Method for manufacturing laminates and apparatus for manufacturing laminates

Abstract

To provide a laminate manufacturing method and a laminate manufacturing apparatus that are capable of suppressing cracks from occurring during bonding.SOLUTION: A method for manufacturing a laminate includes: a first step of pressing a laminate film having a base film and an inorganic layer laminated on the base film onto a first intermediate point between a first end and a second end of a substrate with a pressing tool, and then moving the pressing tool from the first intermediate point toward the first end while pressing the pressing tool onto the laminate film; a second step of moving the pressing tool to the second intermediate point between the first end and the second end without pressing the pressing tool against the laminate film; and a third step of moving the pressing tool from the second intermediate point toward the second end while pressing the pressing tool against the laminate film.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a laminate and an apparatus for manufacturing a laminate.

Background Art

[0002] Anti-reflection films are applied to various parts. For example, an anti-reflection film is laminated on a monitor glass of a liquid crystal panel for vehicle use. The anti-reflection film is laminated on a substrate such as glass.

[0003] For example, Patent Document 1 describes a laminating apparatus for laminating a sheet member onto a long film member.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] When laminating a laminated film having an inorganic layer onto a substrate, cracks may occur in the laminated film when a pressing tool rides on the edge of the substrate.

[0006] The present invention has been made in view of the above problems, and provides a method for manufacturing a laminate and an apparatus for manufacturing a laminate that can suppress the occurrence of cracks during lamination.

Means for Solving the Problems

[0007] In order to solve the above problems, the present invention proposes the following means.

[0008] (1) A method for manufacturing a laminate according to the first embodiment comprises: a first step of pressing a laminated film having a base film and an inorganic layer laminated on the base film against a first intermediate point between the first and second ends of a substrate using a pressing tool, and moving the pressing tool from the first intermediate point toward the first end while pressing the pressing tool against the laminated film; a second step of moving the pressing tool to a second intermediate point between the first and second ends without pressing the pressing tool against the laminated film; and a third step of moving the pressing tool from the second intermediate point toward the second end while pressing the pressing tool against the laminated film.

[0009] (2) In the method for manufacturing a laminate according to the above embodiment, the second intermediate point may coincide with the first intermediate point.

[0010] (3) In the method for manufacturing the laminate according to the above embodiment, the second intermediate point may be closer to the first end than the first intermediate point.

[0011] (4) In the method for manufacturing the laminate according to the above embodiment, the second intermediate point may be closer to the second end than the first intermediate point.

[0012] (5) In the method for manufacturing a laminate according to the above embodiment, the bonding pressure per unit time between the laminated film and the substrate may be greater at the first midpoint than at the first end.

[0013] (6) In the method for manufacturing a laminate according to the above embodiment, the bonding pressure per unit time between the laminated film and the substrate may be greater at the second midpoint than at the second end.

[0014] (7) In the method for manufacturing a laminate according to the above embodiment, the width of the substrate in the second direction perpendicular to the first direction connecting the first end and the second end is not constant, the width of the first portion in the second direction is shorter than that of the second portion, and the bonding pressure per unit time between the laminated film and the substrate may be smaller for the first portion than for the second portion.

[0015] (8) In the method for manufacturing a laminate according to the above embodiment, the pressing tool may have a first roller that contacts the laminated film and a second roller that contacts the substrate.

[0016] (9) In the first and third steps of the method for manufacturing the laminate according to the above embodiment, the bonding pressure used to bond the laminated film and the substrate with the pressing tool may be 0.1 MPa or more and 0.5 MPa or less.

[0017] (10) A laminate manufacturing apparatus according to the second embodiment includes a pressing tool for pressing a laminated film having a base film and an inorganic layer laminated on the base film against a substrate, and a control unit for controlling the relative position between the pressing tool and the substrate, wherein the control unit performs a first operation of pressing the pressing tool against a first midpoint between the first and second ends of the substrate and moving the pressing tool from the first midpoint toward the first end while pressing the pressing tool against the laminated film, a second operation of moving the pressing tool to a second midpoint between the first and second ends without pressing the pressing tool against the laminated film, and a third operation of moving the pressing tool from the second midpoint toward the second end while pressing the pressing tool against the laminated film. [Effects of the Invention]

[0018] The method for manufacturing a laminate and the apparatus for manufacturing a laminate according to this embodiment can suppress the occurrence of cracks during bonding. [Brief explanation of the drawing]

