TW201805656A - Optical film set and production method therefor - Google Patents

Abstract

The purpose of the present invention is to provide an optical film set that enables preferable production of optical display panels of the same configuration even when a roll-to-panel method and a sheet-to-panel method are concurrently used when attaching a thin optically functional film to an optical cell. The present invention pertains to an optical film set having a rolled optical film and a sheet-like optical film, wherein: the rolled optical film is obtained by stacking a release film, a pressure-sensitive adhesive layer, an optically functional film, and a first surface protection film in this order; and the sheet-like optical film is obtained by stacking a release film, a pressure-sensitive adhesive film, an optically functional film, a first surface protection film, and a second surface protection film in this order.

Description

Optical film group and manufacturing method thereof

The present invention relates to an optical film group having a roll-shaped optical film and a monolithic optical film, and a method for manufacturing the same.

The method of bonding an optical film to an optical unit includes: sequentially laminating an optical film having a release film, an adhesive layer, an optical function film (a polarizing film as a representative), and a surface protection film in a roll shape. The optical film sent out from the roll-shaped optical film was cut in a width direction (half-cut) with the adhesive layer, the optical function film, and the surface protection film remaining under the release film, and the release film was cut from The obtained optical film is peeled off, and the optical film is bonded to an optical unit (hereinafter also referred to as a "roll-to-panel method") via the exposed adhesive layer (for example, refer to Patent Documents 1 and 2).

On the other hand, an optical film bonding method different from the roll-to-panel method has the following method: an optical film formed in advance in a single sheet state is bonded to an optical unit through an adhesive layer exposed through a release film peeled off ( Hereinafter, it is also referred to as "sheet-to-panel method" (for example, refer to Patent Document 3).

Prior Technical Documents Patent Documents Patent Document 1: Japanese Patent Laid-Open No. 2011-123208 Patent Document 2: Japanese Patent Laid-Open No. 2015-049115 Patent Document 3: Japanese Patent Laid-Open No. 2006-039238

Problems to be Solved by the Invention However, at the manufacturing site of an optical display panel including a liquid crystal display panel, a newly emerged situation is to manufacture an optical display panel of the same structure using not only a roll-to-panel method but also a sheet-to-panel method. For example, Patent Document 2 discloses that an optical display panel is continuously manufactured using a roll-to-panel method, and an optical display panel determined to be defective is subjected to heavy processing. In the case where defective products do not occur so often, it is conceivable to use a sheet-to-panel method when a new optical functional film is bonded to the optical unit in the heavy processing. For another example, when it is necessary to mass-produce optical display panels with the same structure in a short time, it is also conceivable that the sheet-to-panel method will be used together when the roll-to-panel method cannot supply the entire supply.

In recent years, with the development of thinning of optical display panels, the development of thinner optical functional films (for example, polarizing films having a thickness of 60 μm or less) has been continuously developed, including polarizing films. Such thin optical functional films have low toughness (elastic modulus) and are prone to distortion and warpage.

According to the roll-to-panel method, the thin optical functional film is transported to a laminating position in a state of being laminated on a carrier film (release film), and the optical functional film is removed from the carrier film (releasing type) at the laminating position. The film is peeled off, and then the optical functional film is bonded to the optical unit. Therefore, the thin optical functional film can be continuously bonded to the optical unit while suppressing the occurrence of distortion, warping, and the like. However, in the sheet-to-panel method, it is not easy to handle the transportation of the optically functional film in a single sheet state, the release of the release film, and the bonding process of the optically functional film to the liquid crystal cell. Worry of depression.

An object of the present invention is to provide an optical film group and a method for manufacturing the same. When a thin optical functional film is bonded to an optical unit, even if a roll-to-panel method and a sheet-to-panel method are used together, the same structure Optical display panel.

Means for Solving the Problems The present invention is an optical film group including a roll-shaped optical film and a single-piece optical film, and the roll-shaped optical film is a laminated film with a release film, an adhesive layer, an optical function film, and a first film. In the structure of the surface protection film, the single-sheet optical film has a structure in which the release film, the adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are sequentially laminated.

In the above invention, the second surface protection film may be the same surface protection film as the first surface protection film, or may be a surface protection film different from the first surface protection film.

In the above invention, the interlayer peeling force between the first surface protective film and the optical function film may be greater than the interlayer peeling force between the second surface protective film and the first surface protective film.

