Film with pressure-sensitive adhesive layer

Abstract

To provide a method for manufacturing a wound body of a film with an adhesive layer without a release liner, which can be wound in a long length while achieving suppression of entrainment of air bubbles and occurrence of wrinkles, and suppression of dents. To provide a wound body of a film with an adhesive layer without a release liner, in which entrainment of air bubbles and occurrence of wrinkles are suppressed and a dent is also suppressed.SOLUTION: A method for producing a roll from a long film with a pressure-sensitive adhesive layer, wherein the film with a pressure-sensitive adhesive layer has a release layer, a specific substrate, and a specific pressure-sensitive adhesive layer in this order, the film with a pressure-sensitive adhesive layer is wound around a winding shaft via a touch roll disposed in front of the winding shaft to form a roll, and a touch pressure P of the touch roll is 3. 6N / cm <P <14. 0N / cm as a linear pressure.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a film with a pressure-sensitive adhesive layer. [Background technology]

[0002] In the manufacturing process of optical and electronic components, a surface protection film (SPV) is usually attached to prevent the surface of the component from being scratched during processing, assembly, inspection, transportation, and the like.

[0003] A surface protection film typically has a laminated structure having a substrate and a pressure-sensitive adhesive layer. Conventionally, a surface protection film typically has a release liner provided on the exposed surface of the pressure-sensitive adhesive layer. Many surface protection films having a substrate, a pressure-sensitive adhesive layer, and a release liner in this order have been reported.

[0004] On the other hand, for reasons such as reducing the cost of release liners, there has recently been a demand for surface protection films that do not have a release liner on the exposed surface side of the pressure-sensitive adhesive layer. As such a surface protection film, a surface protection film in which a polyethylene film and a pressure-sensitive adhesive layer are laminated has been reported (Patent Document 1). This surface protection film is produced by extrusion molding, and by embossing the back surface of the polyethylene film, it can be wound and unwound without a release liner, and can be provided as a roll.

[0005] However, polyethylene films tend to contain clumps of resin that have not completely melted (fish eyes), which reduces inspectability during the manufacturing process for optical and electronic components and can lead to problems such as a deterioration in product quality.Furthermore, because the back side of the polyethylene film is embossed, there is a problem that dents are formed on the adherend when it is bonded.

[0006] Recently, a surface protection film has been reported that does not have a release liner and does not use a polyethylene film as a substrate, and that can be wound up and unwound without a release liner (Patent Document 2). [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 06-033022 [Patent Document 2] Japanese Patent Application Publication No. 2022-112659 Summary of the Invention [Problem to be solved by the invention]

[0008] When a surface protection film without a release liner is wound up, the substrate and the adhesive layer are directly overlapped. This makes winding a surface protection film without a release liner extremely difficult, particularly when wound up in long lengths, and there are problems with the inclusion of air bubbles and wrinkles. While thinning the adhesive layer to around 1 μm tends to make winding easier, it also creates the problem of dents caused by foreign matter. On the other hand, increasing the thickness of the adhesive layer reduces the likelihood of dents caused by foreign matter, but makes winding long lengths more difficult.

[0009] An object of the present invention is to provide a method for producing a roll of a pressure-sensitive adhesive layer-attached film without a release liner, which method enables long winding while suppressing the entrapment of air bubbles, the occurrence of wrinkles, and the formation of dents. Another object of the present invention is to provide a roll of a pressure-sensitive adhesive layer-attached film that can be produced by such a production method, in which the entrapment of air bubbles, the occurrence of wrinkles, and the formation of dents are suppressed. [Means for solving the problem]

[0010] [1] A method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is a method for producing a roll from a long length of pressure-sensitive adhesive layer-attached film, the pressure-sensitive adhesive layer-attached film having a release layer, a substrate, and a pressure-sensitive adhesive layer in this order, the release layer and the pressure-sensitive adhesive layer being the outermost layers of the pressure-sensitive adhesive layer-attached film, the substrate containing a polyester-based resin, the pressure-sensitive adhesive layer being a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the pressure-sensitive adhesive layer having a thickness of 4.0 μm to 10.0 μm, the pressure-sensitive adhesive layer-attached film passing through a touch roll arranged in front of a winding shaft and being wound around a winding shaft to form a roll, and the touch pressure P of the touch roll being 3.6 N / cm as a linear pressure. <P<14.0N / cmである。 [2] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to the above item [1], the touch pressure P of the touch roll is 4.3 N / cm as a linear pressure. <P<10.0N / cmであってもよい。 [3] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to [1] or [2] above, the product of the thickness D of the substrate and the touch pressure P may be 0.018 N<(D×P)<0.050 N. [4] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to any one of [1] to [3] above, the surface hardness S of the touch roll is 30° <S<80°であってもよい。 [5] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to any one of [1] to [4] above, a winding tension T of the pressure-sensitive adhesive layer-attached film on a winding shaft is 200 N / m <T<400N / mであってもよい。 [6] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to any one of [1] to [5] above, the low-speed peel strength of the pressure-sensitive adhesive layer from the release layer, measured at a temperature of 23°C and a humidity of 50% RH, at a peel speed of 0.3 m / min and a peel angle of 180°, may be less than 0.01 N / 25 mm. [7] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to any one of [1] to [6] above, the high-speed peel strength of the pressure-sensitive adhesive layer from the release layer, measured at a temperature of 23°C and a humidity of 50% RH, at a peel speed of 30 m / min and a peel angle of 180°, may be less than 0.15 N / 25 mm. [8] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to any one of [1] to [7] above, the roll may have a winding length of 3000 m or more. [9] A roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is a roll of a long pressure-sensitive adhesive layer-attached film, the pressure-sensitive adhesive layer-attached film having a release layer, a base material, and a pressure-sensitive adhesive layer in this order, the release layer and the pressure-sensitive adhesive layer being the outermost layers of the pressure-sensitive adhesive layer-attached film, the base material containing a polyester-based resin, the pressure-sensitive adhesive layer being a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the pressure-sensitive adhesive layer having a thickness of 4.0 μm to 10.0 μm, and the low-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a temperature of 23°C and a humidity of 50% RH at a peel speed of 0.3 m / min and a peel angle of 180 degrees is less than 0.01 N / 25 mm.

[10] In the roll of the pressure-sensitive adhesive layer-attached film described in [9] above, the high-speed peel strength of the pressure-sensitive adhesive layer from the release layer may be less than 0.15 N / 25 mm, measured at a temperature of 23°C and a humidity of 50% RH, at a peel speed of 30 m / min and a peel angle of 180 degrees.

[11] In the roll of the pressure-sensitive adhesive layer-attached film according to the above [9] or

[10] , the roll length may be 3000 m or more. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a method for producing a roll of a pressure-sensitive adhesive layer-attached film without a release liner, which method enables long winding while suppressing the entrapment of air bubbles and the occurrence of wrinkles and the formation of dents. According to the present invention, it is also possible to provide a roll of a pressure-sensitive adhesive layer-attached film that can be produced by such a production method, in which the entrapment of air bubbles and the occurrence of wrinkles and the formation of dents are suppressed. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic explanatory view of one embodiment of a winding device that can be used in a method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0013] When the expression "weight" appears in this specification, it may be read as "mass," which is a commonly used SI unit indicating weight.

[0014] <<1. Film with adhesive layer>> The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is a method for producing a roll from a long length of pressure-sensitive adhesive layer-attached film.

[0015] The pressure-sensitive adhesive layer-attached film has a release layer, a substrate, and a pressure-sensitive adhesive layer in this order. In the pressure-sensitive adhesive layer-attached film, the release layer and the pressure-sensitive adhesive layer are the outermost layers of the pressure-sensitive adhesive layer-attached film. The pressure-sensitive adhesive layer-attached film has a release layer, a substrate, and a pressure-sensitive adhesive layer in this order, and as long as the release layer and the pressure-sensitive adhesive layer are the outermost layers of the pressure-sensitive adhesive layer-attached film, any appropriate other layer may be included as long as the effects of the present invention are not impaired.

[0016] The pressure-sensitive adhesive layer-attached film does not have a separator on the side of the pressure-sensitive adhesive layer opposite the substrate, so that the cost of the separator can be reduced and the separator peeling step can be omitted.

