer / film. The cut-out sheet-like film is used as a product as it is, or is used as a product after further performing arbitrary cutting processing or the like. For example, Patent Document 1 discloses a method for manufacturing a film product, which includes a step of cutting an optical film web having an optical film, an adhesive layer, and a separator film (release liner), and partitioning the in-plane of the optical film web into a cut residue having a plurality of longitudinal bands extending in the longitudinal direction and a plurality of transverse bands extending in the lateral direction, and a film product surrounded by the longitudinal bands and the transverse bands, and a step of separating the cut residue from the film product by pulling out the cut residue during conveyance of the optical film web to remove the cut residue, and pulling out and removing the cut residue without pressing the film product so as not to float and without pressing the longitudinal bands of the cut residue.

[0003] According to the method of Patent Document 1, when pulling out the cut residue, the film product does not follow the cut residue, and the cut residue can be reliably separated and removed from the film product.

Prior Art Documents

Patent Documents

[0004] [Patent Document 1] Japanese Patent Publication No. 2021-164984 [Overview of the project]

[0005] Incidentally, when a roll of raw material with an adhesive layer between two films is cut, the two cut ends that form at the cutting line face each other. As a result, there is a risk that the adhesive from the adhesive layer may adhere to these cut ends. If the adhesive adheres after cutting, when the remaining portion (unnecessary part) is pulled out, the attached adhesive will be stretched like a thread and then torn off. As a result, the stretched-out adhesive may adhere to the surface of the sheet film, potentially staining the sheet film and its surroundings with adhesive. [Problems that the invention aims to solve]

[0006] The object of the present invention is to provide a method for manufacturing a single-sheet film that can prevent stringing of the adhesive when removing the unnecessary portion after cutting a raw material roll having a first film, an adhesive layer, and a second film. [Means for solving the problem]

[0007] The present invention relates to a method for obtaining multiple sheets of film by transporting a long strip of raw material having a first film, an adhesive layer, and a second film downstream in the longitudinal direction, and cutting the raw material with a cutting blade, wherein the raw material is cut so as to divide it into multiple sheets of film and unnecessary portions that remain around each sheet of film in a mesh-like structure in plan view, and immediately after the cutting, the unnecessary portions are pulled out and removed.

[0008] A preferred manufacturing method of the present invention involves pulling out and removing the unwanted portion of the raw roll, which is divided into multiple sheet films and unwanted portions, before it is transported within 300 cm from the downstream cutting position. A preferred manufacturing method of the present invention is one in which the first film of the raw material includes a polarizing film. [Effects of the Invention]

[0009] According to the manufacturing method of the present invention, adhesive is less likely to adhere to the unwanted portion and the cut end surface of the sheet film, and stringing of the adhesive can be prevented when the unwanted portion is pulled out. Therefore, according to the present invention, it is possible to prevent the sheet film and its surroundings from being soiled by adhesive. [Brief explanation of the drawing]

[0010] [Figure 1] Plan view of the raw material. [Figure 2] Plan view of a single-fed film. [Figure 3] A side view showing one example of the layer structure of the raw material. [Figure 4] A side view showing another example of the layer structure of the raw material. [Figure 5] A schematic plan view of a sheet-fed film manufacturing apparatus. [Figure 6] A schematic side view of a sheet-fed film manufacturing apparatus. [Figure 7] Enlarged perspective view of the cutting blade. [Figure 8] A plan view of a roll of raw material, divided into sheet film and unwanted portions. [Figure 9] Enlarged front view from the direction of arrow IX in Figure 6. [Figure 10] Enlarged cross-sectional view taken along line XX in Figure 5. [Figure 11] An enlarged cross-sectional view showing the state when the raw material is cut with a cutting blade. [Figure 12] An enlarged cross-sectional view showing the state when removing the unwanted portion from a roll of raw material that has been divided into sections for the unwanted portion and individual sheets of film. [Figure 13] A reference diagram explaining the principle behind stringing in adhesives. [Figure 14] A schematic side view of the manufacturing apparatus for the first modified example. [Figure 15] A schematic side view of the manufacturing apparatus of the second modified example. [Modes for carrying out the invention]

[0011] In this specification, "plan view" means viewing an object from a vertical direction with respect to the surface of the object, and "plan view shape" and "plan view drawing" mean the shape and drawing of the object when viewed from a vertical direction with respect to the surface of the object. Also, in this specification, the expression "substantially" means including the range acceptable in the technical field of the present invention. Further, in this specification, when a plurality of numerical ranges represented as "not less than the lower limit value and not more than the upper limit value" are separately described, any lower limit value and any upper limit value can be selected.