[0019] [Figure 1] This is a cross-sectional view of the laminated film according to this embodiment. [Figure 2] This is a cross-sectional view illustrating the first step in the manufacturing method of the laminate according to this embodiment. [Figure 3] This is a plan view illustrating the first step in the manufacturing method of the laminate according to this embodiment. [Figure 4]It is a cross-sectional view for explaining the second step in the method for manufacturing a laminate according to the present embodiment. [Figure 5] It is a cross-sectional view for explaining the third step in the method for manufacturing a laminate according to the present embodiment. [Figure 6] It is a plan view for explaining the third step in the method for manufacturing a laminate according to the present embodiment. [Figure 7] It is a plan view for explaining another example of the third step in the method for manufacturing a laminate according to the present embodiment. [Figure 8] It is a plan view for explaining another example of the third step in the method for manufacturing a laminate according to the present embodiment.

Mode for Carrying Out the Invention

[0020] Hereinafter, the present embodiment will be described in detail with appropriate reference to the drawings. The drawings used in the following description may show, for the sake of convenience, the characteristic portions enlarged in order to make the features of the present invention easier to understand, and the dimensional ratios of the respective components may be different from the actual ones. The materials, dimensions, etc. exemplified in the following description are merely examples, and the present invention is not limited thereto, and it can be appropriately modified and implemented within the scope in which the effects can be achieved.

[0021] First, directions are defined. The moving direction of the pressing tool 30 is referred to as the first direction. The x direction is an example of the first direction. In the plane in which the substrate 20 extends, the direction orthogonal to the first direction is referred to as the second direction. The y direction is an example of the second direction. The z direction is the direction orthogonal to the x direction and the y direction. The z direction, for example, coincides with the direction in which pressure is applied when the laminated film 10 and the substrate 20 are bonded together.

[0022] "Method for Manufacturing a Laminate" The method for manufacturing a laminate according to the present embodiment includes a first step, a second step, and a third step. In the method for manufacturing a laminate according to the present embodiment, the laminated film 10 is bonded to the substrate 20 to produce a laminate composed of the laminated film 10 and the substrate 20.

[0023] The substrate 20 is, for example, glass, plastic, etc. The bonding surface 20S to which the laminated film 10 of the substrate 20 is bonded may be flat or curved. If the bonding surface 20S is curved, it may be curved in the z direction with respect to the x direction, for example. The planar shape of the bonding surface 20S is not particularly limited and may be irregular in shape.

[0024] For example, the laminated film 10 is made to be slightly larger than the bonding surface 20S of the substrate 20. After the laminated film 10 is bonded to the substrate 20, the excess portion of the laminated film 10 protrudes around the perimeter of the substrate 20. The excess portion of the laminated film 10 is cut and removed in a later process.

[0025] The laminated film 10 comprises a base film and an inorganic layer laminated on the base film. Figure 1 is a cross-sectional view of the laminated film 10 according to this embodiment. The laminated film 10 shown in Figure 1 includes, for example, a release layer 1, an adhesive layer 2, a base film 3, a hard coat layer 4, an optical functional layer 5, an anti-fouling layer 6, and a protective layer 7. The optical functional layer 5 is an example of an inorganic layer.

[0026] The release layer 1 is a protective layer for the adhesive layer 2. The release layer 1 is peeled off at the time of bonding, and the adhesive layer 2 exposed by peeling off the release layer 1 adheres to the substrate 20. The release layer 1 is, for example, paper or film coated with a release agent. The thickness of the release layer 1 is, for example, 70 μm or more and 80 μm or less.

[0027] The adhesive layer 2 is a layer that is adhered to the substrate 20. The adhesive layer 2 includes, for example, an acrylic adhesive, a silicone adhesive, or a urethane adhesive. The thickness of the adhesive layer 2 is, for example, 10 μm or more and 50 μm or less, preferably 20 μm or more and 30 μm or less.

[0028] The base film 3 is, for example, a plastic film. The constituent materials of the plastic film are, for example, polyester resin, acetate resin, polyethersulfone resin, polycarbonate resin, polyamide resin, polyimide resin, polyolefin resin, (meth)acrylic resin, polyvinyl chloride resin, polyvinylidene chloride resin, polystyrene resin, polyvinyl alcohol resin, polyarylate resin, and polyphenylene sulfide resin.