[0017] The pressure-sensitive adhesive layer-attached film can be used for various applications, such as a surface protection film for protecting the surface of an optical component or an electronic component (e.g., glass, polarizing plate, wavelength plate, retardation plate, optical compensation film, reflective sheet, brightness enhancement film, transparent conductive film, etc. used in liquid crystal displays, etc.) to prevent the surface of the component from being scratched during processing, assembly, inspection, transportation, etc., in the manufacturing process, or a carrier sheet.

[0018] The substrate contains a polyester-based resin. When the substrate contains a polyester-based resin, the effects of the present invention can be more effectively exhibited, and in particular, the problems that have conventionally occurred when a polyethylene-based film is used as the substrate can be resolved.

[0019] The pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive. When the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the effects of the present invention can be more effectively exhibited. Furthermore, when the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, for example, the problem of glue residue generation during processing can be suppressed.

[0020] In the pressure-sensitive adhesive layer-attached film, the thickness of the pressure-sensitive adhesive layer is typically 4.0 μm to 10.0 μm. By adjusting the thickness of the pressure-sensitive adhesive layer within the above range, the effects of the present invention can be more effectively achieved. If the thickness of the pressure-sensitive adhesive layer is too small and outside the above range, there is a risk of dents being caused by foreign matter, for example, when a roll is produced from the pressure-sensitive adhesive layer-attached film. If the thickness of the pressure-sensitive adhesive layer is too large and outside the above range, there is a risk of air bubbles being trapped or wrinkles being generated, making it difficult to wind up the pressure-sensitive adhesive layer-attached film, for example, when a roll is produced from the pressure-sensitive adhesive layer-attached film.

[0021] The low-speed peel strength of the pressure-sensitive adhesive layer-attached film, measured at a temperature of 23°C and a humidity of 50% RH at a peel speed of 0.3 m / min and a peel angle of 180° from the release layer, is preferably less than 0.01 N / 25 mm, and may be 0.008 N / 25 mm or less, or may be 0.006 N / 25 mm or less. The lower limit of the low-speed peel strength is preferably 0.002 N / 25 mm or more, so as to prevent slippage during winding. If the low-speed peel strength is too high, for example, noise may be generated when the wound roll is unwound, adhesive residue may remain on the equipment, or excessive static may occur during peeling after lamination. The method for measuring the low-speed peel strength will be described in detail below.

[0022] The high-speed peel strength of the pressure-sensitive adhesive layer-attached film, measured at a temperature of 23°C and a humidity of 50% RH at a peel speed of 30 m / min and a peel angle of 180° from the release layer, is preferably less than 0.15 N / 25 mm, and may be 0.13 N / 25 mm or less, or may be 0.11 N / 25 mm or less. The lower limit of the high-speed peel strength is preferably 0.05 N / 25 mm or more, so as to prevent slippage during winding. If the high-speed peel strength is too high, for example, when the pressure-sensitive adhesive layer-attached film is unwound from a roll, peeling may be heavy, making unwinding difficult. Details of the method for measuring the high-speed peel strength will be described later.

[0023] The total thickness of the pressure-sensitive adhesive layer-attached film is preferably 20 μm to 100 μm, more preferably 25 μm to 80 μm, and even more preferably 30 μm to 60 μm. When the total thickness of the pressure-sensitive adhesive layer-attached film is within the above range, the effects of the present invention can be more effectively exhibited.

[0024] The pressure-sensitive adhesive layer-attached film can be produced by any appropriate method as long as the effects of the present invention are not impaired. Examples of such a production method include: (1) A method in which a solution or a hot melt of a material for forming an adhesive layer is applied to a substrate provided with a release layer, and then dried as necessary; (2) A method in which a solution or a hot melt of a material for forming an adhesive layer is applied to a release liner, and if necessary, dried to form an adhesive layer, and the resulting adhesive layer is transferred onto a substrate provided with a release layer; (3) A method of forming and applying a material for forming a pressure-sensitive adhesive layer onto a substrate provided with a release layer; (4) A method of extruding a substrate and a pressure-sensitive adhesive layer provided with a release layer in two or more layers. (5) A method of laminating a single layer of an adhesive layer provided with a release layer on a substrate, or a method of laminating a double layer of an adhesive layer together with a laminating layer, (6) A method of laminating a pressure-sensitive adhesive layer and a substrate-forming material such as a film or laminate layer provided with a release layer in a two-layer or multi-layer manner. The coating can be carried out in accordance with any appropriate production method such as those described above. Any appropriate method can be used as the coating method. Examples of such coating methods that can be used include a roll coater method, a comma coater method, a die coater method, a reverse coater method, a silk screen method, and a gravure coater method.

[0025] ≪1-1. Release layer≫ Any suitable material can be used as the material for forming the release layer as long as it does not impair the effects of the present invention. Examples of such materials include silicone-based release agents, fluorine-based release agents, long-chain alkyl-based release agents, and fatty acid amide-based release agents. The release layer can be formed as a coating layer.

[0026] The thickness of the release layer may be any appropriate thickness depending on the purpose, as long as it does not impair the effects of the present invention. Such a thickness is, for example, 1 nm to 3000 nm, or may be 10 nm to 2000 nm, 10 nm to 1500 nm, 10 nm to 1000 nm, or 10 nm to 500 nm.

[0027] The release layer may be a single layer or two or more layers.

[0028] The release layer can be formed, for example, by applying the above-mentioned forming material to the substrate by a conventionally known coating method such as reverse gravure coating, bar coating, or die coating, and then curing the applied material by heat treatment, usually at about 120° C. to 200° C. If necessary, the heat treatment may be combined with irradiation with active energy rays such as ultraviolet light.

[0029] As the release layer, a base material on which a release layer has been previously provided may be used.

[0030] ≪1-2. Base material≫ The substrate contains a polyester resin, which can bring about the effects of the present invention.

[0031] The content of the polyester resin in the substrate is preferably more than 50% by weight and not more than 100% by weight, more preferably 70% to 100% by weight, even more preferably 90% to 100% by weight, particularly preferably 95% to 100% by weight, and most preferably 98% to 100% by weight. When the content of the polyester resin in the substrate is within the above range, the effects of the present invention can be more effectively exhibited.

[0032] As the polyester-based resin, any appropriate polyester-based resin can be used as long as it does not impair the effects of the present invention. As such a polyester-based resin, in terms of being able to further exhibit the effects of the present invention, at least one selected from the group consisting of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and polybutylene terephthalate (PBT) is preferred, and polyethylene terephthalate (PET) is more preferred.

[0033] The elastic modulus of the substrate is, for example, 0.1 GPa to 10 GPa, and may be 2 GPa to 5 GPa. When the elastic modulus of the substrate is within the above range, the effects of the present invention can be more effectively exhibited.

[0034] The haze of the substrate is, for example, 15% or less, or may be 10% or less, 7% or less, or 5% or less. If the haze of the substrate is within the above range, foreign matter can be checked during production using a camera or automatic inspection device.

[0035] The thickness of the substrate is preferably 1 μm to 300 μm, more preferably 5 μm to 200 μm, even more preferably 10 μm to 150 μm, still more preferably 20 μm to 100 μm, particularly preferably 30 μm to 80 μm, and most preferably 30 μm to 60 μm, in order to further exhibit the effects of the present invention.

[0036] The substrate may be made up of only one layer, or two or more layers.

[0037] The substrate may be stretched.

[0038] The substrate may be subjected to a surface treatment, such as corona treatment, plasma treatment, chromic acid treatment, ozone exposure, flame exposure, high-voltage shock exposure, ionizing radiation treatment, or coating with a primer.

[0039] The substrate may contain any suitable additives as long as they do not impair the effects of the present invention. Examples of such additives include antistatic agents, colorants, powders such as pigments, surfactants, plasticizers, tackifiers, low-molecular-weight polymers, surface lubricants, leveling agents, antioxidants, corrosion inhibitors, light stabilizers, UV absorbers, polymerization inhibitors, silane coupling agents, inorganic fillers, organic fillers, metal powders, organic particles, and inorganic particles.

[0040] <1-3. Adhesive layer> The pressure-sensitive adhesive layer may be a single layer or two or more layers.