[0012] [Sheet film manufacturing apparatus] FIG. 5 and FIG. 6 show a manufacturing apparatus A for a sheet film 2. Referring to FIGS. 5 and 6, the manufacturing apparatus A includes a conveyance unit B that conveys a raw sheet 1 and a sheet film 2, a cutting unit C that cuts the raw sheet 1 into a plurality of sheet films 2 and an unnecessary portion 3 having a mesh shape in plan view, a removal unit D that removes the unnecessary portion 3, and an accumulation unit E.

[0013] [Raw sheet] The manufacturing apparatus A of the present invention cuts within the plane of a long strip-shaped raw sheet 1, removes an unnecessary portion 3, and obtains a sheet film 2. The raw sheet 1 is usually long strip-shaped as shown in FIG. 1. However, in FIG. 1, one side in the longitudinal direction of the long strip-shaped raw sheet 1 is omitted. The raw sheet 1 is set in the unwinding portion 41 of the raw sheet feeding unit in a state of being wound in a roll shape. Here, in this specification, "long strip-shaped" means a substantially rectangular shape in plan view in which the length in the longitudinal direction is sufficiently longer than the length in the short direction. The length of the raw sheet 1 in the longitudinal direction is, for example, 5 m or more, and preferably, the length in the longitudinal direction is 10 m or more. The short direction is a direction orthogonal to the longitudinal direction.

[0014] The sheet film 2 obtained from the raw material 1 is formed into a predetermined shape in plan view, as shown in Figure 2. In other words, the sheet film 2 is a film formed into a predetermined shape from the raw material 1. Figure 2 illustrates a sheet film 2 that is roughly rectangular in plan view. The plan view shape of the sheet film 2 is not particularly limited. For example, the plan view shape of the sheet film 2 can be roughly rectangular (roughly rectangular means roughly rectangular or roughly square), roughly triangular, roughly hexagonal, or other roughly polygonal shapes, roughly circular, roughly elliptical, a combination of these shapes, or any other shape. The "roughly" in roughly rectangular, roughly triangular, and roughly polygonal shapes includes, for example, shapes where the corners are chamfered, shapes where part of the edge is slightly bulging or indented, or shapes where the edge is slightly curved. The "roughly" in roughly circular and roughly elliptical shapes includes, for example, shapes where part of the circumference is slightly bulging or indented, or shapes where part of the circumference is slightly straight or diagonal.

[0015] The single-sheet film 2 becomes the final product or an intermediate product. The intermediate product is a product in the process of manufacturing the final product, and the final product is obtained by further cutting and / or surface treatment or other appropriate processing of the intermediate product. The applications of the aforementioned product are not particularly limited. Products obtained from the single-sheet film 2 include, for example, optical or mechanical components incorporated into screens of image display devices or lenses of sunglasses; sealing materials such as tack labels; packaging materials such as wrapping films; and electrical components such as electromagnetic shielding. In particular, since high cleanliness is required, it is preferable to apply the method of the present invention to form products for optical component applications.

[0016] In terms of layer structure, the raw material 1 has a first film, a second film, and an adhesive layer provided between the first and second films. The layer structure of the single-sheet film 2 is the same as that of the raw material 1, and the single-sheet film 2 also has a first film, a second film, and an adhesive layer provided between the first and second films. Since the layer structure of the single-sheet film 2 is the same as that of the raw material 1, the layer structure of the raw material 1 will be described, and the description of the layer structure of the single-sheet film 2 will be omitted. The raw material 1 has a laminated structure of a first film / adhesive layer / second film, and may further have other films or layers.