[0029] The base film 3 is, for example, a polyester resin, an acetate resin, a polycarbonate resin, or a polyolefin resin. For example, polyethylene terephthalate (PET) or triacetylcellulose (TAC) is preferably used as the base film 3.

[0030] The thickness of the base film 3 is, for example, 60 μm or more. If the thickness of the base film 3 is too thin, cracks may occur in the laminated film 10 due to film deflection, etc. The thickness of the base film 3 is, for example, 1 mm or less, preferably 500 μm or less, and more preferably 300 μm or less. If the thickness of the base film 3 is too thick, the transparency of the base film 3 decreases, and its rigidity increases, making it more prone to cracking.

[0031] One surface of the base film 3 may be pre-treated with etching and / or priming treatments such as sputtering, corona discharge, ultraviolet irradiation, electron beam irradiation, chemical conversion, and oxidation. These treatments improve the adhesion of the hard coat layer 4 formed on the base film 3.

[0032] The hard coat layer 4 is formed on one surface of the base film 3. The hard coat layer 4 is not particularly limited, and known materials can be used. The hard coat layer 4 may, for example, contain a binder resin and a filler. The hard coat layer 4 may also contain a leveling agent.

[0033] The binder resin is preferably transparent and may be, for example, an ionizing radiation-curable resin that hardens with ultraviolet light or electron beams, a thermoplastic resin, or a thermosetting resin.

[0034] Examples of ionizing radiation-curable resins used as binder resins include ethyl (meth)acrylate, ethylhexyl (meth)acrylate, styrene, methylstyrene, and N-vinylpyrrolidone. Ionizing radiation-curable resins may also be compounds having two or more unsaturated bonds. Examples of ionizing radiation-curable resins having two or more unsaturated bonds include trimethylolpropane tri(meth)acrylate, tripropylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, 1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, ditrimethylolpropane tetra(meth)acrylate, and dipentaerythritol These include polyfunctional compounds such as lithol penta(meth)acrylate, tripentaerythritol octa(meth)acrylate, tetrapentaerythritol deca(meth)acrylate, isocyanuric acid tri(meth)acrylate, isocyanuric acid di(meth)acrylate, polyester tri(meth)acrylate, polyester di(meth)acrylate, bisphenol di(meth)acrylate, diglycerin tetra(meth)acrylate, adamantyl di(meth)acrylate, isobolonyl di(meth)acrylate, dicyclopentane di(meth)acrylate, tricyclodecane di(meth)acrylate, and ditrimethylolpropane tetra(meth)acrylate. Among these, pentaerythritol triacrylate (PETA), dipentaerythritol hexaacrylate (DPHA), and pentaerythritol tetraacrylate (PETTA) are suitably used as binder resins. Note that "(meth)acrylate" refers to methacrylate and acrylate. Furthermore, the ionizing radiation-curable resin may be one of the above-mentioned compounds modified with PO (propylene oxide), EO (ethylene oxide), CL (caprolactone), etc. An acrylic-based ultraviolet-curable resin composition is preferred for the ionizing radiation-curable resin.

[0035] Examples of thermoplastic resins used as binder resins include styrene resins, (meth)acrylic resins, vinyl acetate resins, vinyl ether resins, halogen-containing resins, alicyclic olefin resins, polycarbonate resins, polyester resins, polyamide resins, cellulose derivatives, silicone resins, and rubber or elastomers. The above thermoplastic resins are amorphous and soluble in organic solvents (especially common solvents capable of dissolving multiple polymers and curable compounds). In particular, from the viewpoint of transparency and weather resistance, the binder resin is preferably a styrene resin, (meth)acrylic resin, alicyclic olefin resin, polyester resin, cellulose derivative (cellulose esters, etc.).

[0036] The thermosetting resin used as the binder resin may be, for example, phenolic resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, amino alkyd resin, melamine-urea cocondensation resin, silicon resin, polysiloxane resin (including so-called silsesquioxanes such as cage-like or ladder-like structures), etc.

[0037] The hard coat layer 4 may contain an organic resin and an inorganic material, or it may be an organic-inorganic hybrid material. One example is one formed by the sol-gel method. Examples of inorganic materials include silica, alumina, zirconia, and titania. An example of an organic material is acrylic resin.

