JP2011210924A - Manufacturing method by sticking of optical filter for display - Google Patents

Abstract

An optical filter for display is manufactured in such a manner that filter members are efficiently bonded together with a small number of steps, and an exposed portion for grounding is left on all four sides of an electromagnetic wave shielding filter.
A first filter member 10AS with a continuous strip-like release sheet in which a release sheet 3 is temporarily bonded to a first filter member 10A of an electromagnetic wave shielding filter is prepared, and a filter layer 4 of an optical filter is bonded to a bonding surface. A sheet-like second filter member 10B provided with the adhesive layer 5 is prepared, and the first filter member with the release sheet is half-cut by the cutting blade 23 during conveyance, and the first filter member is second After separating into sheets on the release sheet that is larger than the filter member, the release sheet is peeled off by the release plate 24, folded and wound, and the first filter member conveyed by the release sheet is pressed onto the second filter member. If bonded at 25, the optical filter 10 for display in which the ground exposed portion 2E is formed is obtained.
[Selection] Figure 1

Description

  The present invention relates to a manufacturing method capable of producing an optical filter for display by efficiently bonding two filter members with few steps. In particular, the present invention relates to a manufacturing method in which an electromagnetic wave shielding filter member and another optical filter member as a filter member and an optical filter can be bonded to each other around the four sides of the electromagnetic wave shielding filter member while leaving an exposed portion for grounding.

  Currently, in addition to the conventional cathode ray tube (CRT) display, various displays such as liquid crystal display (LCD), plasma display panel (hereinafter also referred to as PDP), electroluminescence (EL) display, etc., which become flat panel display (FPD) Is in practical use.

  Further, on the front surface (observer side surface) of the display, for example, in the PDP, since the electromagnetic wave emission from the display is strong, an electromagnetic wave shielding filter that shields the electromagnetic wave and transmits the image light is disposed. In addition, a neon light absorption filter that prevents neon light near the wavelength of 590 nm emitted from the display from affecting the hue of the image, an infrared absorption filter that prevents malfunction of the remote controller due to infrared light emitted from the display, and the like are arranged. Yes. Various optical filters are arranged on the front surface of the display, such as a color correction filter for adjusting the hue of an image and an antireflection filter for preventing external light reflection. In addition, these optical filters are arranged in a state of being closely stacked with a resin layer such as an adhesive layer without leaving a gap (air layer) between the filters in order to minimize the decrease in light transmittance. Often done.

In particular, in the case of an electromagnetic wave shielding filter, unlike a simple optical filter having only optical performance, it is necessary to provide a grounding region for taking out a grounding electrode at the four peripheral edges of the filter. The grounding region is often provided as an exposed grounding exposed portion. For this reason, the lamination of the electromagnetic wave shielding filter member and other optical filter members such as an antireflection filter needs to be bonded so that the exposed portion for grounding is formed. In addition, the optical filter for display is a single-piece when placed on the front of the display, but at the time of manufacture, the base is flexible and roll-to-sheet, apart from a plate-like single-piece such as a glass plate. -It is often manufactured as a continuous belt-like sheet (or film) that can be produced on a roll.
Therefore, in this case, in a certain manufacturing stage, the continuous band-shaped sheet is changed to a single-sheet material such as a single-wafer sheet. Bonding) and exposing the ground exposed part.

Therefore, as a bonding method that can form the exposed portion for grounding, for example, there is the following method.
First, two types of filter members, an electromagnetic wave shielding filter and an optical filter (hereinafter, other optical filters having no electromagnetic wave shielding function are also simply referred to as “optical filters”), It is unwound from a roll and cut into sheet sheets each having a predetermined size. In addition, at this time, the optical filter is cut with a size that is slightly smaller than the size of the electromagnetic shielding filter so that the grounding region at the peripheral portion of the electromagnetic shielding filter is exposed and becomes an exposed portion for grounding. And there exists the method of exposing the exposure part for earth | grounding for electrode extraction to 4 sides of the electromagnetic shielding filter with a big dimension by bonding together the filter members from which a dimension differs. The adhesive for bonding is provided as an adhesive layer on the side of the optical filter that reduces the size, so that the adhesive layer does not cover the exposed portion for grounding and can be bonded ( Patent Document 1).
Here, FIG. 7 is a cross-sectional view for explaining the bonding between the filter members of such a single wafer. 7A, the first filter member 10A has the conductor pattern layer 2 on the transparent substrate 1, and the second filter member 10B has the filter layer 4 attached thereto. In this example, the adhesive layer 5 is provided on the mating side surface. Further, the size of the first filter member 10A is slightly larger than that of the second filter member 10B. When these members are bonded together, as shown in FIG. 7B, the adhesive layer 5 causes the second filter member 10B on the surface of the first filter member 10A on the conductor pattern layer 2 side. And a grounding exposed portion 2E where the conductor pattern layer 2 is exposed is formed around all four sides of the first filter member 10A.