[0041] As mentioned above, the thickness of the pressure-sensitive adhesive layer is typically 4.0 μm to 10.0 μm. By adjusting the thickness of the pressure-sensitive adhesive layer within the above range, the effects of the present invention can be more effectively achieved. If the thickness of the pressure-sensitive adhesive layer is too small and outside the above range, there is a risk of dents due to foreign matter, for example, occurring when a roll is produced from the pressure-sensitive adhesive layer-attached film. If the thickness of the pressure-sensitive adhesive layer is too large and outside the above range, there is a risk of air bubbles being trapped or wrinkles occurring, for example, when a roll is produced from the pressure-sensitive adhesive layer-attached film, making it difficult to wind up the pressure-sensitive adhesive layer-attached film.

[0042] As described above, the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive. When the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the effects of the present invention can be more effectively exhibited. Furthermore, when the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, for example, the problem of glue residue generation during processing can be suppressed.

[0043] The urethane-based pressure-sensitive adhesive is formed from a urethane-based pressure-sensitive adhesive composition. That is, the urethane-based pressure-sensitive adhesive formed from the urethane-based pressure-sensitive adhesive composition forms a layer, thereby forming a pressure-sensitive adhesive layer.

[0044] A urethane-based pressure-sensitive adhesive can be defined as something formed from a urethane-based pressure-sensitive adhesive composition. This is because a urethane-based pressure-sensitive adhesive becomes a urethane-based pressure-sensitive adhesive when the urethane-based pressure-sensitive adhesive composition undergoes a crosslinking reaction due to heating or ultraviolet irradiation, etc., and therefore it is impossible and impractical to directly identify a urethane-based pressure-sensitive adhesive by its structure ("impossible / impractical circumstances"). Therefore, the definition of "something formed from a urethane-based pressure-sensitive adhesive composition" appropriately identifies a urethane-based pressure-sensitive adhesive as a "product."

[0045] The urethane-based pressure-sensitive adhesive is formed from a urethane-based pressure-sensitive adhesive composition. Any appropriate method may be employed as this formation method, provided that the effects of the present invention are not impaired. Examples of such formation methods include conventionally and generally known methods for forming urethane-based pressure-sensitive adhesives. Specific examples of such formation methods include a method in which a urethane-based pressure-sensitive adhesive composition is directly applied to any suitable substrate film (e.g., the substrate in a pressure-sensitive adhesive layer-attached film) and then dried or cured (direct method), and a method in which a urethane-based pressure-sensitive adhesive composition is applied to the surface (release surface) of a release liner and then dried or cured to form a urethane-based pressure-sensitive adhesive layer on the surface, and then the urethane-based pressure-sensitive adhesive layer is then laminated to any suitable substrate film (e.g., the substrate in a pressure-sensitive adhesive layer-attached film) to transfer the urethane-based pressure-sensitive adhesive layer (transfer method). From the viewpoint of the anchoring properties of the pressure-sensitive adhesive layer, the direct method is typically preferably employed. Regarding the various conditions for these formation methods, various conditions for conventionally and generally known methods for forming urethane-based pressure-sensitive adhesives may be employed.

[0046] As a method for providing (typically applying) such a urethane-based pressure-sensitive adhesive layer, various conventionally known methods can be appropriately adopted, such as roll coating, gravure coating, reverse coating, kiss coating, dip roll coating, bar coating, roll brushing, spray coating, knife coating, air knife coating, spray coating, comma coating, direct coating, and coating with a die coater.

[0047] The urethane pressure-sensitive adhesive composition can be dried under heating as needed (for example, by heating to about 60° C. to 150° C.) For example, ultraviolet rays, laser rays, α rays, β rays, γ rays, X-rays, and electron beams can be appropriately used as a means for curing the urethane pressure-sensitive adhesive composition.

[0048] There are two methods for producing urethane-based pressure-sensitive adhesives: the one-shot method, in which a urethane-based pressure-sensitive adhesive is produced by directly reacting a polyol with a polyfunctional isocyanate compound without using a urethane prepolymer, and the prepolymer method, in which a urethane-based pressure-sensitive adhesive is produced by reacting a urethane prepolymer with a polyfunctional isocyanate compound. Here, because a "urethane prepolymer" may have multiple hydroxyl groups, in order to clearly distinguish it from a "polyol," the "polyol (A1)" in the description of this invention does not include the "urethane prepolymer (A2)" in the description of this invention.

[0049] <1-3-1. Urethane adhesives manufactured by the one-shot method> One embodiment of the polyurethane-based pressure-sensitive adhesive is a polyurethane-based pressure-sensitive adhesive obtained by curing a urethane-based pressure-sensitive adhesive composition containing a polyol (A1) and a polyfunctional isocyanate compound (B). That is, the urethane-based pressure-sensitive adhesive composition in this embodiment contains a polyol (A1) and a polyfunctional isocyanate compound (B).

[0050] The total content of the polyol (A1) and the polyfunctional isocyanate compound (B) in the urethane-based pressure-sensitive adhesive composition in this embodiment, excluding the solvent, is preferably 50% by weight to 100% by weight, more preferably 55% by weight to 95% by weight, even more preferably 60% by weight to 90% by weight, particularly preferably 65% ​​by weight to 85% by weight, and most preferably 70% by weight to 80% by weight.

[0051] [1-3-1-a. Polyol (A1)] The polyol (A1) may be one kind or two or more kinds.

[0052] Any suitable polyol having two or more OH groups can be used as the polyol (A1). Examples of such polyol (A1) include a polyol (diol) having two OH groups, a polyol (triol) having three OH groups, a polyol (tetraol) having four OH groups, a polyol (pentaol) having five OH groups, and a polyol (hexaol) having six OH groups.

[0053] In the present invention, the polyol (A1) is preferably a polyol (triol) having three OH groups as an essential component. When the polyol (A1) is a polyol (triol) having three OH groups as an essential component, the effects of the present invention can be more effectively exhibited.

[0054] The content of the polyol having three OH groups (triol) in the polyol (A1) is preferably 50% by weight to 100% by weight, more preferably 70% by weight to 100% by weight, even more preferably 80% by weight to 100% by weight, still more preferably 90% by weight to 100% by weight, particularly preferably 95% by weight to 100% by weight, and most preferably substantially 100% by weight.

[0055] The polyol (A1) preferably contains a polyol having a number average molecular weight Mn of 400 to 20,000. The content of the polyol having a number average molecular weight Mn of 400 to 20,000 in the polyol (A1) is preferably 50% by weight to 100% by weight, more preferably 70% by weight to 100% by weight, even more preferably 90% by weight to 100% by weight, particularly preferably 95% by weight to 100% by weight, and most preferably substantially 100% by weight. By adjusting the content of the polyol having a number average molecular weight Mn of 400 to 20,000 in the polyol (A1) to fall within the above range, the effects of the present invention can be more effectively exhibited.

[0056] In the present invention, when a polyol (triol) having three OH groups is used as an essential component of the polyol (A1), preferably a triol having a number average molecular weight Mn of 7,000 to 20,000, a triol having a number average molecular weight Mn of 2,000 to 6,000, and a triol having a number average molecular weight Mn of 400 to 1,900 are used in combination, more preferably a triol having a number average molecular weight Mn of 8,000 to 15,000, a triol having a number average molecular weight Mn of 2,000 to 5,000, and a triol having a number average molecular weight Mn of 500 to 1,800 are used in combination, and even more preferably a triol having a number average molecular weight Mn of 8,000 to 12,000, a triol having a number average molecular weight Mn of 2,000 to 4,000, and a triol having a number average molecular weight Mn of 500 to 1,500 are used in combination. Using such three types of triols in combination can further enhance the effects of the present invention.

[0057] Examples of the polyol (A1) include polyester polyols, polyether polyols, polycaprolactone polyols, polycarbonate polyols, and castor oil polyols.

[0058] The polyester polyol can be obtained, for example, by an esterification reaction between a polyol component and an acid component.

[0059] Examples of polyol components include ethylene glycol, diethylene glycol, 1,3-butanediol, 1,4-butanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 2-butyl-2-ethyl-1,3-propanediol, 2,4-diethyl-1,5-pentanediol, 1,2-hexanediol, 1,6-hexanediol, 1,8-octanediol, 1,9-nonanediol, 2-methyl-1,8-octanediol, 1,8-decanediol, octadecanediol, glycerin, trimethylolpropane, pentaerythritol, hexanetriol, and polypropylene glycol.