[0038] The filler may consist of organic materials, inorganic materials, or a combination of both. The filler included in the hard coat layer 4 can be selected from a variety of options depending on the application of the laminated film 10, considering factors such as anti-glare properties, adhesion to the optical functional layer 5 (described later), and anti-blocking properties. Specifically, known fillers such as silica (silicon oxide) particles, alumina (aluminum oxide) particles, and organic fine particles can be used.

[0039] When the filler is silica particles and / or alumina particles, the average particle size of the filler is, for example, 800 nm or less, preferably 100 nm or less, and more preferably 40 nm to 70 nm. When the filler is organic fine particles, the average particle size of the organic fine particles is, for example, 10 μm or less, preferably 5 μm or less, and more preferably 3 μm or less.

[0040] The thickness of the hard coat layer 4 is preferably 0.5 μm or more, and more preferably 1 μm or more. The thickness of the hard coat layer 4 is preferably 100 μm or less. The hard coat layer 4 may consist of a single layer or may consist of multiple layers laminated together.

[0041] The optical functional layer 5 is the layer that exhibits optical functions. Optical functions are functions that control the properties of light, such as reflection, transmission, and refraction, and include, for example, anti-reflective functions, selective reflection functions, anti-glare functions, and lens functions.

[0042] The optical functional layer 5 is, for example, a laminated film in which high refractive index layers and low refractive index layers are alternately stacked from the hard coat layer 4 side. The high refractive index layers have a higher refractive index than the low refractive index layers. The refractive index of each high refractive index layer may be the same or different. The refractive index of each low refractive index layer may be the same or different.

[0043] The total number of layers of low-refractive-index and high-refractive-index layers in the optical functional layer 5 is not particularly limited. For example, as shown in Figure 1, the number of layers of each layer may be 4, 3 or less, or 5 or more. The total number of layers of low-refractive-index and high-refractive-index layers in the optical functional layer 5 is preferably 4 to 10, more preferably 4 to 6, and most preferably 4. When the number of layers of the optical functional layer 5 is 4, the productivity is superior compared to when the number of layers is 5 or more, because the number of layers is small and the thickness is thin.

[0044] The optical functional layer 5 exhibits an anti-reflective function by causing interference between reflected light reflected at each interface of the laminate, in which high-refractive-index layers and low-refractive-index layers are alternately stacked, and by diffusing light incident from the anti-fouling layer 6 side.

[0045] The total thickness of the optical functional layer 5 is, for example, 100 μm or more and 800 μm or less.

[0046] The following explanation will use the example of a laminate in which the optical functional layer 5 is a laminate consisting of four layers stacked in order from the side closest to the hard coat layer 4: the first high refractive index layer 5A, the first low refractive index layer 5B, the second high refractive index layer 5C, and the second low refractive index layer 5D. The refractive index of the first high refractive index layer 5A and the second high refractive index layer 5C are higher than that of the first low refractive index layer 5B and the second low refractive index layer 5D, respectively.

[0047] The refractive indices of the first high refractive index layer 5A and the second high refractive index layer 5C are, for example, 2.00 or more and 2.60 or less, preferably 2.10 or more and 2.45 or less. The refractive indices of the first high refractive index layer 5A and the second high refractive index layer 5C may be the same or different.

[0048] Examples of materials for the first high refractive index layer 5A and the second high refractive index layer 5C include niobium pentoxide (Nb2O5, refractive index 2.33), titanium oxide (TiO2, refractive index 2.33-2.55), tungsten oxide (WO3, refractive index 2.2), cerium oxide (CeO2, refractive index 2.2), tantalum pentoxide (Ta2O5, refractive index 2.16), zinc oxide (ZnO, refractive index 2.1), indium tin oxide (ITO, refractive index 2.06), and zirconium oxide (ZrO2, refractive index 2.2). The first high refractive index layer 5A and the second high refractive index layer 5C are preferably made of niobium pentoxide. The materials constituting the first high refractive index layer 5A and the second high refractive index layer 5C may be the same or different.

[0049] The refractive indices of the first low refractive index layer 5B and the second low refractive index layer 5D are, for example, 1.20 or more and 1.60 or less, preferably 1.30 or more and 1.50 or less. The refractive indices of the first low refractive index layer 5B and the second low refractive index layer 5D may be the same or different.

