Wrapped body of a thin film with adhesive layer

Abstract

This invention provides a method for manufacturing a wound body of a film with an adhesive layer. The wound body of the film with the adhesive layer has no release liner, and the manufacturing method can suppress air bubble entrapment or wrinkle formation and suppress dents, while simultaneously performing long strip winding. This invention provides a wound body of a film with an adhesive layer, which has no release liner, and the wound body of the film with the adhesive layer has suppressed air bubble entrapment or wrinkle formation and also suppressed dents. It is a method for manufacturing a wound body from a long strip of film with an adhesive layer; the film with the adhesive layer sequentially has a release layer, a specific substrate, and a specific adhesive layer; the film with the adhesive layer is wound onto a winding shaft after passing through a contact roller disposed in front of the winding shaft to form a wound body; and the contact pressure P of the contact roller, measured by a linear pressure gauge, is 3.6 N / cm < P < 14.0 N / cm.

Description

Technical Field

[0001] This invention relates to a wound body of a thin film with an adhesive layer. Prior Technology

[0002] In the manufacturing process of optical or electronic components, a surface protective film (SPV) is usually applied to prevent damage to the surface of the component during processing, assembly, inspection, and transportation.

[0003] Surface protective films typically have a laminated structure consisting of a substrate and an adhesive layer. Conventionally, surface protective films typically have a release liner disposed on the exposed side of the adhesive layer. Most reports propose a surface protective film having the substrate, adhesive layer, and release liner sequentially.

[0004] On the other hand, as a surface protective film, for reasons such as reducing the cost of release liner, there has recently been a search for a surface protective film that does not have a release liner on the exposed side of the adhesive layer. As such a surface protective film, a surface protective film having a polyethylene film and an adhesive layer laminated together has been reported (Patent Document 1). This surface protective film is manufactured by extrusion molding, and the back side of the polyethylene film is embossed, thereby allowing for winding and unwinding without a release liner, and providing it in the form of a wound.

[0005] However, polyethylene films are prone to containing clumps of incompletely melted resin (fisheyes), which can lead to reduced inspectability during the manufacturing process of optical or electronic components, or deterioration in product quality. Furthermore, because the back of the polyethylene film is embossed, it can cause dents in the adhered substrate during bonding.

[0006] Recently, a surface protective film has been reported that does not have a release liner and does not use polyethylene film as a substrate, and that the surface protective film can be wound and unwound without a release liner (Patent Document 2). Previous technical 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

[0008] The problem the invention aims to solve Non-peel backing surface protective films are produced by directly stacking and winding the substrate and adhesive layer together. However, non-peel backing surface protective films have the following problems: they are technically very difficult to wind, especially for long strips, and are prone to air bubbles or wrinkles. Furthermore, while thinning the adhesive layer to about 1µm makes winding easier, it also introduces the problem of dents caused by foreign objects. Conversely, thickening the adhesive layer reduces the likelihood of dents caused by foreign objects, but makes long strip winding difficult.

[0009] The present invention aims to provide a method for manufacturing a wound body of an adhesive-coated film, wherein the wound body of the adhesive-coated film has no peeling backing, and the manufacturing method can achieve suppression of air bubble entrapment or wrinkle formation and suppression of dents, while simultaneously performing long strip winding. Furthermore, the present invention aims to provide a wound body of an adhesive-coated film that can be manufactured by the manufacturing method described above, wherein the wound body of the adhesive-coated film has suppressed air bubble entrapment or wrinkle formation and also suppressed dents.

[0010] The means to solve the problem [1] The method for manufacturing a wound body of an adhesive-coated film according to an embodiment of the present invention is a method for manufacturing a wound body from a strip of adhesive-coated film; the adhesive-coated film sequentially comprises a release layer, a substrate, and an adhesive layer; the release layer and the adhesive layer are the outermost layers of the adhesive-coated film; the substrate comprises a polyester resin; the adhesive layer is a urethane-based adhesive layer composed of a urethane-based adhesive; the thickness of the adhesive layer is 4.0µm to 10.0µm; the adhesive-coated film is wound onto a take-up shaft after passing through a contact roller disposed in front of the take-up shaft to form a wound body; and the contact pressure P of the contact roller is 3.6 N / cm using a linear pressure gauge. <P<14.0N / cm。 [2] In the manufacturing method of the film winding with adhesive layer as described in [1] above, the contact pressure P of the contact roller can also be 4.3 N / cm using a line pressure gauge. <P<10.0N / cm。 [3] In the manufacturing method of the film winding with adhesive layer as described in [1] or [2] above, the product of the thickness D of the substrate and the contact pressure P can also be 0.018N < (D × P) < 0.050N. [4] In the manufacturing method of the film winding with adhesive layer as described in any of [1] to [3] above, the surface hardness S of the contact roller can also be 30°. <S<80°。 [5] In the manufacturing method of the film with adhesive layer as described in any of [1] to [4] above, the winding tension T when the film with adhesive layer is wound onto the winding shaft can also be 200 N / m. <T<400N / m。 [6] In the manufacturing method of the film winding with adhesive layer as described in any of [1] to [5] above, at a temperature of 23°C and a humidity of 50%RH, the low-speed peeling force of the adhesive layer on the release layer measured at a peeling speed of 0.3 m / min and a peeling angle of 180 degrees can also be less than 0.01 N / 25 mm. [7] In the manufacturing method of the film with adhesive layer as described in any of [1] to [6] above, at a temperature of 23°C and a humidity of 50%RH, the high-speed peeling force measured at a peeling speed of 30m / min and a peeling angle of 180 degrees for the adhesive layer to the release layer can also be less than 0.15N / 25mm. [8] In the manufacturing method of the film with adhesive layer of any of [1] to [7] above, the winding length of the film can also be 3000m or more. [9] The film with adhesive layer of the present invention is a long strip of film with adhesive layer; the film with adhesive layer has a release layer, a substrate and an adhesive layer in sequence; the release layer and the adhesive layer are the outermost layers of the film with adhesive layer; the substrate contains polyester resin; the adhesive layer is a carbamate adhesive layer composed of carbamate adhesive; the thickness of the adhesive layer is 4.0µm~10.0µm; and, at a temperature of 23°C and a humidity of 50%RH, the low-speed peel force of the aforementioned adhesive layer on the aforementioned release layer at a peel speed of 0.3m / min and a peel angle of 180 degrees is less than 0.01N / 25mm.

[10] In the winding of the film with the adhesive layer as described above [9], at a temperature of 23°C and a humidity of 50%RH, the high-speed peeling force measured at a peeling speed of 30m / min and a peeling angle of 180 degrees for the adhesive layer to the release layer can also be less than 0.15N / 25mm.

[11] The winding length of the film with the adhesive layer as described in [9] or

[10] above can also be more than 3000m.

[0011] Invention Effects According to the present invention, a method for manufacturing a wound body of an adhesive-coated film is provided, wherein the wound body of the adhesive-coated film has no peeling backing, and the manufacturing method can achieve suppression of air bubble entrapment or wrinkle generation and suppression of dents, while performing long strip winding. According to the present invention, a wound body of an adhesive-coated film that can be manufactured by the manufacturing method described above is also provided, wherein the wound body of the adhesive-coated film has suppressed air bubble entrapment or wrinkle generation and also suppressed dents. Simple Explanation of the Diagram

[0012] Figure 1 is a schematic diagram illustrating one embodiment of the winding device, which can be used in the manufacturing method of the film winding body with adhesive layer according to the embodiment of the present invention. Implementation

[0013] When the term "weight" appears in this specification, it can be replaced with "mass," which is the SI unit commonly used to express weight.