[0060] Examples of the acid component include succinic acid, methylsuccinic acid, adipic acid, pimelic acid, azelaic acid, sebacic acid, 1,12-dodecanedioic acid, 1,14-tetradecanedioic acid, dimer acid, 2-methyl-1,4-cyclohexanedicarboxylic acid, 2-ethyl-1,4-cyclohexanedicarboxylic acid, terephthalic acid, isophthalic acid, phthalic acid, isophthalic acid, terephthalic acid, 1,4-naphthalenedicarboxylic acid, 4,4'-biphenyldicarboxylic acid, and acid anhydrides thereof.

[0061] Examples of polyether polyols include polyether polyols obtained by addition polymerization of alkylene oxides such as ethylene oxide, propylene oxide, and butylene oxide using as initiators water, low-molecular-weight polyols (propylene glycol, ethylene glycol, glycerin, trimethylolpropane, pentaerythritol, etc.), bisphenols (bisphenol A, etc.), and dihydroxybenzenes (catechol, resorcinol, hydroquinone, etc.). Specific examples of polyether polyols include polyethylene glycol, polypropylene glycol, and polytetramethylene glycol.

[0062] Examples of polycaprolactone polyols include caprolactone-based polyester diols obtained by ring-opening polymerization of cyclic ester monomers such as ε-caprolactone and σ-valerolactone.

[0063] Examples of polycarbonate polyols include polycarbonate polyols obtained by polycondensation of the above polyol components with phosgene; polycarbonate polyols obtained by transesterification of the above polyol components with carbonate diesters such as dimethyl carbonate, diethyl carbonate, dipropyl carbonate, diisopropyl carbonate, dibutyl carbonate, ethylbutyl carbonate, ethylene carbonate, propylene carbonate, diphenyl carbonate, and dibenzyl carbonate; copolymer polycarbonate polyols obtained by combining two or more of the above polyol components; polycarbonate polyols obtained by esterification of the above various polycarbonate polyols with carboxyl group-containing compounds; and various of the above various Examples of the polycarbonate polyol include polycarbonate polyols obtained by etherifying polycarbonate polyols with hydroxyl group-containing compounds; polycarbonate polyols obtained by transesterifying the above-mentioned various polycarbonate polyols with ester compounds; polycarbonate polyols obtained by transesterifying the above-mentioned various polycarbonate polyols with hydroxyl group-containing compounds; polyester-based polycarbonate polyols obtained by polycondensation of the above-mentioned various polycarbonate polyols with dicarboxylic acid compounds; and copolymerized polyether-based polycarbonate polyols obtained by copolymerizing the above-mentioned various polycarbonate polyols with alkylene oxides.

[0064] Examples of castor oil-based polyols include castor oil-based polyols obtained by reacting castor oil fatty acids with the above-mentioned polyol components.Specific examples of castor oil-based polyols include castor oil-based polyols obtained by reacting castor oil fatty acids with polypropylene glycol.

[0065] [1-3-1-b. Polyfunctional isocyanate compound (B) used in the one-shot method] The polyfunctional isocyanate compound (B) used in the one-shot method may be one type only, or two or more types.

[0066] Any suitable polyfunctional isocyanate compound that can be used in a urethanization reaction can be used as the polyfunctional isocyanate compound (B). Examples of such polyfunctional isocyanate compounds (B) include polyfunctional aliphatic isocyanate compounds, polyfunctional alicyclic isocyanate compounds, and polyfunctional aromatic isocyanate compounds.

[0067] Examples of polyfunctional aliphatic isocyanate compounds include trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, pentamethylene diisocyanate, 1,2-propylene diisocyanate, 1,3-butylene diisocyanate, dodecamethylene diisocyanate, and 2,4,4-trimethylhexamethylene diisocyanate.

[0068] Examples of polyfunctional alicyclic isocyanate compounds include 1,3-cyclopentene diisocyanate, 1,3-cyclohexane diisocyanate, 1,4-cyclohexane diisocyanate, isophorone diisocyanate, hydrogenated diphenylmethane diisocyanate, hydrogenated xylylene diisocyanate, hydrogenated tolylene diisocyanate, and hydrogenated tetramethylxylylene diisocyanate.

[0069] Examples of polyfunctional aromatic isocyanate compounds include phenylene diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 2,2'-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, 4,4'-toluidine diisocyanate, 4,4'-diphenyl ether diisocyanate, 4,4'-diphenyl diisocyanate, 1,5-naphthalene diisocyanate, and xylylene diisocyanate.

[0070] Examples of the polyfunctional isocyanate compound (B) include trimethylolpropane adducts of the various polyfunctional isocyanate compounds described above, biuret adducts obtained by reacting with water, and ternary adducts having an isocyanurate ring. These may also be used in combination.

[0071] The content of the polyfunctional isocyanate compound (B) relative to the polyol (A1) is preferably 5% by weight to 60% by weight, more preferably 8% by weight to 60% by weight, and even more preferably 10% by weight to 60% by weight. By adjusting the content of the polyfunctional isocyanate compound (B) within the above range, the effects of the present invention can be more effectively exhibited.

[0072] The equivalent ratio of NCO groups to OH groups in the polyol (A1) and the polyfunctional isocyanate compound (B) is, in terms of NCO groups / OH groups, more than 1.0 and not more than 5.0, preferably 1.1 to 5.0, more preferably 1.2 to 4.0, even more preferably 1.5 to 3.5, and particularly preferably 1.8 to 3.0, in terms of being able to further exhibit the effects of the present invention.

[0073] [1-3-1-c. Other ingredients] The urethane adhesive composition can contain any other suitable component in any suitable amount within the scope that does not impair the effects of the present invention.Such other components include, for example, other resin components, crosslinking agents other than the polyfunctional isocyanate compound (B), crosslinking retarders, ionic compounds, fluorine-based additives, silicone-based additives, fatty acid esters, tackifiers, inorganic fillers, organic fillers, metal powders, pigments, foil-like materials, softeners, antioxidants, conductive agents, UV absorbers, antioxidants, light stabilizers, surface lubricants, leveling agents, corrosion inhibitors, heat stabilizers, polymerization inhibitors, lubricants, solvents, and catalysts.

[0074] <1-3-2. Urethane-based adhesives manufactured by the prepolymer method> One embodiment of the polyurethane-based pressure-sensitive adhesive is a polyurethane-based pressure-sensitive adhesive obtained by curing a urethane-based pressure-sensitive adhesive composition containing a urethane prepolymer (A2) and a polyfunctional isocyanate compound (B). That is, the urethane-based pressure-sensitive adhesive composition in this embodiment contains a urethane prepolymer (A2) and a polyfunctional isocyanate compound (B).

[0075] The total content of the urethane prepolymer (A2) and the polyfunctional isocyanate compound (B) in the urethane-based pressure-sensitive adhesive composition in this embodiment, excluding the solvent, is preferably 50% by weight to 100% by weight, more preferably 55% by weight to 95% by weight, even more preferably 60% by weight to 90% by weight, particularly preferably 65% ​​by weight to 85% by weight, and most preferably 70% by weight to 80% by weight.

[0076] [1-3-2-a. Urethane prepolymer (A2)] The urethane prepolymer (A2) may be of one type only, or of two or more types.

[0077] The number average molecular weight Mn of the urethane prepolymer (A2) is preferably 3,000 to 1,000,000.

[0078] The urethane prepolymer (A2) is preferably a polyurethane polyol, and more preferably is obtained by reacting a polyester polyol (a21) or a polyether polyol (a22), either alone or in the form of a mixture of (a21) and (a22), with an organic polyisocyanate compound (a23) in the presence or absence of a catalyst.

[0079] Any suitable polyester polyol can be used as the polyester polyol (a21). Examples of such polyester polyols (a21) include polyester polyols obtained by reacting an acid component with a glycol component. Examples of acid components include terephthalic acid, adipic acid, azelaic acid, sebacic acid, phthalic anhydride, isophthalic acid, and trimellitic acid. Examples of glycol components include ethylene glycol, propylene glycol, diethylene glycol, butylene glycol, 1,6-hexane glycol, 3-methyl-1,5-pentanediol, 3,3'-dimethylolheptane, polyoxyethylene glycol, polyoxypropylene glycol, 1,4-butanediol, neopentyl glycol, and butylethylpentanediol. Examples of polyol components include glycerin, trimethylolpropane, and pentaerythritol. Other examples of the polyester polyol (a1) include polyester polyols obtained by ring-opening polymerization of lactones such as polycaprolactone, poly(β-methyl-γ-valerolactone), and polyvalerolactone.