According to the relationship of the peeling force, the second surface protective film can be peeled off relatively smoothly.

In the above invention, the optical function film may be a polarizing film.

In the above invention, the thickness of the polarizing film may be 60 μm or less.

In the above invention, the polarizing film may have a structure having a polarizer having a thickness of 10 μm or less.

In the above invention, the first surface protection film may include a first base film and a first adhesive layer, and may be laminated on the optical function film through the first adhesive layer.

In the above invention, the first surface protection film may be a self-adhesive film.

In the above invention, the second surface protective film may include a second base film and a second adhesive layer, and may be laminated on the first surface protective film through the second adhesive layer.

In the above invention, the second surface protection film may be a self-adhesive film.

The above invention may have the following structure: the roll-shaped optical film has a width corresponding to a set of opposite sides of the optical unit; a set of opposite sides of the single-sheet optical film has a length corresponding to the set of opposite sides of the optical unit , And the other set of opposite sides has a length corresponding to the other set of opposite sides of the optical unit.

In the above invention, the roll-shaped optical film and the single-plate optical film may be used for manufacturing an optical display panel, and the optical display panel is a laminated layer of the adhesive layer, the optical function film, and The structure of the first surface protection film.

In the above invention, the roll-shaped optical film may be used for manufacturing the optical display panel in a roll-to-panel manner; the single-sheet optical film may be used for manufacturing the optical display panel in a sheet-to-panel manner.

In the above invention, the single-sheet optical film may be used to remanufacture an optical display panel having a structure in which the optical display panel manufactured by using the roll-shaped optical film in the roll-to-panel method is judged to be defective and After peeling the adhesive layer, the optical functional film, and the first surface protective film, an adhesive layer, an optical functional film, and a first surface protective film are sequentially laminated on one side of the optical unit of the optical display panel.

The "roll-to-panel method" is a method of peeling a release film from an optical film output from a rolled optical film, and bonding the optical film to an optical unit through an exposed adhesive layer. Here, until the release film is peeled off, the optical film may be formed with slits having a predetermined interval under the release film in its width direction. In addition, the optical film may have a slit in its width direction before being output from the roll, or a slit in its width direction after being output and before the release film is peeled.

The "sheet-to-panel method" is a method of peeling a release film from an optical film made in a single piece in advance, and bonding the optical film to an optical unit through an exposed adhesive.

Another invention is a method for manufacturing the aforementioned optical film group. The method for manufacturing the rolled optical film includes the following steps: a step of preparing an optical film blank, the optical film blank is sequentially laminated with the aforementioned release film, the aforementioned adhesive The structure of the agent layer, the optical function film and the first surface protective film, and the step of manufacturing the roll-shaped optical film are steps of slitting and winding the optical film blank to manufacture the roll-shaped optical film; The manufacturing method of a single-sheet optical film includes the following steps: The step of manufacturing an optical film blank is based on bonding the second surface protective film blank to the first surface protective film side of the aforementioned optical film blank, and manufacturing a laminated layer. The optical film blank of the second surface protection film and the step of manufacturing a single-piece optical film are obtained by cutting the optical film blank having the second surface protection film laminated thereon to produce a single-sheet optical film.

In the above invention, "cutting processing" is not limited as long as the optical film blank is processed into a single sheet optical film through a cutting process, and it means the following processing: cutting into a single sheet; cutting into After the single sheet is processed, the end surface is processed; the optical film blank is slit into a predetermined width and then cut in the width direction (but the end surface is not processed).

Another invention is a two-sided optical film group having a first optical film group and a second optical film group, wherein the first optical film group has a roll-shaped first optical film and a single-piece first optical film, and the roll-shaped The first optical film has a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated. The monolithic first optical film is sequentially laminated with the first 1 release film, the first adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film; the second optical film group includes a rolled second optical film and a single sheet The second optical film, the roll-shaped second optical film has a structure in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are sequentially laminated, and the single-piece second The optical film has a structure in which the second release film, the second adhesive layer, the second optical function film, the third surface protection film, and the fourth surface protection film are sequentially laminated.

In the above invention, the roll-shaped first optical film and the monolithic first optical film, and the roll-shaped second optical film and the monolithic second optical film can also be used to manufacture an optical display panel having the following structure: The first adhesive layer, the first optical function film, and the first surface protection film are sequentially laminated on one side of the optical unit, and the second adhesive layer, the first 2 optical function film and the third surface protection film.