JP 2007-36107 A (0082, FIG. 7)

  However, the pasting of the filter members in the conventional optical filter for display as described above is performed by cutting each filter member unwound from the roll of the continuous belt-like sheet into a sheet having a predetermined size. The foliation process is twice, the bonding process for bonding filter members together is once, and a total of three independent processes are required. That is, three steps are necessary. Moreover, in the bonding process between the filter members, it is necessary for the operator to manually align the sheets one by one, and to remove the unnecessary protective film and the release sheet of the adhesive layer. It was bad.

  On the other hand, a continuous band-like filter member that has been unwound from a roll is continuously bonded as it is, and then wound around a roll. However, in this method, the grounding exposed portion 2E cannot be exposed at the peripheral portions of all four sides of the electromagnetic wave shielding filter for each sheet. For this reason, after unwinding the continuous belt-like sheet from the roll wound after bonding and cutting it into a sheet having a predetermined size, the grounding electrode is taken out from the unexposed ground region or exposed. There is a problem in that a complicated process is required in which a sheet laminated on a non-grounded region is peeled and removed by some method and exposed to form an exposed portion for grounding. In addition, such a method has a problem that it cannot be applied when one of the filter members is a non-flexible plate material.

  That is, an object of the present invention is to provide a method capable of efficiently laminating a display optical filter by laminating two filter members, with only a few steps. When the filter member is an electromagnetic wave shielding filter, the object is to provide a method capable of being bonded together leaving exposed ground portions around all four sides.

Therefore, in the present invention, a manufacturing method by bonding optical filters for display having the following configuration is adopted.
[1] In a method for manufacturing a display optical filter by bonding two filter members together, the display optical filter is bonded,
(A1) The first filter member is a continuous belt-like sheet, and is prepared as a first filter member with a release sheet in which a release sheet that is a continuous belt-like sheet is temporarily bonded to the bonding surface.
(A2) The second filter member is a sheet or continuous belt-like sheet, and is prepared as a member having an adhesive layer on the bonding surface of the filter layer,
(B) The first filter member with release sheet is half-cut in the course of unwinding and transporting the first filter member with the release sheet, the release sheet leaves all or part of its thickness, and the first filter member Cuts the entire thickness and turns it into a predetermined size corresponding to one display screen,
(C) Next, only the release sheet is peeled off from the first filter member with the release sheet, and then folded and conveyed.
(D) On the other hand, the separated first filter member is transported while being separated from the release sheet and the downstream side of the tip portion while the upstream side is supported by the release sheet in the state before separation, By sequentially pressing the filter member 1 with a pressure roller to a predetermined position of the second filter member so that the bonding surface faces the adhesive layer surface of the second filter member,
Bonding the first filter member and the second filter member to produce an optical filter for display that can be used for each display screen;
(E) At least the above operations (b), (c), and (d) are performed on the same manufacturing apparatus, and the manufacturing method is performed by bonding optical filters for display.

[2] In the above [1],
The first filter member in (a1) is an electromagnetic wave shielding filter member including at least a transparent substrate and a conductor pattern layer formed on the transparent substrate,
The second filter member in the above (a2) is an optical filter member including at least an adhesive layer and a filter layer having one or more optical filter functions other than the electromagnetic wave shielding function,
The predetermined dimension when the first filter member in (b) is cut into single sheets by half-cut processing is increased in the transport direction with respect to the predetermined dimension of the second filter member,
The width of the first filter member when pasting in (d) is made larger than the width of the second filter member, and the second filter member is laminated around the entire four sides of the first filter member. Create an optical filter for display that can be used for each display screen, with no ground exposed part formed,
A manufacturing method was performed by attaching an optical filter for display.

(1) According to the present invention, the first filter member of the continuous belt-like sheet unwound from the roll is laminated into a single sheet by bonding the two types of filter members, the first filter member and the second filter member. Since the half-cut processing to be performed is performed in-line on the same manufacturing apparatus as the bonding, the number of steps can be reduced by one step. Therefore, when manufacturing a single-sheet display filter for one display screen by laminating the first filter member of the continuous belt-like sheet and the second filter member of the single-wafer, one unit is manufactured. This can be done in one step on the device. As a result, the bonding can be performed efficiently with fewer steps than in the past. In addition, since the release sheet that is temporarily temporarily bonded is merely provided by diverting or replacing the protective film that has been frequently used in the past, an additional step of temporarily bonding the release sheet is not required, and the Since the release sheet is also peeled off by the machine on the same manufacturing apparatus, it is more accurate and efficient than the case where the protective film is peeled off manually and the filter members are bonded together, and can be bonded with high production efficiency. In addition, the present invention is applicable to the second filter member being a flexible sheet (or) or a non-flexible plate.
(2) Moreover, an electromagnetic wave shielding filter member and an optical filter member having other optical filter functions can be efficiently bonded as the two filter members. In this case, the electromagnetic wave shielding filter member is used as the first filter member, and the optical filter member is used as the second filter member, so that the grounding exposure is provided around the four sides of the single sheet corresponding to one display screen of the electromagnetic wave shielding filter member. The optical filter member can be bonded efficiently with fewer steps than in the past, leaving the portion.

BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing which illustrates the manufacturing method by bonding of the optical filter for displays by this invention notionally, and (A) is an expanded sectional view which shows one example of a 1st filter member especially in the figure, (B). FIG. 4 is a plan view showing an example of an optical filter for display when a sheet is formed after bonding. Sectional drawing which shows the example of a form different from FIG. 1 of a 1st filter member. Sectional drawing which shows the example of a form different from FIG. 1 of a 2nd filter member. Sectional drawing explaining the condition of a half cut. Sectional drawing explaining the separation condition of the peeling sheet and 1st filter member in a peeling plate. Sectional drawing which illustrates one form of the 1st filter member (electromagnetic wave shielding filter member) by a drawing primer system intaglio printing method. Explanatory drawing which illustrates notionally an example of the bonding method of the conventional optical filter for displays.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<< A. Embodiment >>
With reference to FIGS. 1-5, embodiment is described about the manufacturing method by bonding of the optical filter for displays by this invention. In the following embodiments, the first filter member 10A is an electromagnetic wave shielding filter member having an electromagnetic wave shielding function, and the second filter member 10B has a contrast improving function as an optical filter function other than the electromagnetic wave shielding function. It is also an example of an optical filter member having two functions of a light reflection preventing function.

(A1) Preparation of first filter member:
When the first filter member 10A is an electromagnetic wave shielding filter member, the layer structure as illustrated in the sectional view of FIG. 1A, for example, the transparent substrate 1 is a continuous belt-like sheet of polyethylene terephthalate film. A printed film in which the conductive pattern layer 2 is printed on one side of the material 1 and a conductive composition (for example, silver paste) is printed in a mesh shape can be used. In addition to the layer structure of FIG. 1A, for example, an electromagnetic wave shielding filter member having a layer structure as illustrated in the cross-sectional view of FIG. 2 may be used.
The first filter member 10A illustrated in FIG. 2 is used for color correction of image light on the surface of the transparent substrate 1 on the side where the conductor pattern layer 2 is not formed, with respect to the configuration illustrated in FIG. The pressure-sensitive adhesive layer 6 colored in the visible light region and a separator film 7 that temporarily protects the pressure-sensitive adhesive layer surface are laminated. The pressure-sensitive adhesive layer 6 and the separator film 7 are laminated by, for example, the pressure-sensitive adhesive obtained by peeling and exposing one separator film 7 from a continuous belt-shaped pressure-sensitive adhesive film in which both surfaces of the pressure-sensitive adhesive layer 6 are protected by the separator film 7. The agent layer 6 is laminated on the surface of the transparent substrate 1. In addition, although the separator film 7 itself is a well-known thing, the peeling sheet 3 mentioned later can also be used.
Each of the illustrated first filter members 10A is prepared as a continuous belt-like sheet. Moreover, the planar view shape of the pattern of the conductor pattern layer 2 is typically a square lattice mesh shape. The mesh shape of the pattern is formed continuously in the conveying direction (longitudinal direction) of the first filter member 10A (with a pattern that does not provide a grounding area with a frame-shaped portion corresponding to one display screen as a whole surface). It may be good.

Then, the continuous strip-like release sheet 3 is laminated on the surface of the first filter member 10A as described above on which the conductor pattern layer 2 is formed, whereby the release sheet 3 is temporarily bonded. A first filter member 10AS with a strip-shaped release sheet can be prepared.
The release sheet 3 is bonded to one side of a resin film such as polyethylene terephthalate during transport or half-cut processing, but it is weak enough to be temporarily bonded with a weak adhesive force that can be easily peeled off. What formed the adhesive layer can be utilized. Further, the release sheet 3 may be used as a protective film for temporarily adhering until the time of use to protect the surface of the filter member.

(A2) Preparation of second filter member:
On the other hand, the second filter member 10B is a member having a structure in which the adhesive layer 5 for bonding is laminated on at least one surface of the filter layer 4 as illustrated in the lower left of FIG. The filter layer 4 may be a composite of various filter functions. For example, as illustrated in the cross-sectional view of FIG. 3, the filter layer 4 is a laminate of an antireflection filter 4a and a contrast enhancement filter 4b. The adhesive layer 5 may be a pressure-sensitive adhesive layer or includes a pressure-sensitive adhesive layer. For example, the second filter member 10B having the above-described configuration is configured such that the continuous belt-like pressure-sensitive adhesive sheet is a pressure-sensitive adhesive layer of the pressure-sensitive adhesive sheet with respect to the filter layer 4 made in the form of a continuous belt-like sheet. 5 can be produced by laminating. At that time, after laminating, the material once wound on a roll is unwound and cut to prepare a sheet having a predetermined size corresponding to one screen of the display in the form of a sheet. be able to.

(Loading of each filter member to the bonding production equipment)
Then, as conceptually shown in FIG. 1, a roll 21 obtained by winding the continuous band-like sheet of the first filter member 10AS with the release sheet, and a sheet obtained by cutting the second filter member 10B into a sheet. The sheet is loaded into the bonded manufacturing apparatus. At this time, the sheet of the second filter member 10B is placed on the transport stage 26a.
The transport stage 26a has a horizontal upper surface, and the second filter member 10B is placed on this surface to transport the second filter member 10B. In FIG. 1, the transport stage 26 a moves horizontally from the left to the right in the drawing to transport the second filter member 10 </ b> B to the bonding portion of the pressure roller 25, and then the bonded display optical filter 10 is discharged rightward in the drawing. In FIG. 1, the transport stage 26a is driven by a number of transport rollers 26b that move the transport stage 26a. The transfer stage 26a and the transfer roller 26b are provided in the bonding manufacturing apparatus as a transfer mechanism for the second filter member 10B.