[0080] The molecular weight of the polyester polyol (a21) can range from low to high. The molecular weight of the polyester polyol (a21) is preferably a number average molecular weight Mn of 100 to 100,000. If the number average molecular weight Mn is less than 100, the reactivity may be high and gelation may occur easily. If the number average molecular weight Mn exceeds 100,000, the reactivity may be low and the cohesive force of the polyurethane polyol itself may be reduced. The amount of polyester polyol (a21) used is preferably 0 mol % to 90 mol % of the polyols constituting the polyurethane polyol.

[0081] Any suitable polyether polyol can be used as the polyether polyol (a22). Examples of such polyether polyols (a22) include polyether polyols obtained by polymerizing oxirane compounds such as ethylene oxide, propylene oxide, butylene oxide, and tetrahydrofuran using a low-molecular-weight polyol such as water, propylene glycol, ethylene glycol, glycerin, or trimethylolpropane as an initiator. Specific examples of such polyether polyols (a22) include polyether polyols having two or more functional groups, such as polypropylene glycol, polyethylene glycol, and polytetramethylene glycol.

[0082] The molecular weight of the polyether polyol (a22) can range from low to high. The molecular weight of the polyether polyol (a22) is preferably a number average molecular weight Mn of 100 to 100,000. If the number average molecular weight Mn is less than 100, the reactivity may be high and gelation may occur easily. If the number average molecular weight Mn exceeds 100,000, the reactivity may be low and the cohesive force of the polyurethane polyol itself may be reduced. The amount of polyether polyol (a22) used is preferably 0 mol % to 90 mol % of the polyols constituting the polyurethane polyol.

[0083] If necessary, the polyether polyol (a22) can be used in combination by replacing a part thereof with glycols such as ethylene glycol, 1,4-butanediol, neopentyl glycol, butylethylpentanediol, glycerin, trimethylolpropane, and pentaerythritol, or polyamines such as ethylenediamine, N-aminoethylethanolamine, isophoronediamine, and xylylenediamine.

[0084] The polyether polyol (a22) may be a bifunctional polyether polyol alone, or may be a polyether polyol having a number average molecular weight Mn of 100 to 100,000 and at least three hydroxyl groups per molecule. When the polyether polyol (a22) is a polyether polyol having a number average molecular weight Mn of 100 to 100,000 and at least three hydroxyl groups per molecule, the balance between adhesive strength and removability can be improved. If the number average molecular weight Mn of such a polyether polyol is less than 100, the reactivity may be high, leading to a risk of gelation. If the number average molecular weight Mn of such a polyether polyol exceeds 100,000, the reactivity may be low, and further, the cohesive strength of the polyurethane polyol itself may be reduced. The number average molecular weight Mn of such a polyether polyol is more preferably 100 to 10,000.

[0085] Any appropriate organic polyisocyanate compound can be used as the organic polyisocyanate compound (a23). Examples of such organic polyisocyanate compound (a23) include aromatic polyisocyanates, aliphatic polyisocyanates, araliphatic polyisocyanates, and alicyclic polyisocyanates.

[0086] Examples of aromatic polyisocyanates include 1,3-phenylene diisocyanate, 4,4'-diphenyl diisocyanate, 1,4-phenylene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4'-toluidine diisocyanate, 2,4,6-triisocyanate toluene, 1,3,5-triisocyanate benzene, dianisidine diisocyanate, 4,4'-diphenyl ether diisocyanate, and 4,4',4"-triphenylmethane triisocyanate.

[0087] Examples of aliphatic polyisocyanates include trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate, pentamethylene diisocyanate, 1,2-propylene diisocyanate, 2,3-butylene diisocyanate, 1,3-butylene diisocyanate, dodecamethylene diisocyanate, and 2,4,4-trimethylhexamethylene diisocyanate.

[0088] Examples of the aromatic aliphatic polyisocyanate include ω,ω'-diisocyanate-1,3-dimethylbenzene, ω,ω'-diisocyanate-1,4-dimethylbenzene, ω,ω'-diisocyanate-1,4-diethylbenzene, 1,4-tetramethylxylylene diisocyanate, and 1,3-tetramethylxylylene diisocyanate.

[0089] Examples of alicyclic polyisocyanates include 3-isocyanatemethyl-3,5,5-trimethylcyclohexyl isocyanate, 1,3-cyclopentane diisocyanate, 1,3-cyclohexane diisocyanate, 1,4-cyclohexane diisocyanate, methyl-2,4-cyclohexane diisocyanate, methyl-2,6-cyclohexane diisocyanate, 4,4'-methylenebis(cyclohexyl isocyanate), 1,4-bis(isocyanatemethyl)cyclohexane, and 1,4-bis(isocyanatemethyl)cyclohexane.

[0090] As the organic polyisocyanate compound (a23), a trimethylolpropane adduct, a biuret product reacted with water, a trimer having an isocyanurate ring, etc. can be used in combination.

[0091] Any suitable catalyst can be used to obtain the polyurethane polyol, including, for example, tertiary amine compounds and organometallic compounds.

[0092] Examples of tertiary amine compounds include triethylamine, triethylenediamine, and 1,8-diazabicyclo(5,4,0)-undecene-7(DBU).

[0093] Examples of organometallic compounds include tin-based compounds and non-tin-based compounds.

[0094] Examples of tin compounds include dibutyltin dichloride, dibutyltin oxide, dibutyltin dibromide, dibutyltin dimaleate, dibutyltin dilaurate (DBTDL), dibutyltin diacetate, dibutyltin sulfide, tributyltin sulfide, tributyltin oxide, tributyltin acetate, triethyltin ethoxide, tributyltin ethoxide, dioctyltin oxide, tributyltin chloride, tributyltin trichloroacetate, and tin 2-ethylhexanoate.

[0095] Examples of non-tin compounds include titanium compounds such as dibutyltitanium dichloride, tetrabutyltitanium, and butoxytitanium trichloride; lead compounds such as lead oleate, lead 2-ethylhexanoate, lead benzoate, and lead naphthenate; iron compounds such as iron 2-ethylhexanoate and iron acetylacetonate; cobalt compounds such as cobalt benzoate and cobalt 2-ethylhexanoate; zinc compounds such as zinc naphthenate and zinc 2-ethylhexanoate; and zirconium compounds such as zirconium naphthenate.

[0096] When a catalyst is used to obtain a polyurethane polyol, in a system containing two types of polyols, a polyester polyol (a21) and a polyether polyol (a22), problems such as gelation or cloudiness of the reaction solution tend to occur in a system using a single catalyst due to the difference in reactivity between the two polyols. Therefore, by using two types of catalysts to obtain a polyurethane polyol, it becomes easier to control the reaction rate, catalyst selectivity, and the like, thereby solving these problems. Examples of such combinations of two types of catalysts include tertiary amine / organometallic, tin / non-tin, and tin / tin. Tin / tin combinations are preferred, and a combination of dibutyltin dilaurate and tin 2-ethylhexanoate is more preferred. The weight ratio of tin 2-ethylhexanoate / dibutyltin dilaurate is preferably less than 1, more preferably 0.2 to 0.6. If the ratio is 1 or more, gelation may occur due to the balance of catalytic activity.

[0097] When a catalyst is used in obtaining the polyurethane polyol, the amount of the catalyst used is preferably 0.01% by weight to 1.0% by weight based on the total amount of the polyester polyol (a21), the polyether polyol (a22), and the organic polyisocyanate compound (a23).

[0098] When a catalyst is used to obtain a polyurethane polyol, the reaction temperature is preferably less than 100° C., and more preferably 85 to 95° C. If the temperature is 100° C. or higher, it may become difficult to control the reaction rate and crosslinked structure, and it may become difficult to obtain a polyurethane polyol having a predetermined molecular weight.

[0099] When obtaining polyurethane polyol, it is not necessary to use a catalyst. In that case, the reaction temperature is preferably 100° C. or higher, more preferably 110° C. or higher. When obtaining polyurethane polyol without a catalyst, the reaction is preferably carried out for 3 hours or longer.