In the above invention, the first optical function film and the second optical function film may be objects having the same optical function, or may be objects having other optical functions.

In the manufacturing method of the optical film set on both sides, the manufacturing method of the roll-shaped first optical film may include the following steps: a step of preparing a first optical film blank, which is sequentially laminated with the first release The structure of the film, the first adhesive layer, the first optical function film, and the first surface protective film, and the step of manufacturing the roll-shaped first optical film are steps of processing the first optical film blank. And winding to manufacture the first rolled optical film; the method for manufacturing the single sheet of the first optical film may include the following steps: a step of manufacturing a second optical film blank, which is based on the first optical film blank The steps of laminating the second surface protection film blank on the first surface protection film side, manufacturing the second optical film blank on which the second surface protection film is laminated, and manufacturing the monolithic first optical film are steps for the foregoing. The second optical film blank having the second surface protective film laminated thereon is cut to produce a single sheet of the first optical film; the method for manufacturing the rolled second optical film may include the following steps: preparing a second light A step of a film blank having a structure in which the aforementioned second release film, the aforementioned second adhesive layer, the aforementioned second optical function film, and the third surface protective film are sequentially laminated, and the aforementioned rolled second The steps of the optical film are performed by slitting and winding the second optical film blank to produce the rolled second optical film. The method for manufacturing the single-piece second optical film may include the following steps: Manufacturing The fourth optical film blank is a step of laminating a fourth surface protective film blank on the third surface protective film side of the second optical film blank and manufacturing a fourth optical film laminated with a fourth surface protective film. The blank material and the step of manufacturing a single sheet of the second optical film are performed by cutting the fourth optical film blank having the fourth surface protective film laminated thereon to produce the single sheet of the second optical film.

In the above invention, when a polarizing film is used as the optical function film (the first optical function film, the second optical function film), or when a polarizing film is included as a component of the optical function film structure, In the optical film (first optical film, second optical film) and the optical film blank (first optical film blank, second optical film blank), the direction of the absorption axis of the polarizing film will not be wrong. The achievement of the object of the present invention is hindered, that is, there is no particular limitation. In other words, even if the roll-to-panel method and the sheet-to-panel method are used together, as long as it is a combination capable of manufacturing an optical display panel having the same structure, a roll-shaped optical film (first optical film, second optical film) and an optical film blank (The first optical film blank and the second optical film blank), the direction of the absorption axis of the polarizing film may be parallel to the length direction, may be orthogonal to it, or may be oblique (for example, at an angle of 45 ° to the length direction) Direction). In addition, the absorption axis direction of the rectangular monolithic polarizing film may be parallel to the longitudinal direction, may be orthogonal, and may be oblique (for example, a direction at an angle of 45 ° to the longitudinal direction). In addition, the absorption axis direction of the square monolithic polarizing film may be parallel to any side, and may be inclined (for example, a direction at an angle of 45 ° to one side).

In the present invention, the roll-shaped optical film can hold the adhesive layer, the optical function film, and the surface protective film in a direction orthogonal to the length direction of the optical film (width direction) under the retained release film to correspond to the other of the optical unit. The space between the opposite sides of the group forms a slit. According to this structure, it is not necessary to cut (half cut) the optical film in the roll-to-panel method.

In the above invention, the optical unit may be a VA-type or IPS-type liquid crystal cell or an organic EL unit.

The shape of the optical unit may be a shape having one set of opposite sides and another set of opposite sides, and may be a square or a rectangle, which is not particularly limited. In addition, in general, one set of opposite sides of the optical unit and the other set of opposite sides are orthogonal to each other.