[0017] The following describes some illustrative examples of the layer configuration of raw material 1 for optical component applications. Figure 3 is a side view showing one example of the layer structure of raw material 1, and Figure 4 is a side view showing another example of the layer structure of raw material 1. The raw material 1 shown in Figure 3 comprises, in order from the surface side, a first film 11, an adhesive layer 15, and a second film 12. Around the perimeter of the raw material 1, the respective end faces 11a and 12a of the first film 11 and the second film 12, and the end face 15a of the adhesive layer 15 extend parallel to each other. In other words, the end face 11a of the first film 11, the end face 15a of the adhesive layer 15, and the end face 12a of the second film 12 form a single continuous plane. Therefore, the end face of the raw material 1 is composed of the set of the respective end faces 11a, 15a, and 12a of the first film 11, the adhesive layer 15, and the second film 12. In this specification, an end face is a plane along the thickness direction, and the surface and back surface are planes perpendicular to the thickness direction. The raw material roll 1 shown in Figure 4 has, in order from the surface side, a third film 13, a first adhesive layer 151, a first film 11, a second adhesive layer 152, and a second film 12. Around the perimeter of the raw material roll 1, the end faces 11a, 12a, 13a of the first to third films 11, 12, 13 and the end faces 151a, 152a of the first and second adhesive layers 151, 152 extend parallel to each other. In other words, the end faces 11a, 12a, 13a of each film 11, 12, 13 and the end faces 151a, 152a of each adhesive layer 151, 152 form a single continuous plane. In addition, although not shown in the figures, the raw material 1 may further have other films and / or adhesive layers. In the raw material 1 having the other films and / or adhesive layers, the end faces of each film and the end faces of each adhesive layer form a single continuous plane.

[0018] The raw material 1 for optical component applications includes an optical film. In this case, all films, such as the first film 11, may be optical films, or at least one film selected from a plurality of films may be an optical film and at least one film may be a film other than an optical film. In the layer configuration shown in Figure 3, for example, the first film 11 is an optical film and the second film 12 is a release liner (a film other than an optical film). In the layer configuration shown in Figure 4, for example, the first film 11 and the third film 13 are optical films and the second film 12 is a release liner. In Figure 3, for example, an optical functional film described later is used as the first film 11. In Figure 4, for example, an optical functional film described later is used as the first film 11 and a protective film described later is used as the third film 13. The release liner is removably bonded to the adhesive layers 15 and 152. Therefore, the release liner and the adhesive layers 15 and 152 can be peeled off at their interface, but the optical film and the adhesive layers 15 and 152 are difficult to peel off. When in use, the release liner is peeled off and removed. Furthermore, if the third film 13 in Figure 4 is a protective film, the third film 13 may be designed to be peelable from the first film 11 along with the adhesive layer 151, or the third film 13 may be bonded to the first film 11 via the adhesive layer 151 in a manner that makes it difficult to peel off.

[0019] Examples of optical films include optically functional films and protective films. Optical films may have a single-layer structure or a multi-layer structure of two or more layers. When an optical film has a multi-layer structure of two or more layers, it may be a laminate formed by stacking two or more films having the same function, or a laminate formed by stacking two or more films having different functions. Examples of such laminates of films having different functions include a laminate of a polarizing film and a phase difference film, and a laminate of a polarizing film and a protective film. Examples of optical functional films include polarizing films, phase difference films, light diffusion films, brightness enhancement films, anti-glare films, and light reflection films. A polarizing film is a film that transmits light vibrating in one specific direction (polarized light) and blocks light vibrating in other directions. A phase difference film is a film that exhibits optical anisotropy, and typical examples include stretched films of acrylic resins, cycloolefin resins, and cellulose resins. A protective film is a film used to protect the optical functional film. Typically, a colorless and transparent film is used as a protective film. The thickness of the optical film is not particularly limited, but is, for example, between 5 μm and 300 μm.

[0020] The release liner has a release surface that is highly detachable from the adhesive layer. Examples of release liners include resin films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester film; paper; porous films such as woven fabrics, nonwoven fabrics, and mesh fabrics; and foamed resin films. Due to their excellent surface smoothness, the release liner is preferably a resin film. Examples of the resin films include polyethylene terephthalate film, polybutylene terephthalate film, polyethylene film, polypropylene film, polybutene film, polybutadiene film, polymethylpentene film, polyvinyl chloride film, vinyl chloride copolymer film, polyurethane film, and ethylene-vinyl acetate copolymer film. The thickness of the peel-off liner is not particularly limited, and is, for example, 5 μm or more and 200 μm or less, preferably 10 μm or more and 100 μm or less.