[0100] Methods for obtaining polyurethane polyol include, for example, 1) a method in which a polyester polyol, a polyether polyol, a catalyst, and an organic polyisocyanate are all charged into a volumetric flask, and 2) a method in which a polyester polyol, a polyether polyol, and a catalyst are charged into a flask and an organic polyisocyanate is added dropwise. Method 2) is preferred as a method for obtaining polyurethane polyol in terms of controlling the reaction.

[0101] Any suitable solvent may be used to obtain the polyurethane polyol. Examples of such solvents include methyl ethyl ketone, ethyl acetate, toluene, xylene, and acetone. Among these solvents, toluene is preferred.

[0102] [1-3-2-b. Polyfunctional isocyanate compound (B) used in the prepolymer method] The polyfunctional isocyanate compound (B) used in the prepolymer method may be one type only, or two or more types.

[0103] As the polyfunctional isocyanate compound (B) used in the prepolymer method, the above-mentioned polyfunctional isocyanate compound (B) used in the one-shot method can be used.

[0104] The equivalent ratio of NCO groups to OH groups in the urethane prepolymer (A2) and the polyfunctional isocyanate compound (B), expressed as NCO groups / OH groups, is preferably 5.0 or less, more preferably 0.01 to 4.75, even more preferably 0.02 to 4.5, particularly preferably 0.03 to 4.25, and most preferably 0.05 to 4.0. When the equivalent ratio of NCO groups / OH groups is within the above range, the effects of the present invention can be more effectively exhibited.

[0105] The content of the polyfunctional isocyanate compound (B) relative to the urethane prepolymer (A2) is preferably 0.01 to 30% by weight, more preferably 0.05 to 25% by weight, even more preferably 0.1 to 20% by weight, particularly preferably 0.5 to 17.5% by weight, and most preferably 1 to 15% by weight. When the content of the polyfunctional isocyanate compound (B) is within the above range, the effects of the present invention can be more effectively exhibited.

[0106] As a method for forming a urethane-based pressure-sensitive adhesive from a urethane-based pressure-sensitive adhesive composition containing a urethane prepolymer (A2) and a polyfunctional isocyanate compound (B), any appropriate production method can be adopted as long as it is a method for producing a polyurethane-based resin using a so-called "urethane prepolymer" as a raw material.

[0107] 2. Method for producing rolled body of film with pressure-sensitive adhesive layer The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is a method for producing a roll from a long length of pressure-sensitive adhesive layer-attached film.

[0108] In a method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, a long length of the pressure-sensitive adhesive layer-attached film is wound around a winding shaft to form a roll. In a method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, the long length of the pressure-sensitive adhesive layer-attached film is wound around the winding shaft via a touch roll arranged in front of the winding shaft.

[0109] The length in the longitudinal direction of the long pressure-sensitive adhesive layer-attached film to be used in the method for producing a roll of pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention is, for example, 1000 m or more, and may be 2000 m to 10000 m, or may be 3000 m to 10000 m.

[0110] The width direction length of the long pressure-sensitive adhesive layer-attached film used in the method for producing a roll of pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention can be any appropriate length as long as the effects of the present invention are not impaired. Such a width direction length is, for example, 100 mm to 5000 mm, or may be 500 mm to 3000 mm, or may be 1000 mm to 2000 mm.

[0111] Fig. 1 is a schematic explanatory diagram of one embodiment of a winding device that can be used in a method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention. In Fig. 1, a long pressure-sensitive adhesive layer-attached film 101 passes through transport rolls 11 and 12 and a touch roll 200, and is wound around a winding shaft 300 to form a roll of a pressure-sensitive adhesive layer-attached film 102. The touch roll 200 is rotatably supported by a position adjustment unit 400.

[0112] As shown in Fig. 1, the touch roll 200 is arranged in front of a winding shaft 300 in a state in contact with a pressure-sensitive adhesive layer-attached film 101. The touch roll 200 is rotatably supported by a position adjustment unit 400 so that a constant pressure can be applied to the pressure-sensitive adhesive layer-attached film 101 when the pressure-sensitive adhesive layer-attached film 101 is wound around the winding shaft 300 to form a roll 102 of the pressure-sensitive adhesive layer-attached film, even if the diameter of the roll increases. The position adjustment unit 400 is, for example, a cylinder (such as an air cylinder). The position adjustment unit 400 can finely adjust the position of the touch roll 200.

[0113] As the touch roll, any appropriate type of touch roll may be used as long as it is applicable to film winding and does not impair the effects of the present invention. Examples of such touch rolls include crown rolls. Examples of materials for the touch roll include rubber.

[0114] Any suitable type of winding shaft can be used as the winding shaft, as long as it can be used to wind a film and does not impair the effects of the present invention. Examples of materials for such winding shafts include rubber, plastic, metal (e.g., aluminum), and composite materials thereof. The surface of the winding shaft may be coated with any suitable other material. The outer diameter of the winding shaft (the distance from the center of the winding core to the outer surface of the winding core) is, for example, 1 inch to 30 inches, and may be 2 inches to 15 inches. The shape of the winding shaft may be cylindrical or columnar.

[0115] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, taper control may or may not be performed. However, in the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, it is preferable not to perform taper control, as this can keep the tension of the pressure-sensitive adhesive layer-attached film constant and suppress air entrainment during winding.

[0116] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, the end of the pressure-sensitive adhesive layer-attached film may or may not be knurled. However, in the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, it is preferable that the end of the pressure-sensitive adhesive layer-attached film is not knurled, because this enables long winding while suppressing the entrapment of air bubbles, the occurrence of wrinkles, and dents.

[0117] In the method for manufacturing a wound body of a film with an adhesive layer according to an embodiment of the present invention, by appropriately adjusting the touch pressure P of the touch roll, it is possible to perform long-length winding while suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. The touch pressure P of the touch roll, as a linear pressure, is preferably 3.6 N / cm < P < 14.0 N / cm, and may be 3.9 N / cm < P < 13.0 N / cm, may be 4.2 N / cm < P < 11.0 N / cm, may be 4.3 N / cm < P < 10.0 N / cm, or may be 4.5 N / cm < P < 9.0 N / cm. By adjusting the touch pressure P of the touch roll within the above range, it is possible to perform long-length winding while suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. Note that the touch pressure P is calculated as a linear pressure by dividing the pressing force applied to the roll by the width of the film.

[0118] In the method for manufacturing a wound body of a film with an adhesive layer according to an embodiment of the present invention, by appropriately adjusting the product of the thickness D of the base material and the touch pressure P, it is possible to perform long-length winding while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. The product D × P of the thickness D of the base material and the touch pressure P is preferably 0.016 N < (D × P) < 0.075 N, and may be 0.017 < (D × P) < 0.063 N, may be 0.018 N < (D × P) < 0.050 N, or may be 0.020 N < (D × P) < 0.045 N. By adjusting the product D × P of the thickness D of the base material and the touch pressure P within the above range, it is possible to perform long-length winding while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations.

[0119] In the method for manufacturing a wound body of a film with an adhesive layer according to an embodiment of the present invention, by appropriately adjusting the surface hardness S of the touch roll, long-length winding can be achieved while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. The surface hardness S of the touch roll is preferably 30° < S < 80°, and may be 40° < S < 60°. By adjusting the surface hardness S of the touch roll within the above range, long-length winding can be achieved while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. The surface hardness S was measured using a durometer type A (manufactured by ASKER).

[0120] In the method for manufacturing a wound body of a film with an adhesive layer according to an embodiment of the present invention, by appropriately adjusting the winding tension T of the film with an adhesive layer onto the winding shaft, long-length winding can be achieved while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations. The winding tension T of the film with an adhesive layer onto the winding shaft is preferably 200 N / m < T < 400 N / m, and may be 220 N / m < T < 380 N / m. By adjusting the winding tension T of the film with an adhesive layer onto the winding shaft within the above range, long-length winding can be achieved while further suppressing the entrainment of air bubbles, the generation of wrinkles, and the formation of indentations.

[0121] In the method for manufacturing a wound body of a film with an adhesive layer according to an embodiment of the present invention, the line speed (winding speed) can be adjusted to any appropriate line speed within a range that does not impair the effects of the present invention. In terms of more effectively expressing the effects of the present invention, the line speed is, for example, 1 m / min to 100 m / min, and may be 5 m / min to 80 m / min, may be 10 m / min to 60 m / min, may be 13 m / min to 40 m / min, may be 15 m / min to 30 m / min, or may be 15 m / min to 28 m / min. [[ID=~9]]

[0122] In the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, long winding is possible while suppressing the entrapment of air bubbles, the occurrence of wrinkles, and dents. Therefore, the roll length of the roll obtained in the method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is preferably 1000 m or more, and may be 2000 m to 10000 m, or may be 3000 m to 10000 m.