[0014] ≪≪1. Thin film with adhesive layer≫≫ The method for manufacturing a wound body of an adhesive layer film according to an embodiment of the present invention is a method for manufacturing a wound body from a long strip of adhesive layer film.

[0015] The film with the adhesive layer sequentially comprises a release layer, a substrate, and an adhesive layer. In the film with the adhesive layer, the release layer and the adhesive layer are the outermost layers. Regarding the film with the adhesive layer, if it sequentially comprises a release layer, a substrate, and an adhesive layer, and the release layer and the adhesive layer are the outermost layers, then any suitable other layers may be included within the scope of not impairing the effects of the present invention.

[0016] The film with the adhesive layer does not have a separator on the side of the adhesive layer opposite to the substrate, thus reducing the cost of the separator and eliminating the separator peeling step.

[0017] Thin films with adhesive layers can be used in a variety of applications. Examples include surface protective films or carrier sheets used in the manufacturing processes of optical or electronic components (such as glass, polarizing plates, wavelength plates, phase refraction plates, optical compensation films, reflective sheets, brightness enhancement films, and transparent conductive films used in liquid crystal displays, etc.) to protect the surface of the components from damage during processing, assembly, inspection, and transportation.

[0018] The substrate comprises a polyester resin. By including a polyester resin in the substrate, the effects of the present invention can be better demonstrated, and in particular, it can solve the conventional problems when using polyethylene films as substrates.

[0019] The adhesive layer is a carbamate-based adhesive layer composed of a carbamate-based adhesive. By using a carbamate-based adhesive layer, the effects of the present invention are better demonstrated. Furthermore, by using a carbamate-based adhesive layer, problems such as the generation of adhesive residue during processing can be suppressed.

[0020] In the adhesive film, the thickness of the adhesive layer is typically 4.0µm to 10.0µm. Adjusting the adhesive layer thickness to within this range enhances the effectiveness of the invention. If the adhesive layer thickness is too small and outside this range, dents may occur due to foreign matter, for example, when manufacturing a wound from the adhesive film. If the adhesive layer thickness is too large and outside this range, there is a risk of air bubbles being trapped or wrinkles forming during the manufacturing of a wound from the adhesive film, making it difficult to wind the adhesive film.

[0021] Regarding films with adhesive layers, at a temperature of 23°C and a humidity of 50%RH, the low-speed peel force measured between the adhesive layer and the release layer at a peel speed of 0.3 m / min and a peel angle of 180 degrees should preferably be less than 0.01 N / 25 mm, and can be less than 0.008 N / 25 mm or less. To ensure that the film does not cause winding deviation during winding, the lower limit of the aforementioned low-speed peel force should preferably be 0.002 N / 25 mm or more. If the aforementioned low-speed peel force is too high, for example, when releasing the wound, there is a risk of generating abnormal noise, leaving adhesive residue on the equipment, or frequently causing static electricity when peeling after bonding. Details of the method for measuring the aforementioned low-speed peel force will be described later.

[0022] Regarding the film with the adhesive layer, at a temperature of 23°C and a humidity of 50%RH, the high-speed peel force of the adhesive layer against the release layer, measured at a peel speed of 30 m / min and a peel angle of 180 degrees, should preferably be less than 0.15 N / 25 mm, and can be less than 0.13 N / 25 mm or less, or even less than 0.11 N / 25 mm. The lower limit of the high-speed peel force should preferably be 0.05 N / 25 mm or more, provided that it does not cause winding deviation during winding. If the high-speed peel force is too high, for example, when unwinding the film with the adhesive layer from the wound state, it may result in heavy peeling, making it difficult to wind out smoothly. Details of the method for measuring the high-speed peel force will be described later.

[0023] The total thickness of the film with the adhesive layer is preferably 20µm to 100µm, more preferably 25µm to 80µm, and even more preferably 30µm to 60µm. If the total thickness of the film with the adhesive layer is within the above range, the effects of the present invention will be more fully realized.

[0024] The adhesive film can be manufactured by any suitable method without compromising the effects of the present invention. Regarding the manufacturing method, for example, any suitable manufacturing method can be followed: (1) Apply a solution or hot melt of the adhesive layer forming material to the substrate having a release layer, and dry it as needed; (2) A method of applying a solution or hot melt of the adhesive layer forming material to a release liner, drying it as needed to form an adhesive layer, and then transferring the formed adhesive layer to a substrate with a release layer; (3) A method of forming a coating by extruding the adhesive layer material onto a substrate having a release layer; (4) A method of extruding a substrate and an adhesive layer with a release layer in two or more layers; (5) A method of laminating a single layer of adhesive with a release layer onto a substrate or a method of laminating the adhesive layer and the laminate together as a second layer; (6) A method of laminating an adhesive layer and a substrate forming material such as a film or laminate with a release layer in two or more layers. Furthermore, any suitable method can be used for the above-mentioned coating. For example, roller coating, corner wheel coating, die coating, reverse coating, screen printing, gravure coating, etc., can be used.

[0025] ≪1-1. Release Layer≫ Regarding the material used to form the release layer, any suitable material can be used within the scope of not compromising the effects of the present invention. Examples of such materials include polysiloxane-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 by coating.

[0026] Regarding the thickness of the release layer, any appropriate thickness can be adopted depending on the purpose, within the range that does not impair the effect of the present invention. For example, the thickness can be 1nm~3000nm, 10nm~2000nm, 10nm~1500nm, 10nm~1000nm, or 10nm~500nm.

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

[0028] The release layer can be formed, for example, by applying the aforementioned material using conventional coating methods such as reverse gravure coating, bar coating, or die coating, followed by heat treatment at approximately 120°C to 200°C to harden it. Alternatively, heat treatment and irradiation with active energy lines such as ultraviolet light can be used as needed.

[0029] Regarding the release layer, a substrate with a pre-installed release layer can also be used.

[0030] ≪1-2. Substrate≫ In order to further enhance the effects of the present invention, the substrate comprises a polyester resin.

[0031] The content of polyester resin in the substrate is preferably greater than 50% by weight and less than 100% by weight, more preferably 70% to 100% by weight, more preferably 90% to 100% by weight, especially preferably 95% to 100% by weight, and most preferably 98% to 100% by weight. If the content of polyester resin in the substrate is within the above range, the effects of the present invention will be better demonstrated.

[0032] Regarding the polyester resin, any suitable polyester resin may be used within the scope of not impairing the effects of the present invention. As to further enhance the effects of the present invention, the polyester resin is preferably selected from at least one of the group consisting of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and polybutylene terephthalate (PBT), with polyethylene terephthalate (PET) being more preferred.

[0033] The elastic modulus of the substrate is, for example, 0.1 GPa to 10 GPa, or 2 GPa to 5 GPa. If the elastic modulus of the substrate is within the above range, the effects of the present invention will be more fully demonstrated.

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

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

[0036] The substrate can be a single layer or two or more layers.