[0050] The first low refractive index layer 5B and the second low refractive index layer 5D contain, for example, an oxide of Si. The first low refractive index layer 5B and the second low refractive index layer 5D are layers mainly composed of, for example, SiO2 (an oxide of Si). Oxides of Si are readily available and cost-effective. The SiO2 monolayer film is colorless and transparent. In this embodiment, the main component is the component that accounts for 50% or more by mass of the components contained in the layer. The refractive indices of the first low refractive index layer 5B and the second low refractive index layer 5D may be the same or different.

[0051] The first low refractive index layer 5B and the second low refractive index layer 5D may contain less than 50% by mass of other elements when Si oxide is the main component. The content of elements other than Si oxide is preferably 10% or less. Examples of other elements are Na, Zr, Al, and N. Na enhances the durability of the first low refractive index layer 5B and the second low refractive index layer 5D. Zr, Al, and N increase the hardness and alkali resistance of the first low refractive index layer 5B and the second low refractive index layer 5D.

[0052] The anti-fouling layer 6 is in contact with the surface of the optical functional layer 5 opposite to the surface in contact with the hard coat layer 4. The anti-fouling layer 6 prevents contamination of the optical functional layer 5. In addition, the anti-fouling layer 6 suppresses wear of the optical functional layer 5 due to pen friction when applied to touch panels, etc.

[0053] The antifouling layer 6 is, for example, a fluorine-based organic compound. A fluorine-based organic compound is, for example, a compound consisting of a fluorine-modified organic group and a reactive silyl group (e.g., alkoxysilane). Commercially available products that can be used for the antifouling layer 6 include Optool DSX (manufactured by Daikin Corporation) and the KY-100 series (manufactured by Shin-Etsu Chemical Co., Ltd.).

[0054] The thickness of the antifouling layer 6 is, for example, 1 nm to 20 nm, preferably 3 nm to 10 nm. If the thickness of the antifouling layer 6 is 1 nm or more, sufficient wear resistance can be ensured when the laminate is applied to touch panel applications. If the thickness of the antifouling layer 6 is 20 nm or less, the time required for deposition is reduced, and manufacturing can be done efficiently.

[0055] The antifouling layer 6 may optionally contain additives such as light stabilizers, ultraviolet absorbers, colorants, antistatic agents, lubricants, leveling agents, defoamers, antioxidants, flame retardants, infrared absorbers, and surfactants.

[0056] The protective layer 7 is a layer that protects the film during transportation and storage. Examples of protective layers 7 include those with a base material such as polypropylene, polyethylene, or polyethylene terephthalate, and an adhesive layer whose main component is natural rubber, synthetic rubber, or acrylic resin.

[0057] Figure 2 is a cross-sectional view illustrating the first step in the manufacturing method of the laminate according to this embodiment. Figure 3 is a plan view illustrating the first step in the manufacturing method of the laminate according to this embodiment.

[0058] In the first step, the laminated film 10 is first pressed against the first midpoint 23 of the substrate 20 using a pressing tool 30. The first midpoint 23 is located between the first end 21 and the second end 22 of the substrate 20 in the x-direction. The first end 21 and the second end 22 are the two ends of the substrate 20 in the x-direction. The operation of the pressing tool 30 is controlled, for example, by a control unit 40. The control unit 40 includes, for example, an operating mechanism that moves the pressing tool 30 relative to the substrate 20, and a processor that instructs the operation of the operating mechanism.

[0059] The pressing tool 30 is not particularly limited as long as it can apply pressure in the thickness direction of the laminated film 10 and the substrate 20. The pressing tool 30 is, for example, a roller whose width in the y direction is wider than that of the substrate 20. The pressing tool 30 moves in the x direction. The pressing tool 30 is, for example, a lamination roller having a first roller 31 and a second roller 32. The first roller 31 contacts the laminated film 10 when pressed. The second roller 32 contacts the substrate 20 when pressed. Either the first roller 31 or the second roller 32 may be omitted, but if the lamination roller has a first roller 31 and a second roller 32, it is easier to move the lamination roller along the lamination surface 20S of the substrate 20 even if the lamination surface 20S of the substrate 20 is curved.

[0060] In the first step, the bonding pressure applied when the pressing tool 30 is pressed against the laminated film 10 or substrate 20 is, for example, 0.1 MPa or more and 0.5 MPa or less, preferably 0.3 MPa or more and 0.4 MPa or less.