[0021] The adhesive layer is adhesive at room temperature and retains its adhesive properties after peeling, allowing for reapplication. The adhesive layer is composed of known adhesives. Examples of such adhesives include colorless and transparent acrylic adhesives, rubber adhesives, silicone adhesives, urethane adhesives, vinyl alkyl ether adhesives, polyvinylpyrrolidone adhesives, polyacrylamide adhesives, and cellulose adhesives. In particular, the method of the present invention is effective when applied to a raw material 1 having an adhesive layer formed by a relatively soft adhesive. The hardness of the adhesive can be indicated, for example, by its storage modulus G'. For a soft adhesive, for example, its storage modulus G' at 25°C is 0.001 MPa or more and 1 MPa or less, preferably 0.01 MPa or more and 1 MPa or less. The storage modulus can be measured by dynamic viscoelasticity measurement. Specifically, the adhesive layer can be measured using a dynamic viscoelasticity measuring device (device name "ARES" manufactured by T.A. Instruments Corporation) at a frequency of 1 Hz, in a temperature range of -20 to 100°C, and at a heating rate of 5°C / min to calculate the storage modulus G' at 25°C. The thickness of the adhesive layer is not particularly limited, but is, for example, 0.1 μm or more and 50 μm or less, and preferably 1 μm or more and 30 μm or less.

[0022] <Conveying Section> Referring to Figures 5 and 6, the conveying section B of the manufacturing apparatus A includes a raw material feeding section for conveying the raw material roll 1, and at least one conveyor belt for conveying the raw material roll 1 before and after cutting, and a plurality of sheet films 2. The raw material feeding section includes an unwinding section 41 into which the raw material roll 1 wound on a roll is loaded, a guide roller 42 for guiding the raw material roll 1, and a drive device (not shown). The raw material feeding section unwinds the raw material roll 1 from the unwinding section 41 and conveys the raw material roll 1 from the upstream side in the longitudinal direction to the downstream side. The longitudinal direction and the conveying direction of the raw material roll 1 are the same, and the short direction and the width direction of the raw material roll 1 are the same. Furthermore, the first conveyor belt 43 carries and transports the raw material 1 before and after cutting. A cutting section C is located above the first conveyor belt 43, and a removal section D is located immediately downstream of the cutting section C. The second conveyor belt 44 carries and transports multiple sheets of film 2. A collection section E for collecting the sheets of film 2 is located downstream of the second conveyor belt 44. A bridging plate 45 is provided between the end of the first conveyor belt 43 and the end of the second conveyor belt 44.

[0023] <Cutting section> Referring to Figures 5 and 6, the cutting section C has a cutter device. The cutter device has a cutting blade 51 and a base plate 52. Furthermore, a support base 53 is provided opposite the cutting blade 51. The support base 53 is made of, for example, a steel plate with excellent strength. The support base 53 is fixed to the frame (not shown) of the manufacturing apparatus A. The support base 53 is positioned on the back side of the first conveyor belt 43. The first conveyor belt 43 has the function of transporting the raw material 1 before and after cutting, as well as functioning as a blade support member. The blade support member refers to a member that receives the cutting edge of the cutting blade 51. When the raw material 1 is cut, the cutting edge of the cutting blade 51 that protrudes from the back side of the raw material 1 bites into the first conveyor belt 43, thereby ensuring that the raw material 1 is cut reliably and preventing deterioration of the cutting edge of the cutting blade 51. As the first conveyor belt 43 that also functions as such a blade support member, a sheet is used that has the flexibility to receive the cutting edge of the cutting blade 51, and furthermore, has sufficient strength and thickness to prevent breakage even when the cutting edge enters it. For example, the first conveyor belt 43 can be made of a synthetic resin sheet, a rubber sheet, a nonwoven fabric, or the like. Furthermore, as disclosed in Patent Document 1 (Japanese Unexamined Patent Publication No. 2021-164984), a separate blade support sheet independent of the conveyor belt may be provided.

[0024] The cutting blade 51 is provided on a base plate 52. The base plate 52 is flat, and the cutting blade 51 is fixedly mounted on the base plate 52. The cutter device (cutting blade 51) moves vertically relative to the surface of the raw material 1 and retracts by a drive device (not shown). The cutter device in the illustrated example moves vertically. The cutter device is a punching-type cutter that punches out the raw material 1 by descending and moves away from the raw material 1 by rising. A typical example of such a cutter device is a die-cutting blade. Furthermore, the cutter device is not limited to a punching method; for example, a rotary die may be used (not shown). Also, the cutter device only needs to be capable of cutting the raw material 1 in the thickness direction, and is not limited to the punching method or rotary dies described above.