[0037] The substrate can also be an extended one.

[0038] The substrate may also undergo surface treatment. Examples of surface treatments include corona treatment, plasma treatment, chromic acid treatment, ozone exposure, flame exposure, high-voltage electric shock exposure, ionization radiation treatment, and coating treatment with a primer.

[0039] The substrate may contain any suitable additives within a range that does not impair the effects of the present invention. Examples of such additives include: powders of antistatic agents, colorants, pigments, etc.; surfactants; plasticizers; thickeners; low molecular weight polymers; surface lubricants; leveling agents; antioxidants; preservatives; light stabilizers; ultraviolet absorbers; polymerization inhibitors; silane coupling agents; inorganic fillers; organic fillers; metal powders; organic particles; inorganic particles, etc.

[0040] ≪1-3. Adhesive layer≫ The adhesive layer can be a single layer or two or more layers.

[0041] The thickness of the adhesive layer, as described above, is typically 4.0µm to 10.0µm. Adjusting the adhesive layer thickness to within this range enhances the effectiveness of the invention. If the adhesive layer thickness is too small and outside this range, dents may occur due to foreign matter, for example, when manufacturing a wound from the film with the adhesive layer attached. If the adhesive layer thickness is too large and outside this range, there may be concerns about air bubbles being trapped or wrinkles forming during the manufacturing of a wound from the film with the adhesive layer attached, making it difficult to wind the film with the adhesive layer attached.

[0042] As described above, the adhesive layer is a carbamate-based adhesive layer composed of a carbamate-based adhesive. By using a carbamate-based adhesive layer, the effects of the present invention are better demonstrated. Furthermore, by using a carbamate-based adhesive layer, problems such as the generation of adhesive residue during processing can be suppressed.

[0043] Carbamate adhesives are formed from carbamate adhesive compositions. That is, the carbamate adhesive, formed from carbamate adhesive compositions, forms a layered adhesive layer.

[0044] Carbamate adhesives can be limited to those formed from carbamate adhesive compositions. The reason for this is that carbamate adhesives are formed from carbamate adhesive compositions through cross-linking reactions induced by heating or ultraviolet radiation. Therefore, directly defining carbamate adhesives based on their structure is impossible or nearly impractical ("impossible / impractical reasons"). Thus, by limiting them to "formed from carbamate adhesive compositions," carbamate adhesives are properly defined in the form of "things."

[0045] The carbamate-based adhesive is formed from a carbamate-based adhesive composition. Regarding the formation method, any suitable method can be employed within the scope of not impairing the effects of the present invention. For example, conventionally known methods for forming carbamate-based adhesives can be used. Specifically, examples of such methods include: directly applying the carbamate-based adhesive composition to any suitable substrate film (e.g., a substrate in a film with an adhesive layer) and allowing it to dry or harden (direct method); applying the carbamate-based adhesive composition to the surface (peel surface) of a release liner and allowing it to dry or harden, thereby bonding the carbamate-based adhesive layer formed on that surface to any suitable substrate film (e.g., a substrate in a film with an adhesive layer), and transferring the carbamate-based adhesive layer (transfer method). From the viewpoint of the anchoring properties of the adhesive layer, the direct method is representatively suitable. Regarding the various conditions in these formation methods, the various conditions in the formation methods of carbamate adhesives that are generally known in the past can be used.

[0046] Regarding the method of applying the carbamate adhesive layer (represented by coating), various conventionally known methods may be appropriately employed, such as roller coating, gravure coating, reverse coating, contact coating, dip roller coating, bar coating, roller brush coating, spraying, doctor blade coating, air knife coating, spraying, corner wheel coating, direct coating, and coating using a die coater.

[0047] The drying of carbamate-based adhesive compositions can be carried out under heating (e.g., heating to approximately 60°C to 150°C) as needed. Methods for hardening carbamate-based adhesive compositions include, for example, ultraviolet light, laser, alpha rays, beta rays, gamma rays, X-rays, and electron beams.

[0048] Regarding the manufacturing methods of carbamate-based adhesives, there are two methods: the one-shot method and the prepolymer method. The one-shot method involves directly reacting a polyol with a polyfunctional isocyanate compound to manufacture the carbamate-based adhesive without using a carbamate prepolymer. The prepolymer method involves reacting a carbamate prepolymer with a polyfunctional isocyanate compound to manufacture the carbamate-based adhesive. Here, "carbamate prepolymer" can have multiple hydroxyl groups; therefore, to clearly distinguish it from "polyol," it is defined that "polyol (A1)" in this invention does not include "carbamate prepolymer (A2)" in this invention.

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

[0050] In the carbamate-based adhesive composition of this form, the total content ratio of polyol (A1) and polyfunctional isocyanate compound (B), excluding solvent, is preferably 50% to 100% by weight, more preferably 55% to 95% by weight, even more preferably 60% to 90% by weight, especially preferably 65% ​​to 85% by weight, and most preferably 70% to 80% by weight.

[0051] [1-3-1-a. Polyol (A1)] The polyol (A1) can be a single type or two or more types.

[0052] Regarding the polyol (A1), if it is a polyol having two or more OH groups, any suitable polyol can be used. Examples of the polyol (A1) include: polyols with two OH groups (diols), polyols with three OH groups (triols), polyols with four OH groups (tetraols), polyols with five OH groups (pentaols), and polyols with six OH groups (hexaols).

[0053] In this invention, a polyol (triol) having three OH groups is preferably used as the necessary component of the polyol (A1). Using a polyol (triol) having three OH groups as the necessary component of the polyol (A1) further enhances the effectiveness of this invention.

[0054] The proportion of polyols (A1) containing three OH groups (triols) is preferably 50% to 100% by weight, more preferably 70% to 100% by weight, even more preferably 80% to 100% by weight, even more preferably 90% to 100% by weight, especially preferably 95% to 100% by weight, and most preferably substantially 100% by weight.

[0055] Regarding the polyol (A1), it is preferable to include polyols with a number average molecular weight Mn of 400 to 20,000. The proportion of polyols with a number average molecular weight Mn of 400 to 20,000 in the polyol (A1) is preferably 50% to 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 substantially 100% by weight. By adjusting the proportion of polyols with a number average molecular weight Mn of 400 to 20,000 in the polyol (A1) to the above range, the effects of the present invention can be further demonstrated.

[0056] In this invention, when a polyol (triol) having three OH groups is used as an essential component of the polyol (Al), it is preferable to use triols with a number average molecular weight Mn of 7000-20000, triols with a number average molecular weight Mn of 2000-6000, and triols with a number average molecular weight Mn of 400-1900. It is also preferable to use triols with a number average molecular weight Mn of 8000-15000, triols with a number average molecular weight Mn of 2000-5000, and triols with a number average molecular weight Mn of 500-1800. Even more preferable is the use of triols with a number average molecular weight Mn of 8000-12000, triols with a number average molecular weight Mn of 2000-4000, and triols with a number average molecular weight Mn of 500-1500. Using all three types of triols together will further enhance the effectiveness of this invention.

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

[0058] Polyester polyols, for example, can be obtained through esterification of polyol components and acid components.