[0061] The pressing tool 30 may be stopped when it reaches the first end 21 from the first midpoint 23. Alternatively, the pressing tool 30 may continue beyond the first end 21 in the direction of travel (-x direction). When the pressing tool 30 rides over the step between the laminated film 10 and the substrate 20, cracks are likely to occur in the laminated film 10, but when descending the step, cracks are less likely to occur, and there is no problem even if the pressing tool 30 continues beyond the first end 21 in the direction of travel.

[0062] The bonding pressure per unit time between the laminated film 10 and the substrate 20 may differ at the first midpoint 23 and the first end 21. The bonding pressure per unit time between the laminated film 10 and the substrate 20 is the pressure per unit time at which the pressing tool 30 is pressed against the laminated film 10 or the substrate 20. For example, the bonding pressure per unit time at the first midpoint 23 may be greater than the bonding pressure per unit time at the first end 21. By not applying a large pressure near the first end 21, where cracks are likely to occur, the occurrence of cracks in the laminated film 10 can be further suppressed.

[0063] Furthermore, if the width of the substrate 20 in the y-direction is not constant, the bonding pressure per unit time between the laminated film 10 and the substrate 20 may be changed according to the width of the substrate 20 in the y-direction. For example, as shown in Figure 3, if the width of the substrate 20 in the y-direction is not constant, the bonding pressure per unit time is changed for the first part 25 and the second part 26. The width of the first part 25 in the y-direction W 25 The width W in the y-direction of the second part 26 is 26 It is narrower. In this case, the bonding pressure per unit time in the first part 25 is made smaller than the bonding pressure per unit time in the second part 26. By changing the bonding pressure per unit time according to the shape of the substrate 20, it is possible to suppress the application of large localized pressure and the occurrence of cracks in the laminated film 10.

[0064] The bonding pressure per unit time can be controlled by the speed of the pressing tool 30, the pressing pressure of the pressing tool 30, etc. For example, if the pressing tool 30 is a bonding roller, the speed of the pressing tool 30, the pressing pressure, etc. can be controlled by the gap between the first roller 31 and the second roller 32, and the rotational speeds of the first roller 31 and the second roller 32.

[0065] Figure 4 is a cross-sectional view illustrating the second step in the manufacturing method of the laminate according to this embodiment.

[0066] In the second step, the pressing tool 30 is moved to the second intermediate point 24 without being pressed against the laminated film 10. The movement of the pressing tool 30 is controlled, for example, by the control unit 40. The second intermediate point 24 is located between the first end 21 and the second end 22 in the x-direction. Details of the second intermediate point 24 will be described later.

[0067] Not pressing the pressing tool 30 against the laminated film 10 means that no bonding pressure is applied between the laminated film 10 and the substrate 20. Even if the pressing tool 30 is in contact with the laminated film 10, if no bonding pressure is applied, it can be said that the pressing tool 30 is not being pressed against the laminated film 10. For example, in the second step, the pressing tool 30 is separated from the laminated film 10 and the substrate 20. For example, the first roller 31 is separated from the laminated film 10 and the second roller 32 is separated from the substrate 20.

[0068] Figure 5 is a cross-sectional view illustrating the third step in the manufacturing method of the laminate according to this embodiment. Figure 6 is a plan view illustrating the third step in the manufacturing method of the laminate according to this embodiment.

[0069] In the third step, the pressing tool 30 is pressed against the laminated film 10 again. The pressing tool 30 is pressed against the second midpoint 24 of the substrate 20. Then, in the third step, the pressing tool 30 is moved from the second midpoint 24 toward the second end 22. The movement of the pressing tool 30 is controlled, for example, by the control unit 40.

[0070] As shown in Figure 6, the second intermediate point 24 may coincide with the first intermediate point 23. In this case, the position where pressing begins in the first step coincides with the position where pressing begins in the third step.

[0071] Furthermore, as shown in Figures 7 and 8, the second intermediate point 24 does not have to coincide with the first intermediate point 23. Figures 7 and 8 are plan views illustrating another example of the third step in the manufacturing method of the laminate according to this embodiment.