[0025] Figure 7 is an enlarged perspective view of the cutter device including the cutting blade 51. Note that the cutter device in Figure 7 is a perspective view of the cutter device in Figure 6, viewed from below, and the upper part of the paper in Figure 7 corresponds to the lower part of the paper in Figure 6. Figure 7 also includes an enlarged view partially showing the three-dimensional shape of the cutting blade 51. In Figure 7, cutting blades 51 are provided protruding from the surface of the base plate 52. Generally, multiple cutting blades 51 are provided on one base plate 52 in order to punch out multiple sheets of film 2 simultaneously with a single downward movement. Each of the cutting blades 51 is an endless annular shape in plan view and is provided at regular intervals in the conveying direction and width direction of the raw material roll 1. In the illustrated example, two rows of cutting blades 51 are arranged in the conveying direction of the raw material 1, and four rows in the width direction. However, the number of cutting blades 51 is not limited to this. Furthermore, the planar shape of the cutting blades 51 is not limited to the approximately rectangular shape shown in the illustrated example, but is set according to the shape of the sheet film 2 to be formed. The angle α of the cutting edge 51a of the cutting blade 51 is not particularly limited, and is, for example, 10 degrees or more and 100 degrees or less, preferably 20 degrees or more and 90 degrees or less. By having the angle α of the cutting edge 51a within the above range, it is possible to prevent the adhesive from re-adhering to the unnecessary portion 3 and the cut end surface of the sheet film 2.

[0026] In the cutting section C, the cutting blade 51 of the cutter device is pressed against the raw material 1 from the surface side, creating a cutting line on the surface of the raw material 1 that has the same shape as the planar shape of the cutting blade 51. The inner portion enclosed by this cutting line becomes the sheet film 2, and the outer portion of the cutting line becomes the unwanted portion 3. Figure 8 is a plan view showing a roll of raw material 1 divided into a single-sheet film 2 and a waste portion 3. To make it easier to distinguish between the single-sheet film 2 and the waste portion 3, the waste portion 3 is marked with numerous dots. As shown in Figure 8, the surface of the cut raw material 1 is divided into multiple sheet films 2 and a network of unwanted portions 3 in plan view. The aforementioned unnecessary portion 3 is composed of a plurality of vertical strips 3a extending in a strip shape in the transport direction and a plurality of horizontal strips 3b extending in a strip shape in the width direction. The unnecessary portion 3, consisting of such vertical strips 3a and horizontal strips 3b, forms a grid shape in plan view. However, the unnecessary portion 3 is not limited to a grid shape in plan view, provided that it forms a mesh shape in plan view; for example, it may also be a diagonal grid shape.

[0027] <Removal part> The removal unit D removes the remaining unwanted portion 3 around the sheet film 2 (the portion enclosed by the cutting line) formed within the surface of the raw material roll 1 by the cutting unit C. Figure 9 is an enlarged front view of the removal section D as seen from the downstream side in the conveying direction, and Figure 10 is an enlarged cross-sectional view of the cutting section C and the removal section D cut along the conveying direction. Referring to Figures 5, 6, 9, and 10, the removal unit D includes a separation member 61 for separating the unwanted portion 3 from the sheet film 2, a recovery roller 62 for winding up the unwanted portion 3, and optionally a guide roller 63. The separating member 61 consists of a rod-shaped body extending in the width direction of the raw material 1, and is composed of, for example, a cylindrical body. Alternatively, the separating member 61 may be the separating member disclosed in Patent Document 1, which has a pressing portion and a non-pressing portion.