[0059] Examples of polyols include: ethylene glycol, diethylene glycol, 1,3-butanediol, 1,4-butanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 2-but-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, glycerol, trimethylolpropane, neopentyl tertrol, hexanediol, and polypropylene glycol.

[0060] Regarding acidic components, examples include: succinic acid, methylsuccinic acid, adipic acid, pimelic acid, azelaic acid, sebacic acid, 1,12-dodecanoic acid, 1,14-tetradecanoic acid, dicarboxylic acid, 2-methyl-1,4-cyclohexanedicarboxylic acid, 2-ethyl-1,4-cyclohexanedicarboxylic acid, p-phthalic acid, isophthalic acid, phthalic acid, isophthalic acid, p-phthalic acid, 1,4-naphthalenedicarboxylic acid, 4,4'-biphenyldicarboxylic acid, and their anhydrides.

[0061] Polyether polyols can be exemplified by using water, low-molecular-weight polyols (propylene glycol, ethylene glycol, glycerol, trimethylolpropane, neopentyl terephthalol, etc.), bisphenols (bisphenol A, etc.), and dihydroxybenzenes (catechol, resorcinol, hydroquinone, etc.) as initiators to induce the addition polymerization of olefin oxides such as ethylene oxide, propylene oxide, and butene oxide. Specific examples of polyether polyols include polyethylene glycol, polypropylene glycol, and polytetramethylene glycol.

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

[0063] Regarding polycarbonate polyols, examples include: polycarbonate polyols obtained by condensation polymerization of the above-mentioned polyol components with phosgene; polycarbonate polyols obtained by transesterification condensation of the above-mentioned polyol components with dimethyl carbonate, diethyl carbonate, dipropyl carbonate, diisopropyl carbonate, dibutyl carbonate, ethylbutyl carbonate, ethylbenzyl carbonate, propylbenzyl carbonate, diphenyl carbonate, dibenzyl carbonate, etc., which are carbonate diesters; and copolymerized polycarbonate polyols obtained by using two or more of the above-mentioned polyol components; and various polycarbonate polyols with carboxyl-containing compounds. Polycarbonate polyols obtained by esterification reaction; polycarbonate polyols obtained by etherification reaction of the above-mentioned polycarbonate polyols and hydroxyl-containing compounds; polycarbonate polyols obtained by transesterification reaction of the above-mentioned polycarbonate polyols and ester compounds; polycarbonate polyols obtained by transesterification reaction of the above-mentioned polycarbonate polyols and hydroxyl-containing compounds; polyester-based polycarbonate polyols obtained by condensation polymerization reaction of the above-mentioned polycarbonate polyols and dicarboxylic acid compounds; and copolymer polyether-based polycarbonate polyols obtained by copolymerization of the above-mentioned polycarbonate polyols and olefin oxides.

[0064] Regarding castor oil polyols, examples include castor oil-based polyols obtained by reacting castor oil fatty acids with the aforementioned polyol components. Specifically, castor oil-based polyols can be obtained by reacting castor oil fatty acids with polypropylene glycol.

[0065] [1-3-1-b. Polyfunctional isocyanate compounds used in the one-stage process (B)] The polyfunctional isocyanate compound (B) used in the one-stage method can be only one type or more than two types.

[0066] Regarding the polyfunctional isocyanate compound (B), any suitable polyfunctional isocyanate compound that can be used in carbamate reactions can be used. Examples of the polyfunctional isocyanate compound (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-epoxypropyl diisocyanate, 1,3-epoxybutyl 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, isoflavone diisocyanate, hydrogenated diphenylmethane diisocyanate, hydrogenated styrene diisocyanate, hydrogenated toluene diisocyanate, and hydrogenated tetramethylstyrene diisocyanate.

[0069] Examples of polyfunctional aromatic isocyanate compounds include: phenylene diisocyanate, toluene 2,4-diisocyanate, toluene 2,6-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 phenylene diisocyanate.

[0070] Regarding polyfunctional isocyanate compounds (B), examples include trimethylolpropane adducts of various polyfunctional isocyanate compounds mentioned above, biuret formed by reaction with water, and trimers having a triisocyanate ring. Furthermore, these can be used in combination.

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

[0072] In order to further enhance the effects of the present invention, the equivalence ratio of NCO groups to OH groups in the polyol (A1) and the polyfunctional isocyanate compound (B), expressed as NCO groups / OH groups, is greater than 1.0 and less than 5.0, preferably 1.1 to 5.0, more preferably 1.2 to 4.0, more preferably 1.5 to 3.5, and especially preferably 1.8 to 3.0.

[0073] [1-3-1-c. Other ingredients] Carbamate-based adhesive compositions may contain any suitable other ingredients in any suitable amount without impairing the effects of the present invention. Examples of such other ingredients include, for instance: other resin components, crosslinking agents other than polyfunctional isocyanate compounds (B), crosslinking delay agents, ionic compounds, fluorinated additives, polysiloxane additives, fatty acid esters, tackifiers, inorganic fillers, organic fillers, metal powders, pigments, foils, softeners, anti-aging agents, conductive agents, ultraviolet absorbers, antioxidants, light stabilizers, surface lubricants, leveling agents, preservatives, heat stabilizers, polymerization inhibitors, lubricants, solvents, and catalysts.

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

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

[0076] [1-3-2-a. Carbamate prepolymer (A2)] The carbamate prepolymer (A2) may be one type or two or more types.

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

[0078] The urethane prepolymer (A2) is preferably a polyurethane polyol, and more preferably it is formed by reacting a polyester polyol (a21) or a polyether polyol (a22) alone or in a mixture of (a21) and (a22) with an organic polyisocyanate compound (a23) in the presence or without a catalyst.

[0079] Regarding the polyester polyol (a21), any suitable polyester polyol can be used. Examples of polyester polyols (a21) include those obtained by reacting an acidic component with a glycol component. Examples of acidic components include phthalic 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, butanediol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, 3,3'-dimethylolheptane, polyoxyethylene glycol, polyoxypropylene glycol, 1,4-butanediol, neopentyl glycol, and butylethylpentanediol; examples of polyol components include glycerol, trimethylolpropane, and neopentyl tertrol. In addition, examples of polyester polyols (a1) include those obtained by ring-opening polymerization of lactones such as polycaprolactone, poly(β-methyl-γ-valerolactone), and polyvalerol.

[0080] Regarding the molecular weight of polyester polyol (a21), it can range from low to high molecular weight. The number average molecular weight (Mn) of polyester polyol (a21) should preferably be between 100 and 100,000. If the number average molecular weight (Mn) is less than 100, there is a risk of increased reactivity and easier gelation. If the number average molecular weight (Mn) is greater than 100,000, there is a risk of decreased reactivity and consequently, a decrease in the agglomerating power of the polyurethane polyol itself. The amount of polyester polyol (a21) used in the polyol constituting the polyurethane polyol should preferably be between 0 mol% and 90 mol%.

[0081] Regarding the polyether polyol (a22), any suitable polyether polyol can be used. Examples of the polyether polyol (a22) include: polyether polyols obtained by polymerizing ethylene oxide compounds such as ethylene oxide, propylene oxide, butene oxide, and tetrahydrofuran using low molecular weight polyols such as water, propylene glycol, ethylene glycol, glycerol, and trimethylolpropane as initiators. Specifically, examples of the polyether polyol (a22) include polypropylene glycol, polyethylene glycol, and polytetramethylene glycol, which have a functional group number of 2 or more.