[0123] According to the method for manufacturing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, it is possible to perform long winding while suppressing the entrapment of air bubbles, the occurrence of wrinkles, and the formation of dents. For example, even if foreign matter with a maximum particle size of 3 μm or less is caught in the roll during production, it is possible to perform long winding without causing dents.

[0124] In a method for manufacturing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention, a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive is used as the pressure-sensitive adhesive layer of the pressure-sensitive adhesive layer-attached film. Furthermore, in the pressure-sensitive adhesive layer-attached film unwound from the roll, the pressure-sensitive adhesive layer is the outermost layer of the pressure-sensitive adhesive layer-attached film. Therefore, when the pressure-sensitive adhesive layer-attached film is unwound from the roll for bonding to another member, the surface of the pressure-sensitive adhesive layer can come into contact with the rotating roll, which makes it possible to clean the rotating roll without leaving any adhesive residue.

[0125] ≪≪3. Rolled film with adhesive layer≫≫ The roll of the pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention is a roll of a long pressure-sensitive adhesive layer-attached film.

[0126] The roll length of the pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention is preferably 1000 m or more, more preferably 2000 m or more, and even more preferably 3000 m or more. Conventional rolls of pressure-sensitive adhesive layer-attached film without a release liner have had difficulty in achieving long roll lengths due to the inclusion of air bubbles, the occurrence of wrinkles, and the occurrence of dents. According to the present invention, a roll having the above-mentioned long roll length can be provided.

[0127] The description of the adhesive layer-attached film in the previous section <<1. Adhesive layer-attached film>> can be directly applied to the description of the long adhesive layer-attached film that will become the roll of adhesive layer-attached film according to an embodiment of the present invention.

[0128] The long pressure-sensitive adhesive layer-attached film to be wound into a roll of pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention preferably has a release layer, a substrate, and a pressure-sensitive adhesive layer in this order, the release layer and the pressure-sensitive adhesive layer being the outermost layers of the pressure-sensitive adhesive layer-attached film, the substrate containing a polyester resin, the pressure-sensitive adhesive layer being a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the pressure-sensitive adhesive layer having a thickness of 4.0 μm to 10.0 μm, and exhibiting a low-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a temperature of 23° C. and a humidity of 50% RH at a peel speed of 0.3 m / min and a peel angle of 180° of less than 0.01 N / 25 mm. More preferably, the long pressure-sensitive adhesive layer-attached film to be wound into a roll of pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention is the pressure-sensitive adhesive layer-attached film embodiment described above in the section <<1. Pressure-sensitive adhesive layer-attached film>>.

[0129] The roll of the pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention can suppress the entrapment of air bubbles and the occurrence of wrinkles, and can also suppress dents, even if the rolled length is long.

[0130] The roll of the pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention can be produced by any appropriate method as long as the effects of the present invention are not impaired. Examples of such a production method include the method for producing the roll of the pressure-sensitive adhesive layer-attached film according to the embodiment of the present invention. [Example]

[0131] The present invention will be specifically described below using examples, but the present invention is not limited to these examples. The test and evaluation methods used in the examples are as follows. The term "parts" means "parts by weight" unless otherwise specified, and the term "%" means "% by weight" unless otherwise specified.

[0132] <Thickness measurement> The thickness of the pressure-sensitive adhesive layer in the examples and comparative examples was measured using an interference film thickness meter (manufactured by Otsuka Electronics Co., Ltd., product name "MCPD-3700").

[0133] <Low speed peel force measurement at a peel speed of 0.3 m / min and a peel angle of 180 degrees> For two of the produced pressure-sensitive adhesive films, the pressure-sensitive adhesive layer was pressed onto the release layer with a hand roller, then laminated at 0.25 MPa and 0.3 m / min. The laminate was then left at 23°C and 50% RH for 20 minutes. The film was then cut to a width of 25 mm and attached to a SUS plate (SUS304BA) with the side opposite the release layer. A universal tensile tester (Minebea Co., Ltd., product name: TCM-1kNB) was used to peel the pressure-sensitive adhesive layer from the release layer at a peel speed of 0.3 m / min and a peel angle of 180°. The measured peel force was defined as the low-speed peel force.

[0134] <High-speed peel force measurement at a peel speed of 30 m / min and a peel angle of 180 degrees> The pressure-sensitive adhesive layer was pressed onto the release layer using a hand roller, and then the resulting film was laminated at 0.25 MPa and 0.3 m / min. The film was then left for 20 minutes at 23°C and 50% relative humidity. The film was then cut to a width of 25 mm and attached to a SUS plate (SUS304BA) with the side of the pressure-sensitive adhesive layer opposite the release layer. A universal tensile tester (Minebea Co., Ltd., product name: TCM-1kNB) was used to peel the pressure-sensitive adhesive layer from the release layer at a peel speed of 30 m / min and a peel angle of 180°. The high-speed peel force was measured.

[0135] <Evaluation of the appearance of bubbles and wrinkles> After 3000 m of the pressure-sensitive adhesive layered film was wound up, one revolution was unwound from the roll and discarded, and then the surface of the roll was checked for bubbles and wrinkles. The evaluation was carried out according to the following criteria. ○: No bubbles or wrinkles within the area. △: No bubbles or wrinkles of 15 mm or more within the area. ×: There are bubbles or wrinkles of 1 mm or more within the area.

[0136] <Appearance evaluation of foreign matter impact marks> After 3000 m of the adhesive layered film was wound up, one turn was unwound from the roll and discarded, and then the appearance of a 2 m length was checked. The evaluation was carried out according to the following criteria. ○: No foreign matter dents were found. ×: Foreign matter dents were observed.

[0137] <Evaluation of winding length> The windings that were good (rated "good") in both the appearance evaluation for bubbles and wrinkles and the appearance evaluation for foreign matter dents were further wound up to 4000 m, and the appearance evaluation for bubbles and wrinkles was carried out in the same manner as above.

[0138] [Synthesis Example 1] Preparation of urethane-based pressure-sensitive adhesive composition (1) The polyol used was 90 parts by weight of Preminol S3011 (manufactured by Asahi Glass Co., Ltd., Mn=10000), a polyol having three hydroxyl groups; 5 parts by weight of Sannix GP3000 (manufactured by Sanyo Chemical Co., Ltd., Mn=3000), a polyol having three hydroxyl groups; 1 part by weight of Sannix GP1000 (manufactured by Sanyo Chemical Co., Ltd., Mn=1000), a polyol having three hydroxyl groups; 10 parts by weight of an isocyanate compound (Coronate HX:C / HX, manufactured by Nippon Polyurethane Industry Co., Ltd.) as a crosslinking agent; and naphthalene nitrate as a catalyst. 0.15 parts by weight of ferrous iron (manufactured by Nippon Chemical Industry Co., Ltd.), 0.04 parts by weight of polyether-modified silicone (manufactured by Shin-Etsu Chemical Co., Ltd., product name "KF6004") as a silicone compound, 0.8 parts by weight of Elexcel AS110 (manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd.) as an ionic compound, and 5.0 parts by weight of Salacos 816(L) (2-cetyl ethylhexanoate, molecular weight = 368, manufactured by Nisshin Oillio Group, Ltd.) as a fatty acid ester were diluted with ethyl acetate to a total solids content of 20% by weight, to obtain a urethane-based pressure-sensitive adhesive composition (1).

[0139] [Synthesis Example 2] Preparation of acrylic pressure-sensitive adhesive composition (1) An acrylic adhesive (SK Dyne, manufactured by Soken Chemical & Engineering Co., Ltd.) was diluted with toluene to 35% by weight, and 5 parts by weight of a crosslinking agent (polyisocyanate, manufactured by Tosoh Corporation, Coronate HX) in a solid content, 0.5 parts by solid content of a crosslinking catalyst (a tin catalyst, dioctyltin dilaurate, manufactured by Tokyo Fine Chemical Co., Ltd., Envirizer OL-1), and 10 parts by weight of acetylacetone were added per 100 parts by weight of solid content, and the mixture was mixed and stirred to prepare an acrylic adhesive composition (1).