Effects of the Invention The optical film assembly of the present invention is used for manufacturing an optical display panel having the same structure. The roll-shaped optical film can be used in a roll-to-panel manner. The single-sheet optical film can be used in a sheet-to-panel manner. The single-layer optical film may have the same laminated structure as the roll-shaped optical film except that the second surface protective film is provided. The roll-shaped optical film is used for manufacturing an optical display panel by a roll-to-panel method, and the structure of the optical display panel is that an adhesive layer, an optical function film, and a first surface protection film are sequentially laminated on one side of the optical unit. In addition, since the single-sheet optical film provided with the second surface protection film has improved operability, it can suppress the occurrence of distortion, warping, and the like, and can be suitably bonded to the optical unit using a sheet-to-panel method. In addition, by removing (for example, peeling off) the second surface protection film from the single-sheet optical film attached to the optical display panel, it is possible to manufacture an optical display panel having the same laminated structure as the roll-to-panel optical display panel. Optical display panel. That is, according to the optical film group of the present invention, when the optical film is bonded to the optical unit, even when the roll-to-panel method and the sheet-to-panel method are used together, an optical display panel having the same structure can be appropriately manufactured. .

(Embodiment 1: Optical film group) FIG. 1 is a schematic diagram showing an optical film group. The upper side of FIG. 1 shows an enlarged cross-sectional view of a side surface, a plane, and a portion of the rolled first optical film 1. The lower part of FIG. 1 is an enlarged cross-sectional view of a side surface, a plane, and a part of the first sheet of the first optical film 2. The roll-shaped first optical film 1 is sequentially laminated with a first release film 11, a first adhesive layer 12, a first optical function film 13, and a first surface protection film 14.

The roll-shaped first optical film 1 is used for manufacturing an optical display panel by a roll-to-panel method. In this case, the strip-shaped first optical film 10 having a width a which has been output from the roll-shaped first optical film 1 is cut by the cutting means C at a predetermined interval b while retaining the release film 11. The symbol s is a slit formed in the first optical film 30 by the cutting.

In addition, the single-piece first optical film 2 includes a first release film 21, a first adhesive layer 22, a first optical function film 23, a first surface protection film 24, and a second surface protection film 25, which are sequentially laminated. The dimensions of the single-plate-shaped first optical film 2 are vertical a and horizontal b. The monolithic first optical film 2 is used for manufacturing an optical display panel by a sheet-to-panel method.

In this embodiment, the first release film 11 and the first release film 21 have the same structure. The first adhesive layer 12 has the same structure as the first adhesive layer 22. The first optical functional film 13 has the same structure as the first optical functional film 23. The first surface protection film 14 and the first surface protection film 24 have the same structure as the second surface protection film 25. The so-called "same structure" may be substantially the same (for example, the manufacturing quality is the same), and it is not necessarily the same that the materials and thicknesses are completely the same.

In this embodiment, the first surface protection film 14 (or 24) has a first base film and a first adhesive layer, and is laminated on the first optical function film 13 (or 23) through the first adhesive layer. In addition, in another embodiment, the first surface protection film 14 (or 24) may be a self-adhesive film.

In this embodiment, the second surface protection film 25 includes a second base film and a second adhesive layer, and is laminated on the first surface protection film 24 through the second adhesive layer. In addition, in another embodiment, the second surface protection film 25 may be a self-adhesive film.

(Relationship between Interlayer Peeling Forces) In terms of structure, the interlayer peeling force of the first surface protective film 24 and the first optical function film 23 is larger than the interlayer peeling force of the second surface protective film 25 and the first surface protective film 24. Thereby, the 2nd surface protection film 25 can be peeled relatively smoothly. The peeling force can be measured using a tensile tester, for example. In terms of peeling conditions, 0.3 m / min 180 ° peeling was used for measurement. The peeling force is controlled by the composition or thickness of the adhesive.

The magnitude relationship of the peeling force between the layers in the single-plate first optical film 2 is as follows. The interlayer peeling force A between the first release film 21 and the first adhesive layer 22, the interlayer peel force B between the first adhesive layer 22 and the first optical function film 23, the first optical function film 23, and the first surface When the interlayer peeling force C of the protective film 24 and the interlayer peeling force D of the first surface protective film 24 and the second surface protective film 25 are A <B, A <C, A <D. Preferably, A <D <C ≦ B, or A <D <B ≦ C. Preferably, A <D <C <B. Based on the relationship between the interlayer peeling forces, when the first release film is peeled off, peeling of the second surface protection film can be suppressed.

<Optical functional film> The first optical functional films 13, 23 are not particularly limited as long as they are optical films, and examples thereof include polarizing films, retardation films, brightness enhancement films, and diffusion films. Typical examples are polarizing films. .