(B) Single wafer processing by half-cut processing:
And 1st filter member 10AS with a peeling sheet of a continuous strip | belt-shaped sheet | seat is half-cut with the cutting blade 23 in the middle of the path | route which unwinds from the roll 21 and conveys toward the press roller 25. FIG. The half cut is made from the first filter member 10A side, the release sheet 3 is cut leaving all or part of the thickness, and the first filter member 10A cuts the entire thickness. By this half cut, only the first filter member 10 </ b> A is cut into a predetermined dimension corresponding to one display screen, and is separated into sheets on the release sheet 3. The half cut is usually put in the full width of the continuous strip sheet in parallel with the (sheet) width direction of the continuous strip sheet.

In the half cut, the entire thickness of the first filter member 10A is cut. Here, the “total thickness” will be further described. FIG. 4 is a cross-sectional view for explaining the state of half cut. In the figure, a receiving roller 23a is provided so as to sandwich the first filter member 10A facing the cutting blade 23, and the cutting blade 23 and the receiving roller serve as a half-cut means. The receiving roller 23a can make a half cut with a precise depth. The half-cut means is not limited to the method shown in FIG. 4, and any known half-cut means can be adopted as appropriate.
Further, in the first filter member 10A of the same figure, the conductor pattern layer 2 formed on one side of the transparent substrate 1 is exposed (in a state where the release sheet 3 to be temporarily bonded is not laminated), It is the member of the composition which became. And the peeling sheet 3 is laminated | stacked on the uneven | corrugated surface of this conductor pattern layer 2, and temporarily adhere | attached, and it becomes 1st filter member 10AS with a peeling sheet. At this time, if the release sheet 3 does not completely follow the recess of the concave and convex surface of the conductive pattern layer 2 (the white portion in the drawing, which is a non-formed portion of the conductive pattern layer 2), a void remains. .
When the “total thickness” of the first filter member 10A is cut, when the filter member has such an uneven surface formed by the conductor pattern layer 2, the transparent substrate 1 and the conductor pattern layer The total thickness of the transparent substrate 1 excluding the thickness of the conductor pattern layer 2 may be the total thickness Tt including the gap portion, that is, the total thickness Tt including the void portion. A total thickness Tr may be used. In addition, in the case of half-cutting with substantial full thickness Tr, it means that the substantial part of the conductor pattern layer 2 cannot be cut. However, since the total thickness (= Tr) of the transparent base material 1 that is stronger in strength as a support for the conductor pattern layer 2 is cut, the first filter member 10A can be easily divided into sheets.

  In addition, when carrying out a half cut, conveyance of 1st filter member 10AS with a peeling sheet may be stopped temporarily so that a position and a cutting depth can be half cut more correctly. In this case, the conveyance is intermittent feeding. Further, when the conveyance is temporarily stopped, when the first filter member 10A and the second filter member 10B are not in the process of being bonded at the bonding part, which is a pressure application part by the pressure roller 25, for example, bonding As a non-existing portion, the portion of the grounding exposed portion 2E (the portion outside the screen) is preferably located immediately below the pressure roller 25. This is because if the rotation of the pressure roller 25 is temporarily stopped during the bonding, the portion immediately below the pressure roller 25 is likely to have a trace of unevenness extending in the width direction.

(C) Release operation of release sheet:
Then, as shown in the cross-sectional view of FIG. 5, the first filter member 10AS with the release sheet after the single wafer operation by the half-cut processing is a release means installed on the release sheet side. By the plate 24, only the release sheet 3 is folded and conveyed at a large angle exceeding 90 degrees in the direction substantially opposite to the conventional conveying direction. In the case of FIG. 1, the folded release sheet 3 is conveyed to the roll 22, wound around the roll 22, and collected. On the other hand, the first filter member 10 </ b> A that is a sheet after the release sheet 3 is peeled off is supported by the release sheet 3 at an upstream portion that is not yet separated from the release sheet 3 without being folded back. Thus, the leading end portion on the downstream side in the transport direction separated from the release sheet 3 becomes a free end with respect to the release sheet, and generally proceeds in the transport direction so far.

(D) Bonding process:
The first filter member 10A after being peeled off by the peeling plate 24 is supported and transported by the release sheet 3 on the upstream side, while the second filter member 10B also peels off the transport speed. In the same manner as the first filter member 10AS with a sheet, the sheet is conveyed synchronously so that the attachment start positions are aligned with each other at a predetermined position. Then, the first filter member 10A comes into contact with a predetermined bonding surface of the second filter member 10B, and bonding starts.
Further, referring back to FIG. 1, the first filter member 10 </ b> A of the single wafer sheet is continuously pressed against the surface of the adhesive layer 5 of the second filter member 10 </ b> B by the press roller 25. Thus, the first filter member 10A and the second filter member 10B are bonded together in a predetermined positional relationship. In FIG. 1, the drawing in the thickness direction of the first filter member 10 </ b> A before and after the bonding with the pressure roller 25 is changed, and the drawing before the bonding is simplified.
And in the case of the same figure, since the 2nd filter member 10B was supplied as a sheet, the obtained display filter 10 is already a sheet. That is, the single-sheet optical filter 10 for display as shown in the plan view of FIG. 1B is obtained.