[0082] Regarding the molecular weight of polyether polyol (a22), it can range from low to high molecular weight. The number average molecular weight (Mn) of polyether polyol (a22) should preferably be between 100 and 100,000. If the number average molecular weight (Mn) is less than 100, there is a risk of increased reactivity and easier gelation. If the number average molecular weight (Mn) is greater than 100,000, there is a risk of decreased reactivity and consequently, a decrease in the agglomerating power of the polyurethane polyol itself. The amount of polyether polyol (a22) used in the polyol constituting the polyurethane polyol should preferably be between 0 mol% and 90 mol%.

[0083] Polyether polyols (a22) can also be partially replaced by glycols such as ethylene glycol, 1,4-butanediol, neopentyl glycol, butyl ethyl pentyl glycol, glycerol, trimethylolpropane, neopentyl tertrol, or polyamines such as ethylenediamine, N-aminoethyl ethanolamine, isophorone diamine, and succinyl diamine, depending on the requirements.

[0084] Regarding polyether polyols (a22), only difunctional polyether polyols can be used, or polyether polyols with a number average molecular weight (Mn) of 100 to 100,000 and having at least three hydroxyl groups per molecule can be used partially or entirely. If polyether polyols with a number average molecular weight (Mn) of 100 to 100,000 and having at least three hydroxyl groups per molecule are used as polyether polyol (a22), a good balance between adhesion and re-peelability can be achieved. With the aforementioned polyether polyols, if the number average molecular weight (Mn) is less than 100, there is a risk of increased reactivity and easy gelation. Furthermore, with the aforementioned polyether polyols, if the number average molecular weight (Mn) is greater than 100,000, there is a risk of decreased reactivity and consequently, a decrease in the agglomeration power of the polyurethane polyol itself. The number average molecular weight (Mn) of the aforementioned polyether polyols is preferably 100 to 10,000.

[0085] Regarding the organic polyisocyanate compound (a23), any suitable organic polyisocyanate compound can be used. Examples of the organic polyisocyanate compound (a23) include aromatic polyisocyanates, aliphatic polyisocyanates, aromatic aliphatic polyisocyanates, alicyclic polyisocyanates, etc.

[0086] Examples of aromatic polyisocyanates include: 1,3-epoxyphenyl diisocyanate, 4,4'-diphenyl diisocyanate, 1,4-epoxyphenyl diisocyanate, 4,4'-diphenylmethane diisocyanate, toluene 2,4-diisocyanate, toluene 2,6-diisocyanate, 4,4'-toluidine diisocyanate, toluene 2,4,6-triisocyanate, benzene 1,3,5-triisocyanate, benzene 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-endenylpropyl diisocyanate, 2,3-endenylbutyl diisocyanate, 1,3-endenylbutyl diisocyanate, dodecamethyl diisocyanate, and 2,4,4-trimethylhexamethylene diisocyanate.

[0088] Examples of aromatic aliphatic polyisocyanates include: ω, ω'-diisocyanate-1,3-dimethylbenzene, ω, ω'-diisocyanate-1,4-dimethylbenzene, ω, ω'-diisocyanate-1,4-diethylbenzene, 1,4-tetramethylenyl diisocyanate, and 1,3-tetramethylenyl diisocyanate.

[0089] Examples of alicyclic polyisocyanates include: 3-isocyanate methyl-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'-methylene bis(cyclohexyl isocyanate), 1,4-bis(isocyanate methyl)cyclohexane, and 1,4-bis(isocyanate methyl)cyclohexane.

[0090] Regarding organic polyisocyanate compounds (a23), they can be combined with trimethylolpropane adducts, biuret compounds resulting from the reaction with water, and trimers having a triisocyanate ring, etc.

[0091] Regarding the catalyst that can be used to obtain polyurethane polyols, any suitable catalyst can be used. Examples of such catalysts include 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] Organometallic compounds include, for example, 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 disulfide, 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 dibutyl titanium dichloride, tetrabutyl titanate, and titanium trichloride; lead compounds such as lead oleate, lead 2-ethylhexanoate, lead benzoate, and lead naphthenate; iron compounds such as iron 2-ethylhexanoate and iron acetone; 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 using a catalyst to obtain polyurethane polyols, in systems containing two polyols—polyester polyol (a21) and polyether polyol (a22)—their different reactivity can easily lead to gelation or turbidity of the reaction solution in a single catalyst system. Therefore, by using two catalysts to obtain polyurethane polyols, these problems can be solved by easily controlling the reaction rate and catalyst selectivity. Regarding the combination of the two catalysts, examples include tertiary amine / organometallic, tin / non-tin, and tin / tin; tin / tin is preferred, and a combination of dibutyltin dilaurate and tin 2-ethylhexanoate is particularly suitable. The mixing ratio, by weight, should preferably be less than 1, preferably 0.2~0.6. A mixing ratio greater than 1 may easily lead to gelation due to the imbalance of catalyst activity.

[0097] When using a catalyst to obtain polyurethane polyols, the amount of catalyst used should be 0.01% to 1.0% by weight relative to the total amount of polyester polyol (a21), polyether polyol (a22), and organic polyisocyanate compound (a23).

[0098] When using a catalyst to obtain polyurethane polyols, the reaction temperature should preferably be below 100°C, and more preferably between 85°C and 95°C. If the temperature exceeds 100°C, it may be difficult to control the reaction rate and cross-linking structure, and it may be difficult to obtain polyurethane polyols with the predetermined molecular weight.

[0099] To obtain polyurethane polyols, a catalyst may not be used. In this case, the reaction temperature should preferably be above 100°C, and more preferably above 110°C. Furthermore, to obtain polyurethane polyols without a catalyst, the reaction should be allowed to proceed for at least 3 hours.

[0100] Regarding methods for obtaining polyurethane polyols, examples include: 1) feeding all the polyester polyol, polyether polyol, catalyst, and organic polyisocyanate into a flask; and 2) feeding the polyester polyol, polyether polyol, and catalyst into a flask and then adding the organic polyisocyanate dropwise. For obtaining polyurethane polyols, method 2) is preferable in terms of reaction control.

[0101] To obtain polyurethane polyols, any suitable solvent can be used. Examples of such solvents include methyl ethyl ketone, ethyl acetate, toluene, xylene, and acetone. Toluene is particularly preferred among these solvents.

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

[0103] Regarding the polyfunctional isocyanate compound (B) used in the prepolymer method, the aforementioned polyfunctional isocyanate compound (B) used in the one-stage method can be referenced.

[0104] In the carbamate prepolymer (A2) and the polyfunctional isocyanate compound (B), the equivalent ratio of NCO groups to OH groups, 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. If the equivalent ratio of NCO groups / OH groups is within the above range, the effects of the present invention will be more fully realized.

[0105] Regarding the content ratio of the polyfunctional isocyanate compound (B), relative to the carbamate prepolymer (A2), the polyfunctional isocyanate compound (B) 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. If the content ratio of the polyfunctional isocyanate compound (B) is within the above range, the effects of the present invention will be more fully realized.