[0140] [Production Example 1] Production of pressure-sensitive adhesive layer-attached film (1) A long PET film with a release layer (manufactured by Mitsubishi Chemical, trade name "MRF38", thickness = 38 μm, width length = 1480 mm, release layer thickness = 20 nm) was used as the substrate, and the urethane-based adhesive composition (1) obtained in Synthesis Example 1 was applied to the surface of the substrate opposite the release layer on a line at a line speed of 20 m / min so that the thickness after drying would be 5 μm. The composition was then dried at 130°C for 30 seconds to form a urethane-based adhesive layer with a thickness of 5 μm, and a long adhesive layer-attached film (1) with a "release layer / substrate / adhesive layer" configuration was produced on the line.

[0141] [Production Example 2] Production of adhesive layer-attached film (2) A long adhesive layer-attached film (2) having a "release layer / substrate / adhesive layer" configuration was produced in the same manner as in Production Example 1, except that a long PET film with a release layer (manufactured by Mitsubishi Chemical, product name "MRF50", thickness = 50 μm, width length = 1480 mm, release layer thickness = 20 nm) was used as the substrate.

[0142] [Production Example 3] Production of pressure-sensitive adhesive layer-attached film (3) A long adhesive layer-attached film (3) having a structure of "release layer / substrate / adhesive layer" was produced in the same manner as in Production Example 1, except that the urethane-based adhesive composition (1) was applied so that the thickness after drying would be 7 μm.

[0143] [Production Example 4] Production of pressure-sensitive adhesive layer-attached film (4) A long adhesive layer-attached film (4) having a structure of "release layer / substrate / adhesive layer" was produced in the same manner as in Production Example 1, except that the urethane-based adhesive composition (1) was applied so that the thickness after drying would be 10 μm.

[0144] [Production Example 5] Production of pressure-sensitive adhesive film (5) A long adhesive layer-attached film (5) having a structure of "release layer / substrate / adhesive layer" was produced in the same manner as in Production Example 1, except that the urethane-based adhesive composition (1) was applied so that the thickness after drying was 3 μm.

[0145] [Production Example 6] Production of pressure-sensitive adhesive layer-attached film (6) A long PET film with a release layer (manufactured by Mitsubishi Chemical, trade name "MRF38", thickness = 38 μm, width direction length = 1480 mm, release layer thickness = 20 nm) was used as the substrate, and the acrylic pressure-sensitive adhesive composition (1) obtained in Synthesis Example 2 was applied on the surface of the substrate opposite the release layer at a line speed of 20 m / min so that the thickness after drying would be 5 μm. The composition was then dried at 130°C for 30 seconds to form an acrylic pressure-sensitive adhesive layer with a thickness of 5 μm, and a long pressure-sensitive adhesive layer-attached film (6) having a "release layer / substrate / pressure-sensitive adhesive layer" configuration was produced on the line.

[0146] [Production Example 7] Production of pressure-sensitive adhesive film (7) A long PET film (manufactured by Mitsubishi Chemical Corporation, trade name "Diafoil T100C38", thickness = 38 μm, width direction length = 1400 mm) was used as the substrate, and an anti-fouling layer made of a polyvinyl butyral compound was formed on one side of this substrate on a production line. Subsequently, on the production line, the urethane-based pressure-sensitive adhesive composition (1) obtained in Synthesis Example 1 was applied to the surface of the substrate opposite the anti-fouling layer at a line speed of 20 m / min so as to have a thickness of 5 μm after drying, and dried at 130 ° C. for 30 seconds to form a urethane-based pressure-sensitive adhesive layer with a thickness of 5 μm, and a long pressure-sensitive adhesive layer-attached film (7) having an "anti-fouling layer / substrate / pressure-sensitive adhesive layer" configuration was produced on the production line.

[0147] [Production Example 8] Production of pressure-sensitive adhesive film (8) A long adhesive layer-attached film (8) having a structure of "release layer / substrate / adhesive layer" was produced in the same manner as in Production Example 1, except that the urethane-based adhesive composition (1) was applied so that the thickness after drying would be 12 μm.

[0148] [Examples 1 to 12, Comparative Examples 1 to 8] Using the winding device shown in FIG. 1, any of the pressure-sensitive adhesive layer-attached films (1) to (8) obtained in Production Examples 1 to 8 was wound around a winding shaft under the conditions shown in Table 1 to obtain wound bodies (1) to (7), (C1) to (C8). The results are shown in Table 1.

[0149] [Table 1] [Industrial Applicability]

[0150] The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention can be effectively used for producing rolls of various films used in the manufacturing processes of optical members and electronic members, for example. Also, the roll of a pressure-sensitive adhesive layer-attached film according to an embodiment of the present invention can be effectively used as a roll of various films used in the manufacturing processes of optical members and electronic members, for example. [Explanation of symbols]

[0151] 101 Film with adhesive layer 102 Roll of film with adhesive layer 200 Touch Roll 300 Winding shaft 400 Position adjustment section 11 Transport roll 12 Transport roll

Claims

1. A method for producing a roll from a long pressure-sensitive adhesive layer-attached film, comprising: The pressure-sensitive adhesive layer-attached film has a release layer, a substrate, and a pressure-sensitive adhesive layer in this order, the release layer and the pressure-sensitive adhesive layer are the outermost layers of the pressure-sensitive adhesive layer-attached film, the substrate contains a polyester-based resin, the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the thickness of the pressure-sensitive adhesive layer is 4.0 μm to 10.0 μm, the pressure-sensitive adhesive layer-attached film is wound around a winding shaft via a touch roll arranged in front of the winding shaft to form a roll, The touch pressure P of the touch roll is, in terms of linear pressure, 3.6 N / cm<P<14.0 N / cm. A method for producing a roll of a film with a pressure-sensitive adhesive layer.

2. The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to claim 1, wherein the touch pressure P of the touch roll is, in terms of linear pressure, 4.3 N / cm<P<10.0 N / cm.

3. The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to claim 1, wherein the product of the thickness D of the substrate and the touch pressure P satisfies 0.018 N < (D × P) < 0.050 N.

4. The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to claim 1, wherein the surface hardness S of the touch roll is 30°<S<80°.

5. The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to claim 1, wherein a winding tension T of the pressure-sensitive adhesive layer-attached film on a winding shaft is 200 N / m<T<400 N / m.

6. 2. The method for producing a roll of a film with a pressure-sensitive adhesive layer according to claim 1, wherein the low-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a peel speed of 0.3 m / min and a peel angle of 180 degrees at a temperature of 23°C and a humidity of 50% RH is less than 0.01 N / 25 mm.

7. 2. The method for producing a roll of a film with a pressure-sensitive adhesive layer according to claim 1, wherein the high-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a peel speed of 30 m / min and a peel angle of 180 degrees at a temperature of 23°C and a humidity of 50% RH is less than 0.15 N / 25 mm.

8. The method for producing a roll of a pressure-sensitive adhesive layer-attached film according to claim 1, wherein the roll has a winding length of 3000 m or more.

9. A roll of a long pressure-sensitive adhesive layer-attached film, The pressure-sensitive adhesive layer-attached film has a release layer, a substrate, and a pressure-sensitive adhesive layer in this order, the release layer and the pressure-sensitive adhesive layer are the outermost layers of the pressure-sensitive adhesive layer-attached film, the substrate contains a polyester-based resin, the pressure-sensitive adhesive layer is a urethane-based pressure-sensitive adhesive layer composed of a urethane-based pressure-sensitive adhesive, the thickness of the pressure-sensitive adhesive layer is 4.0 μm to 10.0 μm, the low-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a peel speed of 0.3 m / min and a peel angle of 180 degrees at a temperature of 23°C and a humidity of 50% RH is less than 0.01 N / 25 mm; A roll of film with an adhesive layer.

10. 10. A roll of a film with a pressure-sensitive adhesive layer according to claim 9, wherein the high-speed peel strength of the pressure-sensitive adhesive layer from the release layer measured at a peel speed of 30 m / min and a peel angle of 180 degrees at a temperature of 23°C and a humidity of 50% RH is less than 0.15 N / 25 mm.

11. The roll of the pressure-sensitive adhesive layer-attached film according to claim 9, having a roll length of 3000 m or more.

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