  In addition, at the time of bonding, the first film member 10A and the second filter member 10B are each a sheet of a predetermined size. For this reason, by making the first filter member 10A one size larger than the second filter member 10B to the extent that the grounding exposed portion 2E can be exposed in the vicinity of all four sides in the transport direction and the width direction. When the second filter member 10B is aligned and bonded so as to be positioned at the center of the first filter member 10A, the entire circumference of the four sides of the first filter member 10A is obtained as shown in the plan view of FIG. Can be bonded together leaving the exposed portion 2E for grounding.

  Note that the size of the first filter member 10A is slightly larger in the transport direction than the second filter member 10B is during half-cutting. On the other hand, in order to make the size slightly larger in the width direction orthogonal to the conveying direction, the sheet width of the continuous belt-like sheet of the roll 21 loaded in the manufacturing apparatus is preferably made to be slightly larger in size. Alternatively, the roll 21 to be loaded may have a wider width, and may be slit in the conveying path from unwinding and bonding to a predetermined larger width.

(E) Continuous processing on the same manufacturing equipment:
As described above, in the present invention, the sheet processing of the first filter member 10A, which is a continuous belt-like sheet, and the bonding process of the first filter member 10A and the second filter member 10B are performed on the same manufacturing apparatus. Therefore, all of these operations are completed in one process, and a display filter can be efficiently manufactured by bonding.

  Further, the display optical filter 10 as illustrated in FIG. 1B obtained in this way is for grounding in which the conductor pattern layer 2 is exposed around all four sides of a rectangle (rectangle). It is a filter which has the exposed part 2E as a part left at the time of bonding. That is, the grounding exposed portion 2E is not exposed by peeling off the second filter member 10B that has been bonded onto the grounding exposed portion 2E, but is left to be bonded at the time of bonding. It was exposed at. Therefore, the conductor pattern layer 2 is not accidentally cut as compared to the case where the conductor pattern layer 2 is peeled and exposed after bonding, and a highly reliable grounding portion is obtained.

<< B. Details of each part >>
In the above embodiment, the first filter member 10A is an electromagnetic wave shielding filter member configured as shown in FIGS. 1 and 2, and the second filter member 10B is an optical filter member configured as shown in FIGS. However, here, other forms of these members will be further described.

First, the filter functions of the first filter member 10A and the second filter member 10B are usually members having different filter functions, but members having the same filter function can also be used. For example, the filter function is strengthened by overlapping two sheets, and when the contrast improving filter or the like has anisotropy in the plane direction, the same filter is crossed with the direction of the plane direction being changed.
In addition, both the first filter member 10A and the second filter member 10B can be members in which a plurality of filter functions are combined.
In the present invention, the “member” is referred to as a “member” because it is a material that is a constituent element of the display filter, and includes a member that can be used alone as a filter for the display.
Further, the difference between the first filter member 10A and the second filter member 10B is in the shape element that the first filter member 10A is essential to be prepared and used as a continuous belt-like sheet.
Therefore, there is basically no particular limitation on each filter function of the filter function provided in the first filter member 10A and the filter function provided in the second filter member 10B.
However, in the embodiment, the first filter member 10A has an electromagnetic wave shielding function, and the second filter member 10B has a filter function (optical filter function) other than the electromagnetic wave shielding function. Therefore, in the following description, the electromagnetic wave shielding function will be described in the column of the first filter member 10A, and the other optical filter functions will be described in the column of the second filter member 10B for convenience. Whether it belongs is not limited to the following description.

[First filter member with release sheet]
As the first filter member 10 </ b> A of the first filter member 10 </ b> AS with the release sheet, a conventionally known filter as a display filter can be appropriately selected and employed depending on the application. For example, it is the first filter member 10 </ b> A including the transparent substrate 1 and the conductor pattern layer 2. So, below, this transparent base material and a conductor pattern layer are demonstrated, and a peeling sheet is demonstrated after that.

[Transparent substrate]
The continuous strip-shaped transparent substrate 1 exemplified as the first filter member 10A is a resin sheet (or film) in that it can be wound around a roll. “Sheet” may generally mean a thicker material than “film”. However, in the present invention, there is only a difference in name, and there is no particular distinction between the meanings.
Examples of the resin of the resin sheet include polyester resins such as polyethylene terephthalate, acrylic resins, polycarbonate resins, polyamide resins, polyolefin resins such as cycloolefin polymers, and cellulose resins such as triacetyl cellulose. It is. Among these, a biaxially stretched polyethylene terephthalate film is a suitable material. The thickness of the transparent substrate 1 is usually 12 to 500 μm, preferably 25 to 200 μm, from the viewpoints of handleability and cost, but is not particularly limited.