[0072] In the example shown in Figure 7, the second midpoint 24 is closer to the first end 21 than the first midpoint 23. In this case, the portion to which bonding pressure is applied in the first step and the portion to which bonding pressure is applied in the third step overlap in some areas. When the portions to which bonding pressure is applied overlap between the first and third steps, it is possible to better prevent air bubbles and other imperfections from getting trapped between the laminated film 10 and the substrate 20.

[0073] In the example shown in Figure 8, the second intermediate point 24 is closer to the second end 21 than the first intermediate point 23. That is, there is a gap between the first intermediate point 23 and the second intermediate point 24. No bonding pressure is applied to the region between the first intermediate point 23 and the second intermediate point 24 in either the first or third step. Even if no bonding pressure is applied to the region between the first intermediate point 23 and the second intermediate point 24, this region will be bonded naturally through the first and third steps. In this case, even if the precision of the operation of the pressing tool 30 is low, it can be adequately handled, and the manufacturing equipment for the laminate can be made inexpensive. The distance between the first intermediate point 23 and the second intermediate point 24 is, for example, 10 mm or less, preferably 3 mm or less.

[0074] In the third step, the bonding pressure applied when the pressing tool 30 is pressed against the laminated film 10 or substrate 20 is, for example, 0.1 MPa or more and 0.5 MPa or less, preferably 0.3 MPa or more and 0.4 MPa or less.

[0075] The pressing tool 30 may be stopped when it reaches the second end 22 from the second midpoint 24. Alternatively, the pressing tool 30 may continue beyond the second end 22 in the direction of travel (+x direction). When the pressing tool 30 rides over the step between the laminated film 10 and the substrate 20, cracks are likely to occur in the laminated film 10, but when descending the step, cracks are less likely to occur, and there is no problem even if the pressing tool 30 continues beyond the second end 22 in the direction of travel.

[0076] The bonding pressure per unit time between the laminated film 10 and the substrate 20 may differ at the second midpoint 24 and the second end 22. For example, the bonding pressure per unit time at the second midpoint 24 may be greater than the bonding pressure per unit time at the second end 22. By not applying a large pressure near the second end 22, where cracks are likely to occur, the occurrence of cracks in the laminated film 10 can be further suppressed.

[0077] Furthermore, if the width of the substrate 20 in the y-direction is not constant, the bonding pressure per unit time between the laminated film 10 and the substrate 20 may be changed according to the width of the substrate 20 in the y-direction. For example, as shown in Figures 6 to 8, if the width of the substrate 20 in the y-direction is not constant, the bonding pressure per unit time is changed for the first part 28 and the second part 27. The width of the first part 28 in the y-direction W 28 The width W in the y-direction of the second part 27 is 27 It is narrower. In this case, the bonding pressure per unit time in the first part 28 is made smaller than the bonding pressure per unit time in the second part 27. By changing the bonding pressure per unit time according to the shape of the substrate 20, it is possible to suppress the application of large localized pressure and the occurrence of cracks in the laminated film 10.

[0078] In the manufacturing method of the laminate according to this embodiment, no pressure is applied between the substrate 20 and the laminated film 10 when the pressing tool 30 rides over the step between the substrate 20 and the laminated film 10. Cracks in the laminated film 10 occur when the pressing tool 30 comes into contact with the laminated film 10, causing strain in the organic layer, such as the base film 3, and this strain causes stress to be applied to the inorganic layer, such as the optical functional layer 5. When the pressing tool 30 rides over the step between the substrate 20 and the laminated film 10, a large stress is generated in the laminated film 10. As described above, in the manufacturing method of the laminate according to this embodiment, since no pressure is applied between the substrate 20 and the laminated film 10 when the pressing tool 30 rides over the step between the substrate 20 and the laminated film 10, the occurrence of cracks in the laminated film 10 can be suppressed.

[0079] "Laminate manufacturing equipment" The laminate manufacturing apparatus according to this embodiment includes a pressing tool 30 and a control unit 40. The laminate manufacturing apparatus will be described using Figure 3 as an example.

[0080] The pressing tool 30 presses the laminated film 10 against the substrate 20. The pressing tool 30 is not particularly limited as long as it can apply pressure in the thickness direction of the laminated film 10 and the substrate 20.

[0081] The control unit 40 controls the relative position between the pressing tool 30 and the substrate 20. The control unit 40 is, for example, a microprocessor. The control unit 40 controls the operation of the pressing tool 30 based on a program stored in the microprocessor. The control unit 40 performs, for example, a first operation, a second operation, and a third operation.