[0028] The separating member 61 is positioned so as to be in contact with the surface of the raw material roll 1, which is divided into the unwanted portion 3 and the sheet film 2. In the cutting processing section C, the raw material roll 1 is divided into the unwanted portion 3 and the sheet film 2, and then transported to the removal section D by the first conveyor belt 43. Specifically, the raw material roll 1, which is divided into multiple sheet films 2 and unwanted portions 3, is transported downstream on the first conveyor belt 43. The separation member 61 is positioned so as to be in contact with the raw material roll 1 during transport. By pulling out the unwanted portion 3 along the circumferential surface of the separating member 61, the unwanted portion 3 is separated from the adjacent sheet film 2 at the cutting line. Hereinafter, the point at which the unwanted portion 3 and the sheet film 2 separate when the unwanted portion 3 is pulled out will be referred to as the "separation point". The unwanted portion 3 is generated by cutting the raw material 1 with the cutter device. According to the inventors' findings, stringing of the adhesive can be prevented by removing the unwanted portion 3 as quickly as possible after cutting the raw material 1. For this reason, it is preferable to position the separating member 61 so that the separation point is within 300 cm from the furthest downstream cutting position, and it is even more preferable to position the separating member 61 so that the separation point is within 250 cm from the furthest downstream cutting position. The furthest downstream cutting position is the cutting position at the furthest downstream end (this downstream side means the downstream side in the conveying direction of the raw material 1) when the raw material 1 is cut by the cutting blade 51, as shown in Figure 10. In Figure 10, the distance from the furthest downstream cutting position to the separation point is indicated by the symbol L1. The time from the cutting of the raw material 1 to the removal of the unnecessary portion 3 can be determined from the distance L1 and the transport speed of the raw material 1.

[0029] <Collection Unit> The accumulation unit E collects the single-sheet film 2 obtained by removing the unnecessary portion 3 in the removal unit D. For example, a container 71 is located in the stacking section E, and the sheet films 2 transported by the second conveyor belt 44 are sequentially placed inside the container 71. The sheet films 2, which are packed inside the container 71, can be cut and / or processed as needed to obtain products.

[0030] [Manufacturing method for sheet film] The present invention provides a method for manufacturing a single-sheet film 2, which involves transporting a long, strip-shaped raw material 1 having a first film, an adhesive layer, and a second film downstream in the longitudinal direction, and cutting the raw material 1 so as to divide it into a plurality of single-sheet films 2 and unnecessary portions 3 that remain around each single-sheet film 2 in a mesh-like structure in plan view. In this invention, the unnecessary portions 3 are pulled out and removed immediately after cutting the raw material 1.

[0031] As shown in Figure 10, the base plate 52 located above the raw material 1 is lowered, and the raw material 1 is cut with the cutting blade 51 (see Figure 11). Next, as shown in Figure 12, the base plate 52 is raised and the cutting blade 51 is removed from the raw material 1. The raw material 1 cut by the cutting blade 51 is divided into multiple sheets of film 2 and a mesh-like unwanted portion 3 in plan view. The raw material 1 divided into the sheets of film 2 and the unwanted portion 3 is conveyed downstream by the first conveyor belt 43, and the unwanted portion 3 is pulled out and removed by the separation member 61. The pulled-out unwanted portion 3 is wound onto the recovery roller 62. The pulling out of the unwanted portion 3 is performed immediately after the cutting of the raw material 1. For example, with the arrangement of the separation member 61 in the <Cutting Processing Section> section above, it is preferable to pull out the unwanted portion 3 before the raw material 1 divided into the sheets of film 2 and the unwanted portion 3 is conveyed to within 300 cm (preferably within 250 cm) from the furthest downstream cutting position. The removal of the unwanted portion 3 is performed in synchronization with the transport of the raw material roll 1. Therefore, the removal speed of the unwanted portion 3 and the transport speed of the raw material roll 1 are the same. For example, the transport speed of the raw material roll 1 is 1 m / min or more, preferably 2 m / min or more. Although there is no particular upper limit to the transport speed of the raw material roll 1, as it is preferable to keep it as fast as possible from the viewpoint of preventing adhesive from re-adhering to the cut end surface, an upper limit to the transport speed is set considering the processing of the entire line.

[0032] As in this embodiment, when a punch-out type cutter device is used, the raw material 1 is transported for a length approximately corresponding to the area cut by one descent of the cutter device. For example, if two sheets of film 2 are formed between the horizontal strips 3b (parts of the unnecessary portion 3) by one descent of the cutter device, the material is transported for a length approximately corresponding to those two sheets. This transport length L2 for one descent is equal to the transport direction length of one horizontal strip 3b + the transport direction length of one sheet of film 2 + the transport direction length of one horizontal strip 3b + the transport direction length of one sheet of film 2, as shown in Figure 12. After transporting the raw material 1 for the length of one transport cycle and removing the unwanted portion 3, if the transport of the raw material 1 and the removal of the unwanted portion 3 are temporarily stopped, the state shown in Figure 10 will be reached. Afterward, the process of lowering the cutter device shown in Figure 11, transporting the cut raw material 1 and removing the unwanted portion 3 as shown in Figure 12, and then temporarily pausing the transport and removal process are repeated as one cycle. The remaining sheets of film 2 after the removal of the unnecessary portion 3 are transported downstream by the second conveyor belt 44. The second conveyor belt 44 may repeatedly transport and pause the sheets of film 2 in synchronization with the transport of the raw material roll 1, or it may transport the sheets of film 2 continuously without stopping.