[Conductor pattern layer]
The conductor pattern layer 2 is a layer having a function of shielding electromagnetic waves formed in a pattern on the transparent substrate 1, and is a filter that shields electromagnetic waves in a so-called radio wave region centering around the kHz to GHz band and transmits visible light. It has a function.
There is no restriction | limiting in particular as the conductor pattern layer 2, A well-known thing may be used. For example, a metal mesh layer formed by etching a metal layer such as a metal foil, or a conductive composition layer formed by printing a conductive composition (also referred to as conductive paste or conductive ink).
The metal of the metal layer is typically copper, but may be aluminum or the like. The conductive composition is a liquid composition containing conductive particles and a resin binder (also called conductive paste, conductive ink, etc.), and the conductive particles include gold, silver, platinum, copper Further, metal-coated particles in which the surface of low-conductive particles such as particles of aluminum or the like, resin particles, inorganic non-metallic particles, or the like is coated with the metal may be used.
Further, as the resin of the resin binder (binder resin), a thermoplastic resin, a thermosetting resin, an ionizing radiation curable resin, or the like is used alone or in combination. A thermoplastic polyester resin, a thermoplastic acrylic resin, or the like can be used as the thermoplastic resin, and a melamine resin, a thermosetting polyester resin, a thermosetting acrylic resin, a thermosetting urethane resin, or the like can be used as the thermosetting resin. As the ionizing radiation curable resin, an acrylate-based or methacrylate-based one can be used. As ionizing radiation, ultraviolet rays, electron beams, etc. are usually used.

  In addition, the planar view shape of the pattern of the conductor pattern layer 2 is arbitrary, such as a known shape. For example, a mesh shape (a unit lattice is a lattice pattern such as a hexagon or a quadrangle), a stripe shape (a linear stripe pattern, a spiral) Geometric shape). Of these, a mesh shape and a square lattice shape are typical. The shape of the opening 9 (see FIG. 6) which is a non-formation part of the conductor pattern layer 2 is a square shape when the mesh shape is, for example, a square lattice shape, and a belt shape when the stripe shape is used. Moreover, the line width of a pattern, ie, the line width of the formation part of the conductor pattern layer 2, is normally 5-50 micrometers from viewpoints, such as electromagnetic shielding performance. The period of the pattern of the geometric pattern such as a lattice or stripe is usually 100 to 500 μm. Further, the aperture ratio of the conductor pattern layer 2 [(total area of the openings 9 of the conductor pattern layer 2 / total covering area including the openings 9 of the conductor pattern layer 2 and the formation portions of the conductor pattern layer 2) X100]] is about 50 to 95% from the viewpoint of compatibility with electromagnetic wave shielding performance and visible light transparency.

  In the case where the conductor pattern layer 2 is printed and formed as a conductor composition layer, it is preferable that the “pulling primer type intaglio printing method” disclosed in the pamphlet of International Publication No. 2008/149969 can be used in terms of high definition. . In this intaglio printing method, a primer layer made of ionizing radiation curable resin or the like that pulls out the ink (conductive paste) filled in the recesses of the intaglio plate surface and promotes the transfer to the substrate is printed during printing. In this method, the material is allowed to act in a fluid state and solidified on the plate surface, and then released and printed.

  Such a printed matter obtained by the “pulling-out primer type intaglio printing method” has a major feature that is not seen in other printing methods. As illustrated in the cross-sectional view of FIG. 6, the primer layer 8 and the conductor pattern layer 2. The thickness of the primer layer 8 in the formation part of the conductor pattern layer 2 is thicker than the thickness in the non-formation part of the conductor pattern layer 2. Note that the thickness of the non-formed part is grasped by the thickness at the non-formed part, that is, the central part of the opening 9, which is not affected by the thickness of the formed part. The first filter member 10 </ b> A illustrated in the figure has a configuration in which the conductor pattern layer 2 is formed on the transparent substrate 1 via the primer layer 8.

  The primer layer 8 is a transparent resin layer, and a thermoplastic resin, a curable resin, or the like can be used as the resin, and a thermosetting resin, an ionizing radiation curable resin, or the like can be used as the curable resin. An ionizing radiation curable resin that is hardened by ultraviolet irradiation or the like is preferred because of its rapid solidification.

[Peeling sheet]
Since the release sheet 3 may be opaque, it may be made of paper or an opaque resin sheet. However, the release sheet 3 is preferably transparent in terms of easy quality confirmation of the filter member, and in this respect, a transparent resin sheet is preferable. As the transparent resin sheet, the resin sheets listed on the transparent substrate can be used.
The release sheet 3 is temporarily bonded to the first filter member 10A until just before being bonded, and in the temporarily bonded state, it is easily peeled off in a roll state, when it is unwound and conveyed, or at half cut. It must be adhered with a weak adhesive strength that does not fall off. As such a release sheet 3, a sheet in which a weak pressure-sensitive adhesive layer having weak adhesive force is formed on the surface of the resin sheet can be used. Moreover, as a weak adhesive of a weak adhesive layer, well-known weak adhesives, such as an acrylic type and a silicone type, can be used, for example.