[0082] The first operation is the operation corresponding to the first step described above. In the first operation, the pressing tool 30 is pressed against the first midpoint 23 of the substrate 20, and while pressing the pressing tool 30 against the laminated film 10, the pressing tool 30 is moved from the first midpoint 23 toward the first end 21.

[0083] The second operation is the operation corresponding to the second step described above. In the second operation, the pressing tool 30 is moved to the second intermediate point 24 without pressing it against the laminated film 10. The second intermediate point 24 may or may not coincide with the first intermediate point 23.

[0084] The third operation is the operation corresponding to the third step described above. In the third operation, the pressing tool 30 is pressed against the laminated film 10 and moved from the second midpoint 24 toward the second end 22.

[0085] The laminate manufacturing apparatus according to this embodiment can easily realize the above-described method for manufacturing laminates. Therefore, when a laminate consisting of a laminated film 10 and a substrate 20 is manufactured using the laminate manufacturing apparatus according to this embodiment, cracks are less likely to occur in the laminated film 10.

[0086] Although preferred embodiments of the present invention have been described in detail above, the present invention is not limited to any particular embodiment, and various modifications and changes are possible within the scope of the gist of the present invention as described in the claims. [Explanation of Symbols]

[0087] 1…Release layer, 2…Adhesive layer, 3…Base film, 4…Hard coat layer, 5…Optical functional layer, 5A…First high refractive index layer, 5B…First low refractive index layer, 5C…Second high refractive index layer, 5D…Second low refractive index layer, 6…Anti-fouling layer, 7…Protective layer, 10…Laminated film, 20…Substrate, 20S…Bonding surface, 21…First end, 22…Second end, 23…First midpoint, 24…Second midpoint, 25,28…First part, 26,27…Second part, 30…Pressing tool, 31…First roller, 32…Second roller, 40…Control unit

Claims

1. A laminated film having a base film and an inorganic layer laminated on the base film is pressed against a first midpoint between the first and second ends of a substrate using a pressing tool, and while pressing the pressing tool against the laminated film, the pressing tool is moved from the first midpoint toward the first end; A second step involves moving the pressing tool to a second midpoint between the first end and the second end without pressing the pressing tool against the laminated film, A method for manufacturing a laminate, comprising: a third step of moving the pressing tool from the second midpoint toward the second end while pressing the pressing tool against the laminated film.

2. The method for manufacturing a laminate according to claim 1, wherein the second intermediate point coincides with the first intermediate point.

3. The method for manufacturing a laminate according to claim 1, wherein the second intermediate point is closer to the first end than the first intermediate point.

4. The method for manufacturing a laminate according to claim 1, wherein the second intermediate point is closer to the second end than the first intermediate point.

5. The method for manufacturing a laminate according to claim 1, wherein the bonding pressure per unit time between the laminated film and the substrate is greater at the first midpoint than at the first end.

6. The method for manufacturing a laminate according to claim 1, wherein the bonding pressure per unit time between the laminated film and the substrate is greater at the second midpoint than at the second end.

7. The substrate has a width that is not constant in the second direction perpendicular to the first direction connecting the first end and the second end. The first part has a shorter width in the second direction than the second part. The method for manufacturing a laminate according to claim 1, wherein the bonding pressure per unit time between the laminated film and the substrate is smaller in the first portion than in the second portion.

8. The method for manufacturing a laminate according to claim 1, wherein the pressing tool comprises a first roller that contacts the laminated film and a second roller that contacts the substrate.

9. The method for manufacturing a laminate according to claim 1, wherein in the first and third steps, the bonding pressure used to bond the laminated film and the substrate with the pressing tool is 0.1 MPa or more and 0.5 MPa or less.

10. A pressing tool for pressing a laminated film having a base film and an inorganic layer laminated on the base film against a substrate, The system includes a control unit that controls the relative position between the pressing tool and the substrate, The control unit, A first operation involves pressing the pressing tool against a first midpoint between the first and second ends of the substrate, and moving the pressing tool from the first midpoint toward the first end while pressing it against the laminated film, A second operation involves moving the pressing tool to a second midpoint between the first end and the second end without pressing the pressing tool against the laminated film, A laminate manufacturing apparatus that performs a third operation of moving the pressing tool from the second midpoint toward the second end while pressing the pressing tool against the laminated film.

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