[0106] Regarding the method of forming a carbamate adhesive from a carbamate adhesive composition containing a carbamate prepolymer (A2) and a polyfunctional isocyanate compound (B), if it is a method of manufacturing polyurethane resin using the so-called "carbamate prepolymer" as a raw material, any suitable manufacturing method can be adopted.

[0107] ≪≪2. Manufacturing method of a wound body with an adhesive layer≫≫ The method for manufacturing a wound body of an adhesive layer film according to an embodiment of the present invention is a method for manufacturing a wound body from a long strip of adhesive layer film.

[0108] In the manufacturing method of the adhesive layer film of the embodiment of the present invention, a long strip of adhesive layer film is wound onto a winding shaft to form a winding body. In the manufacturing method of the adhesive layer film of the embodiment of the present invention, the long strip of adhesive layer film is wound onto a winding shaft via a contact roller disposed in front of the winding shaft.

[0109] The length of the strip adhesive layer film in the long side direction of the manufacturing method of the film winding body of the adhesive layer film provided in the embodiment of the present invention is, for example, 1000m or more, 2000m to 10000m, or 3000m to 10000m.

[0110] The length in the width direction of the strip adhesive layer film in the manufacturing method of the film winding body of the adhesive layer provided in the embodiment of the present invention can be any suitable length within the range that does not impair the effect of the present invention. The length in the width direction is, for example, 100mm~5000mm, 500mm~3000mm, or 1000mm~2000mm.

[0111] Figure 1 is a schematic diagram illustrating one embodiment of the winding device, which can be used in the manufacturing method of the film winding body with adhesive layer according to an embodiment of the present invention. In Figure 1, the strip of film 101 with adhesive layer passes through the conveyor rollers 11 and 12, and then passes through the contact roller 200 and is wound onto the winding shaft 300 to become the film winding body 102 with adhesive layer. The contact roller 200 is rotatably supported by the position adjustment unit 400.

[0112] As shown in Figure 1, the contact roller 200 is positioned in front of the take-up shaft 300 while in contact with the adhesive-coated film 101. After the adhesive-coated film 101 is wound onto the take-up shaft 300, it becomes a wound body 102 of the adhesive-coated film. Even if the diameter of this wound body increases, the contact roller 200 is rotatably supported by a position adjustment unit 400 in order to apply a certain pressure to the adhesive-coated film 101. The position adjustment unit 400 is, for example, a cylinder (air cylinder, etc.). The position adjustment unit 400 can finely adjust the position of the contact roller 200.

[0113] Regarding the contact roller, if it is a contact roller applicable to film winding, any suitable type of contact roller can be used within the scope of not compromising the effects of the present invention. Examples of contact rollers include crown rolls. Examples of materials for the contact rollers include rubber.

[0114] Regarding the take-up shaft, if it is a take-up shaft that can be used for winding a film, any appropriate type of take-up shaft can be adopted within the scope that does not damage the effects of the present invention. Regarding the material of the take-up shaft, examples include rubber, plastic, metal (such as aluminum), and composites thereof. The surface of the take-up shaft can also be coated with any appropriate other material. The outer diameter of the take-up shaft (the distance from the center of the core to the outer surface of the core) is, for example, 1 inch to 30 inches, and can also be 2 inches to 15 inches. The shape of the take-up shaft can be cylindrical or columnar.

[0115] In the manufacturing method of the wound body of the film with the adhesive layer according to the embodiment of the present invention, taper control can be performed or not. However, in the manufacturing method of the wound body of the film with the adhesive layer according to the embodiment of the present invention, from the perspective of maintaining the tension of the film with the adhesive layer fixed and suppressing the entrainment of air during winding, it is advisable not to perform taper control.

[0116] In the manufacturing method of the wound body of the film with the adhesive layer according to the embodiment of the present invention, the end of the film with the adhesive layer can be subjected to knurling formation processing or not. However, in the manufacturing method of the wound body of the film with the adhesive layer according to the embodiment of the present invention, since it is possible to achieve suppressing the entrainment of bubbles or the generation of wrinkles and suppressing indentations while performing long-strip winding, it is advisable that the end of the film with the adhesive layer is not subjected to knurling formation processing.

[0117] In the manufacturing method of the wound body of the film with the adhesive layer according to the embodiment of the present invention, by appropriately adjusting the contact pressure P of the contact roller, it is possible to achieve suppressing the entrainment of bubbles or the generation of wrinkles and suppressing indentations while performing long-strip winding. The contact pressure P of the contact roller should be 3.6 N / cm < P < 14.0 N / cm in terms of line pressure, can be 3.9 N / cm < P < 13.0 N / cm, can be 4.2 N / cm < P < 11.0 N / cm, can be 4.3 N / cm < P < 10.0 N / cm, and can also be 4.5 N / cm < P < 9.0 N / cm. By adjusting the contact pressure P of the contact roller within the above range, it is possible to achieve suppressing the entrainment of bubbles or the generation of wrinkles and suppressing indentations while performing long-strip winding. In addition, the contact pressure P is calculated by dividing the pressing force applied to the roller by the width of the film as the line pressure.

[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 contact pressure P, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding. The product D×P of the thickness D of the base material and the contact pressure P should preferably be 0.016 N < (D×P) < 0.075 N, and can be 0.017 < (D×P) < 0.063 N, can be 0.018 N < (D×P) < 0.050 N, or can also 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 contact pressure P to the above range, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding.

[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 contact roller, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding. The surface hardness S of the contact roller should preferably be 30° < S < 80°, and can also be 40° < S < 60°. By adjusting the surface hardness S of the contact roller to the above range, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding. In addition, the surface hardness S is measured using a hardness meter type A (manufactured by ASKER Corporation).

[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 of the adhesive layer wound around the winding shaft, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding. The winding tension T of the film of the adhesive layer wound around the winding shaft should preferably be 200 N / m < T < 400 N / m, and can also be 220 N / m < T < 380 N / m. By adjusting the winding tension T of the film of the adhesive layer wound around the winding shaft to the above range, it is possible to further achieve suppression of air bubble entrainment or wrinkle generation and suppression of indentations, while performing long-strip winding.

[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 production line speed (winding speed) can be adjusted to any appropriate production line speed within the range that does not impair the effects of the present invention. In terms of further demonstrating the effects of the present invention, the production line speed is, for example, 1 m / minute to 100 m / minute, can be 5 m / minute to 80 m / minute, can be 10 m / minute to 60 m / minute, can be 13 m / minute to 40 m / minute, can be 15 m / minute to 30 m / minute, or can also be 15 m / minute to 28 m / minute.

[0122] The manufacturing method of the adhesive layer film winding body according to the embodiment of the present invention can achieve the effects of suppressing air bubble entrainment or wrinkle generation and suppressing dents, while simultaneously performing long strip winding. Therefore, the winding length of the winding body obtained by the manufacturing method of the adhesive layer film winding body according to the embodiment of the present invention is preferably 1000m or more, and can be 2000m to 10000m, or 3000m to 10000m.

[0123] According to the manufacturing method of the film of adhesive layer of the present invention, it is possible to suppress the incorporation of air bubbles or the generation of wrinkles and suppress dents, while performing long strip winding. Even if foreign objects with a maximum particle size of less than 3µm are inserted during manufacturing of the winding, long strip winding can still be performed without causing dents.