[0033] As in the present invention, stringing of the adhesive can be prevented by removing the unnecessary portion 3 immediately after cutting the raw material 1. In detail, when the raw material 1 is cut and divided into a waste portion 3 and a sheet film 2, the cut end surface 3X of the waste portion 3 and the cut end surface 2X of the sheet film 2 face each other, as shown in Figure 13(a). When the raw material 1 in this state is transported by a conveyor belt or the like, the adhesive may swell due to vibrations of the equipment, and as shown in Figure 13(b), the cut end surface 31X of the adhesive layer 31 of the waste portion 3 and the cut end surface 21X of the adhesive layer 21 of the sheet film 2 may stick together. When the waste portion 3 is pulled out with the adhesive stuck together in this state, the adhesive Y is stretched out like a thread, as shown in Figure 13(c) (so-called adhesive stringing). The stringy adhesive Y then tears apart. The torn thread-like adhesive then adheres to the surface of the sheet film 2, the cut end surface, or the surface of the conveyor belt. In particular, with adhesive layers made of the soft adhesive described above, adhesive adhesion to the cut end surface is more likely to occur.

[0034] In this regard, as in the present invention, if the unnecessary portion 3 is removed immediately after cutting the raw material 1, the adhesive is less likely to adhere to the cut end surface of the unnecessary portion 3 and the cut end surface of the sheet film 2, thereby preventing the adhesive from stringing. In other words, the present invention prevents the adhesive from stringing because the unnecessary portion 3 is pulled out before the adhesive adheres to the cut end surface (i.e., immediately after cutting). Therefore, according to the method of the present invention, it is possible to prevent the sheet film 2 and its surroundings from becoming soiled by adhesive.

[0035] [Differentiation] In the cutting processing unit C of the above embodiment, a punching-type cutter device was exemplified, but a rotary cutter device may also be used, for example, as shown in Figure 14. In the case of a rotary cutter device, the raw material 1 is cut at the point where the circumferential surface of the rotary die 55, which has a cutting blade 54, comes into contact with the raw material 1. Therefore, when using a rotary cutter device, the downstream cutting position S2 is the contact point where the circumferential surface of the rotating rotary die 55 comes into contact with the raw material 1. In addition, with a rotary cutter device, the raw material 1 is transported at a constant speed without stopping, and the unwanted portion 3 is pulled out at the same speed in synchronization with this.

[0036] In the above embodiment, the unnecessary portion 3 was pulled upward and wound up, but for example, as shown in Figure 15, the unnecessary portion 3 may be pulled downward and wound onto the recovery roller 62. When pulling out the unwanted portion 3 downwards, for example, as shown in Figure 15, the unwanted portion 3 can be inverted using the circumferential surface of the conveyor belt. [Explanation of Symbols]

[0037] 1 Original fabric 11 Film 1 15,151,152 Adhesive layer 12. Second film 2-sheet film 3 Unnecessary part S1 separation point S2 Cutting position on the downstream side

Claims

1. A method for producing a plurality of film sheets by conveying a long strip-shaped raw material having a first film, a pressure-sensitive adhesive layer, and a second film downstream in a longitudinal direction and cutting the raw material with a cutting blade, comprising: The cutting edge angle of the cutting blade is 10 degrees or more and 100 degrees or less, The cutting edge of the cutting blade is pressed against the front surface side of the raw roll to cut the raw roll into a plurality of film sheets and unnecessary portions remaining around each of the film sheets; Immediately after the cutting, the unnecessary portion is pulled out and removed. A method for manufacturing sheet-fed film.

2. A method for manufacturing a sheet-form film as described in claim 1, wherein the unnecessary portion is pulled out and removed while the adhesive of the adhesive layer is not adhering to the cut end surface created by the cutting.

3. The method for producing a sheet-fed film according to claim 1 or 2, wherein the first film of the raw roll comprises a polarizing film.

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