Here, if an example of the above moderate adhesive force is shown as an example, the first filter member 10AS with the release sheet is cut into a strip shape having a length of 30 cm in the transport direction and a width of 25 mm in the width direction perpendicular to the transport direction. Further, when the release sheet 3 is peeled off from the test piece at a peeling rate of 300 mm / min in accordance with the 180-degree peel test, the test piece is preferably 50 mN or more and 250 mN or less.
In addition, the said 180 degree | times peeling test is a test based on JISK6854-2 (Adhesive-peeling adhesive strength test method-2nd part: 180 degree peeling).
If the adhesive force is too weak, such as less than 50 mN, it will easily be peeled off unexpectedly when half-cut into a predetermined dimension on the manufacturing apparatus. On the other hand, if the adhesive force exceeds 250 mN and is too strong, it becomes difficult to smoothly peel the release sheet 3 by a peeling means such as the peeling plate 24. Accordingly, the weak adhesive strength is preferably an adhesive strength of 50 to 250 mN in the above test method.
Moreover, in the said peeling test, it is desirable for the expansion-contraction amount in the conveyance direction of the peeling sheet 3 after peeling to be less than +/- 2 mm. If the expansion / contraction amount is out of this range, the first filter member 10A including the plus (extension) side and the minus (contraction) side is supported by the release sheet 3 and cannot be stably conveyed. If it cannot be stably conveyed at a constant speed, it cannot be bonded at a constant speed, and unevenness is likely to occur in the adhesive layer 5.

  In addition, 1st filter member 10AS with release sheet illustrated in FIG. 1 is a form example in which 1st filter member 10A consists of the transparent base material 1 and the conductor pattern layer 2, and also the release sheet 3 is conductor. In this example, the pattern layer 2 was temporarily bonded to the pattern layer 2 side. However, the surface to which the release sheet 3 is temporarily bonded may be either the front or back surface of the first filter member 10A, or the surface on the transparent substrate 1 side.

[Second filter member]
The second filter member 10B is not particularly limited as long as it is a member having at least the filter layer 4 and the adhesive layer 5 for bonding. As the filter layer 4, various known filters having various filter functions can be appropriately employed.

  Further, it is not essential that the second filter member 10B is a continuous belt-like sheet like the first filter member 10A. The second filter member 10B may be a glass plate or a plastic plate in addition to the resin sheet as a single wafer. Therefore, when the second filter member 10B includes the transparent base material 1 as exemplified by the first filter member 10A, the transparent base material 1 is made of glass other than an organic material such as a resin sheet. Alternatively, an inorganic material such as ceramic, or a composite material in which an organic material and an inorganic material are laminated or mixed may be used. The transparent substrate 1 is a concept included in the filter layer 4 in the second filter member 10B.

[Filter layer]
The filter function of the filter layer 4 is typically an optical filter function. As an optical filter function, a known optical filter function, for example, a near-infrared absorption function that absorbs near infrared rays, an ultraviolet absorption function that absorbs ultraviolet rays, or neon that absorbs neon light of a PDP that provides a visual effect. A light absorption function, a specific light transmission function such as a color correction function for correcting a display image to a desired color tone, an antireflection function (antiglare, antireflection, antiglare and antireflection), and the like. As the optical filter function, one or more of these functions can be realized by a single layer or a multilayer structure.

In order to realize these various optical filter functions, for example, a near-infrared absorption function, a neon light absorption function, a color correction function, and the like are dyes corresponding to these functions (near-infrared absorption dyes, neon light absorption dyes, color correction dyes). ) And an ultraviolet absorbing function can be realized by a known material and method such as using an ultraviolet absorber. For example, it can be formed as a resin layer in which these materials are dispersed in a resin.
In addition, as one of the filter functions of the second filter member 10B, the conductor pattern layer, that is, an electromagnetic wave shielding function may be provided.

  Further, the filter layer 4 here originally means an optical filter function, but in the present invention, a functional layer other than the optical function is also included. For example, a surface protective layer that protects the surface of the conductor pattern layer 2 and the optical filter, a hard coat layer, an antistatic layer, a contamination preventive layer, an impact resistant layer, and the like.

<< C. Variations >>
The present invention can take the following modified forms other than those described above, for example.

When one of the filter members is an electromagnetic wave shielding filter member having the conductor pattern layer 2, the filter member can be used as the second filter member 10B (the formation of the ground exposed portion 2E is left for the time being). good.
Further, when a predetermined dimension between the first filter member 10A and the second filter member 10B has a magnitude relationship, which one should be increased may be determined according to the purpose. Although it is possible to bond the same predetermined dimensions, in the case of the electromagnetic wave shielding filter member, it is necessary to take out a grounding electrode.
In addition, the second filter member 10B is a single sheet in the embodiment. However, the second filter member 10B is prepared as a continuous belt-like sheet, and the continuous belt-like sheet unwound from the roll is cut on a bonding manufacturing apparatus to obtain a single-wafer sheet. After the cutting, the sheet may be placed on the transfer stage 26a by a robot as shown in FIG. In this case, since the first filter member 10 </ b> A and the second filter member 10 </ b> B can be formed in a single process continuously in-line on the same manufacturing apparatus as the bonding, each sheet forming process and the bonding process are performed. The total of 3 steps can be reduced to 1 step.
Thus, the manufacturing method by bonding according to the present invention may include other steps.
In addition, when it is not necessary to form the exposed portion 2E for grounding, the second filter member 10B can be bonded to the continuous belt-like sheet, and can be cut into sheets after bonding.
In addition, during the pasting, the position of the rotating pressing roller 25 is fixed in the above-described embodiment. However, the pasting object may be stopped and the pressing roller 25 may be moved along the pasting surface.