[0124] In the manufacturing method of the film with adhesive layer according to the embodiment of the present invention, a carbamate-based adhesive layer composed of a carbamate-based adhesive is used as the adhesive layer of the film with adhesive layer. Furthermore, in the film with adhesive layer released from the winding body, the adhesive layer becomes the outermost layer of the film with adhesive layer. Therefore, the adhesive layer of the film with adhesive layer released from the winding body for bonding with other components, etc., becomes accessible to the rotating roller, thereby allowing the rotating roller to be cleaned without adhesive residue.

[0125] ≪≪3. Wrapped body of film with adhesive layer≫≫ The present invention relates to a winding system for a film with an adhesive layer, specifically a winding of a long strip of film with an adhesive layer.

[0126] The winding length of the film with adhesive layer in the embodiment of the present invention is preferably 1000m or more, more preferably 2000m or more, and more preferably 3000m or more. Conventionally, the winding of films with adhesive layers without a release liner can result in air bubbles, wrinkles, or dents, making it difficult to achieve long winding lengths. According to the present invention, a winding body with a winding length as described above can be provided.

[0127] Regarding the winding body of the adhesive layer film of the embodiment of the present invention, the description of the strip adhesive layer film forming the winding body can be directly referenced from the description of the adhesive layer film in the item ≪≪1. Adhesive Layer Film≫≫.

[0128] Regarding the wound body of the adhesive layer film according to the embodiments of the present invention, the long strip adhesive layer film forming the wound body preferably comprises: a release layer, a substrate, and an adhesive layer in sequence; the release layer and the adhesive layer are the outermost layers of the adhesive layer film; the substrate comprises a polyester resin; the adhesive layer is a urethane adhesive layer composed of a urethane adhesive; the thickness of the adhesive layer is 4.0µm to 10.0µm; at a temperature of 23°C and a humidity of 50%RH, the low-speed peel force of the aforementioned adhesive layer on the aforementioned release layer, measured at a peel speed of 0.3m / min and a peel angle of 180 degrees, is less than 0.01N / 25mm. Regarding the wound body of the adhesive layer film of the embodiment of the present invention, for the strip adhesive layer film forming the wound body, it is more appropriate to refer to the embodiment of the adhesive layer film described in the item ≪≪1. Adhesive Layer Film≫≫.

[0129] Even with a long winding length, the film with adhesive layer of the present invention can still suppress the formation of air bubbles or wrinkles, and can also suppress dents.

[0130] The film winding with the adhesive layer of the embodiment of the present invention can be manufactured by any suitable method within the scope of not compromising the effects of the present invention. For example, the manufacturing method of the film winding with the adhesive layer of the embodiment of the present invention can be cited as an example.

[0131] Example The present invention will now be specifically described by way of examples, but the present invention is not limited to these examples. Furthermore, the testing and evaluation methods in the examples are as follows. Additionally, when referred to as "parts," unless otherwise specified, it refers to "parts by weight," and when referred to as "%," unless otherwise specified, it refers to "% by weight."

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

[0133] <Determination of low-speed peeling force at a peeling speed of 0.3 m / min and a peeling angle of 180 degrees> For two films with adhesive layers, the adhesive layers were pressed onto the release layer using a hand roller, and then laminated under a pressing condition of 0.25 MPa and 0.3 m / min. The films were then placed at 23°C and 50% RH for 20 minutes. The films were then cut to 25 mm widths, and the side of the adhesive layer opposite to the release layer was adhered to an SUS board (SUS304BA) and secured. Using a universal tensile testing machine (manufactured by Minebea Corporation, product name: TCM-1kNB), the adhesive layers were peeled from the release layer at a peel speed of 0.3 m / min and a peel angle of 180 degrees. The peel force at this point was measured as the low-speed peel force.

[0134] <Determination of high-speed peeling force at a peeling speed of 30 m / min and a peeling angle of 180 degrees> For the prepared film with the adhesive layer, the adhesive layer was pressed onto the release layer using a hand roller, and then laminated under a pressing condition of 0.25 MPa and 0.3 m / min, and placed in an environment of 23°C and 50% RH for 20 minutes. Then, the film was cut into 25 mm widths, and the side of the adhesive layer opposite to the release layer was adhered to an SUS board (SUS304BA) and fixed. Using a universal tensile testing machine (manufactured by Minebea Corporation, product name: TCM-1kNB), the adhesive layer was peeled from the release layer at a peel speed of 30 m / min and a peel angle of 180 degrees, and the peel force at this time was measured as the high-speed peel force.

[0135] <Appearance Evaluation of Bubbles and Wrinkles> After winding a 3000m film with an adhesive layer, release one turn from the winding and discard it, then check for bubbles or wrinkles on the surface of the winding. The assessment was conducted based on the following criteria. ○: No bubbles or wrinkles within the specified range. △: No bubbles or wrinkles larger than 15mm are present within the specified range. ×: There are bubbles or wrinkles larger than 1mm within the range.

[0136] <Appearance Assessment of Foreign Object Dents> After winding a 3000m film with an adhesive layer, one turn is released from the winding and discarded, and the appearance is confirmed to be 2m long. The assessment was conducted based on the following criteria. ○: No foreign object dents were found. ×: There are foreign object dents.

[0137] <Evaluation of winding length> The winding body that has been rated as "○" in terms of appearance evaluation of bubbles, wrinkles and foreign object dents is further wound up to 4000m, and the appearance evaluation of bubbles and wrinkles is performed in the same manner as above.

[0138] [Synthetic Example 1] Preparation of carbamate-based adhesive composition (1) Ethyl acetate was used as the polyol in the following mixture: 90 parts by weight of PREMINOL S3011 (manufactured by Asahi Glass Co., Ltd., Mn=10000), a polyol with three hydroxyl groups; 5 parts by weight of SANNIX GP3000 (manufactured by Sanyo Chemical Co., Ltd., Mn=3000), a polyol with three hydroxyl groups; 1 part by weight of SANNIX GP1000 (manufactured by Sanyo Chemical Co., Ltd., Mn=1000), a polyol with three hydroxyl groups; 10 parts by weight of isocyanate compound (Coronate HX:C / HX, manufactured by Nippon Polyurethane Industry Co., Ltd.) as a crosslinking agent; 0.15 parts by weight of acetoacetone iron (III) (manufactured by Nippon Chemical Industry Co., Ltd.) as a catalyst; 0.04 parts by weight of polyether-modified polysiloxane (manufactured by Shin-Etsu Chemical Industry Co., Ltd., trade name "KF6004") as a polysiloxane compound; and Elexcel as an ionic compound. 0.8 parts by weight of AS110 (manufactured by Daiichi Kogyo Pharmaceutical Co., Ltd.) and 5.0 parts by weight of SALACOS 816(L) (2-ethylhexanoate hexadecyl ester, molecular weight = 368, manufactured by The Nisshin OilliO Group) as fatty acid esters were diluted to make the total solid content 20% by weight, and a carbamate adhesive composition (1) was obtained.