In the above embodiment (see FIG. 1), the second filter member 10B is transported by being placed on the transport stage 26a driven by the transport roller 26b. For example, in FIG. 1, the second filter member 10 </ b> B can be directly placed on the transport roller 26 b and transported.
In the embodiment (see FIG. 1), the first filter member 10A is half cut by the cutting blade 23 and the receiving roller 23a provided with the first filter member 10A interposed therebetween. For example, in FIG. 1, instead of the receiving roller 23a, a half-cut receiving plate having a flat plate shape or a curved plate shape having a width equal to or larger than the entire width of the first filter member 10A is used. The first filter member 10A in the vicinity of the portion is supported in a wide area, and the first filter member 10A has a first filter that extends in the sheet feeding direction before and after the cutting blade 23 on the side surface opposite to the receiving plate. Half-cut while preventing the first filter member 10A from floating, misaligned or wrinkling by pressing with a flat plate or curved plate holding plate having a width equal to or greater than the full width of the member 10A. Rukoto can also be.

<< D. Application >>
The optical filter 10 for display according to the present invention is a PDP used in a display unit of a television receiver manufacturing apparatus, measuring equipment and instruments, office equipment, medical equipment, computing equipment, telephones, electronic signage, amusement equipment, etc. It is suitable for a front filter of various image display manufacturing apparatuses such as CRT, LCD, and EL, and particularly suitable for a PDP. In addition, electromagnetic wave shielding applications and reflections in windows of buildings such as houses, schools, hospitals, offices, stores, vehicles, vehicles, aircraft, ships, etc., windows of various household appliances such as microwave ovens, etc. It can also be used for prevention applications, heat ray shielding applications, ultraviolet ray shielding applications, light shielding applications, and the like.

DESCRIPTION OF SYMBOLS 1 Transparent base material 2 Conductor pattern layer 2E Ground exposed part 3 Release sheet 4 Filter layer 4a Antireflection filter 4b Contrast improvement filter 5 Adhesive layer 6 Adhesive layer 7 Separator film 8 Primer layer 9 Opening 10 Optical filter for display DESCRIPTION OF SYMBOLS 10A 1st filter member 10AS 1st filter member with a peeling sheet 10B 2nd filter member 21 (Unwinding) roll 22 (Winding) roll 23 Cutting blade for half cut processing 23a Receiving roller for half cut processing 24 Peeling plate (peeling means)
25 Pressure roller 26a Conveying stage (conveying means)
26b Conveying roller (conveying means)
Tr Substantive total thickness captured only by the solid portion Tt Total thickness captured including the void portion

Claims (2)

In the manufacturing method by bonding the optical filter for display, the optical filter for display is manufactured by bonding two filter members,
(A1) The first filter member is a continuous belt-like sheet, and is prepared as a first filter member with a release sheet in which a release sheet that is a continuous belt-like sheet is temporarily bonded to the bonding surface.
(A2) The second filter member is a sheet or continuous belt-like sheet, and is prepared as a member having an adhesive layer on the bonding surface of the filter layer,
(B) The first filter member with release sheet is half-cut in the course of unwinding and transporting the first filter member with the release sheet, the release sheet leaves all or part of its thickness, and the first filter member Cuts the entire thickness and turns it into a predetermined size corresponding to one display screen,
(C) Next, only the release sheet is peeled off from the first filter member with the release sheet, and then folded and conveyed.
(D) On the other hand, the separated first filter member is transported while being separated from the release sheet and the downstream side of the tip portion while the upstream side is supported by the release sheet in the state before separation, By sequentially pressing the filter member 1 with a pressure roller to a predetermined position of the second filter member so that the bonding surface faces the adhesive layer surface of the second filter member,
Bonding the first filter member and the second filter member to produce an optical filter for display that can be used for each display screen;
(E) At least the operations (b), (c), and (d) are performed on the same manufacturing apparatus.
Manufacturing method by bonding optical filter for display. The first filter member in (a1) is an electromagnetic wave shielding filter member including at least a transparent substrate and a conductor pattern layer formed on the transparent substrate,
The second filter member in the above (a2) is an optical filter member including at least an adhesive layer and a filter layer having one or more optical filter functions other than the electromagnetic wave shielding function,
The predetermined dimension when the first filter member in (b) is cut into single sheets by half-cut processing is increased in the transport direction with respect to the predetermined dimension of the second filter member,
The width of the first filter member when pasting in (d) is made larger than the width of the second filter member, and the second filter member is laminated around the entire four sides of the first filter member. Create an optical filter for display that can be used for each display screen, with no ground exposed part formed,
The manufacturing method by bonding of the optical filter for displays of Claim 1.

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