[0139] [Synthesis Example 2] Preparation of acrylic adhesive composition (1) Acrylic adhesive (SK-Dyne, manufactured by Sogen Chemical Co., Ltd.) was diluted to 35% by weight with toluene. For every 100 parts by weight of solid component, 5 parts by weight of solid component of crosslinking agent (polyisocyanate, Coronate HX, manufactured by Tosoh Co., Ltd.), 0.5 parts by weight of solid component of crosslinking catalyst (dioctyltin dilaurate, a tin catalyst, manufactured by Tokyo Fine Chemical Co., Ltd., EMBILIZER OL-1), and 10 parts by weight of acetone were added and mixed to prepare an acrylic adhesive composition (1).

[0140] [Manufacturing Example 1] Manufacturing of a film (1) with an adhesive layer Using a strip of PET film with a release layer (manufactured by Mitsubishi Chemical Co., trade name "MRF38", thickness = 38µm, width length = 1480mm, release layer thickness = 20nm) as the substrate, the carbamate adhesive composition (1) obtained in Synthesis Example 1 was coated onto the surface of the substrate opposite to the release layer at a production line speed of 20m / min, with a dried thickness of 5µm. The film was then dried at 130°C for 30 seconds to form a carbamate adhesive layer with a thickness of 5µm. A strip of film (1) with an adhesive layer consisting of a release layer / substrate / adhesive layer was produced on the production line.

[0141] [Manufacturing Example 2] Manufacturing of a film (2) with an adhesive layer In addition to using a strip of PET film with a release layer (Mitsubishi Chemical Co., trade name "MRF50", thickness = 50µm, width length = 1480mm, release layer thickness = 20nm) as the substrate, the same method as in manufacturing example 1 was used to produce a strip of film with an adhesive layer consisting of a release layer / substrate / adhesive layer (2).

[0142] [Manufacturing Example 3] Manufacturing of a film (3) with an adhesive layer In addition to coating the carbamate-based adhesive composition (1) to a thickness of 7µm after drying, a long strip of adhesive film (3) consisting of a "release layer / substrate / adhesive layer" was produced in the same manner as in Manufacturing Example 1.

[0143] [Manufacturing Example 4] Manufacturing of a film (4) with an adhesive layer In addition to coating the carbamate-based adhesive composition (1) so that the thickness after drying is 10µm, the same method as in Manufacturing Example 1 is followed to produce a long strip of adhesive film (4) consisting of a "release layer / substrate / adhesive layer".

[0144] [Manufacturing Example 5] Manufacturing of a film (5) with an adhesive layer In addition to coating the carbamate-based adhesive composition (1) in such a way that the thickness after drying is 3µm, the same method as in Manufacturing Example 1 is followed to produce a long strip of adhesive film (5) consisting of a "release layer / substrate / adhesive layer".

[0145] [Manufacturing Example 6] Manufacturing of a film (6) with an adhesive layer Using a strip of PET film with a release layer (manufactured by Mitsubishi Chemical Co., trade name "MRF38", thickness = 38µm, width length = 1480mm, release layer thickness = 20nm) as the substrate, the acrylic adhesive composition (1) obtained in Synthesis Example 2 was coated on the surface of the substrate opposite to the release layer at a production line speed of 20m / min, and dried at 130°C for 30 seconds to form an acrylic adhesive layer with a thickness of 5µm. A strip of film with an adhesive layer consisting of "release layer / substrate / adhesive layer" (6) was produced on the production line.

[0146] [Manufacturing Example 7] Manufacturing of a film (7) with an adhesive layer Using a strip of PET film (manufactured by Mitsubishi Chemical, trade name "DIAFOIL T100C38", thickness = 38µm, width length = 1400mm) as the substrate, an antifouling layer composed of polyvinyl butyral compound was formed on one side of the substrate on a production line. Next, at a production line speed of 20m / min, the carbamate adhesive composition (1) obtained in Synthesis Example 1 was coated on the surface of the substrate opposite to the antifouling layer with a thickness of 5µm after drying, and dried at 130°C for 30 seconds to form a carbamate adhesive layer with a thickness of 5µm. A strip of film (7) consisting of an antifouling layer / substrate / adhesive layer was produced on the production line.

[0147] [Manufacturing Example 8] Manufacturing of a film (8) with an adhesive layer In addition to coating the carbamate-based adhesive composition (1) so that the thickness after drying is 12µm, the same method as in Manufacturing Example 1 is followed to produce a long strip of adhesive film (8) consisting of a "release layer / substrate / adhesive layer".

[0148] [Examples 1-12, Comparative Examples 1-8] Using the winding device shown in Figure 1, any one of the films (1) to (8) with adhesive layers obtained in Manufacturing Examples 1 to 8 is wound onto a winding shaft under the conditions shown in Table 1 to obtain winding bodies (1) to (7) and (C1) to (C8). The results are listed in Table 1.

[0149] [Table 1]

[0150] Industrial availability The method for manufacturing a wound body of an adhesive layer film according to an embodiment of the present invention can be effectively used, for example, in manufacturing various wound bodies of thin films used in the manufacturing process of optical components or electronic components. Furthermore, the wound body of an adhesive layer film according to an embodiment of the present invention can be effectively utilized in various forms of wound bodies of thin films used, for example, in the manufacturing process of optical components or electronic components.

[0151] 101: Thin film with adhesive layer 102: Wrapped body of a thin film with an adhesive layer 200: Contact Roller 300: Winding shaft 400: Position Adjustment Section 11: Conveyor Roller 12: Conveyor Roller

Claims

1. A method for manufacturing a wound body of a film with an adhesive layer, comprising a method for manufacturing a wound body from a strip of film with an adhesive layer; the film with the adhesive layer sequentially comprises a release layer, a substrate, and an adhesive layer; the release layer and the adhesive layer are the outermost layers of the film with the adhesive layer; the substrate comprises a polyester resin; the adhesive layer is a urethane-based adhesive layer composed of a urethane-based adhesive; the thickness of the adhesive layer is 4.0µm to 10.0µm; the film with the adhesive layer is wound onto a take-up shaft after passing through a contact roller disposed in front of the take-up shaft to form a wound body; and the contact pressure P of the contact roller is 3.6N / cm < P < 14.0N / cm using a linear pressure gauge.

2. The method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein the contact pressure P of the aforementioned contact roller is 4.3 N / cm < P < 10.0 N / cm using a linear pressure gauge.

3. A method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein the product of the thickness D of the aforementioned substrate and the aforementioned contact pressure P is 0.018N < (D × P) < 0.050N.

4. A method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein the surface hardness S of the aforementioned contact roller is 30° < S < 80°.

5. A method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein the winding tension T of the aforementioned film with the adhesive layer being wound onto the winding shaft is 200 N / m < T < 400 N / m.

6. A method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein at a temperature of 23°C and a humidity of 50%RH, the low-speed peel force of the aforementioned adhesive layer on the aforementioned release layer, measured at a peel speed of 0.3 m / min and a peel angle of 180 degrees, is less than 0.01 N / 25 mm.

7. A method for manufacturing a wound body of a film with an adhesive layer as claimed in claim 1, wherein at a temperature of 23°C and a humidity of 50%RH, the high-speed peel force of the aforementioned adhesive layer on the aforementioned release layer, measured at a peeling speed of 30m / min and a peeling angle of 180 degrees, is less than 0.15N / 25mm.

8. A method for manufacturing a wound body of a film with an adhesive layer as described in claim 1, wherein the winding length of the aforementioned wound body is 3000m or more.

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