(Polarizing Film) In this embodiment, it is preferable to use a polarizing film having a thickness (total thickness) of 60 μm or less, more preferably 55 μm or less, and 50 μm or less from the viewpoint of thinning. Examples of the polarizing film include: (1) a structure in which protective films (also referred to as "polarizer protective films") are laminated on both sides of the polarizer (also known as "double-sided protective polarizer films"); (2) only on one side of the polarizer The laminated structure has a protective film (also known as a "single-sided protective polarizing film").

(Polarizer) The polarizer is made of a polyvinyl alcohol resin. Examples of polarizers include adsorption of iodine or dichroic dyes on hydrophilic polymer films such as polyvinyl alcohol-based films, partially formalized polyvinyl alcohol-based films, and ethylene-vinyl acetate copolymer-based saponified films. Polychromatic materials with uniaxial elongation, and polyolefin-based alignment films such as dehydrated products of polyvinyl alcohol or dehydrochlorinated products of polyvinyl chloride. Among these, a polarizer made of a polyvinyl alcohol film and a dichroic material such as iodine is preferable.

For example, a polarizer made of a polyvinyl alcohol-based film dyed with iodine and then uniaxially stretched can be produced by, for example, immersing a polyvinyl alcohol film in an aqueous solution of iodine for dyeing, and then extending to 3 to 7 Times. It can also be immersed in an aqueous solution, such as boric acid or potassium iodide, which can contain zinc sulfate or zinc chloride, as needed. Further, if necessary, the polyvinyl alcohol-based film is immersed in water and washed with water before dyeing. By washing the polyvinyl alcohol-based film with water, dirt and anticaking agents on the surface of the polyvinyl alcohol-based film can be cleaned. In addition, the polyvinyl alcohol-based film can swell and prevent uneven dyeing and other effects. Stretching can be performed after dyeing with iodine, or it can be stretched while dyeing, or it can be dyed with iodine after stretching. It can also be extended in an aqueous solution such as boric acid or potassium iodide or in a water bath.

From the viewpoint of thinning, the thickness of the polarizer is preferably 10 μm or less, 8 μm or less, 7 μm or less, and 6 μm or less. On the other hand, the thickness of the polarizer is preferably 2 μm or more, and more preferably 3 μm or more. Such a thin polarizer has a small thickness variation, excellent visibility, and low dimensional change, so it has excellent durability against thermal shock. On the other hand, in a polarizing film containing a polarizer having a thickness of 10 μm or less, since the film toughness (elastic modulus) is significantly lowered, there is a high possibility of distortion or warpage in the sheet-to-panel method. Therefore, the polarizing film is particularly suitable in the present invention.

Representative examples of thin polarizers include Japanese Patent No. 4751486, Japanese Patent No. 4751481, Japanese Patent No. 4815544, Japanese Patent No. 5048120, and International Publication No. 2014/077599. The thin polarizer described in the manual No. 2014/077636 and the like, or the thin polarizer obtained by the manufacturing method described in them.

The aforementioned polarizer should be configured such that the optical characteristics represented by the single transmittance T and the polarization degree P satisfy the following formula: P>-(10 ^0.929T-42.4 -1) × 100 (but T <42.3), P ≧ 99.9 (but T ≧ 42.3). A polarizer configured to satisfy the aforementioned conditions will undoubtedly have the performance required for a liquid crystal television display using a large display element. Specifically, the contrast is 1000: 1 or more and the maximum luminance is 500cd / m2 or more. In other applications, for example, it can be attached to the viewing side of the organic EL unit.

As the aforementioned thin polarizer, in a manufacturing method including a step of stretching in a laminated body state and a dyeing step, in terms of being capable of being stretched at a high magnification and improving polarization performance, it is preferably, for example, Japanese Patent No. 4751486, Japanese Patent In particular, those obtained by a production method including an extension step in an aqueous boric acid solution as described in the specification No. 4751481 and Japanese Patent No. 4815544 are particularly suitable for inclusion in boric acid described in the specification No. 4751481 and Japanese Patent No. 4815544 Obtained by a method for performing an auxiliary aerial stretching step before stretching in an aqueous solution. These thin polarizers can be produced by a manufacturing method including the following steps: a step of stretching a polyvinyl alcohol-based resin (hereinafter also referred to as a PVA-based resin) layer and a resin substrate for stretching in a laminated state and dyeing A step of. According to this manufacturing method, even if the PVA-based resin layer is thin, it can be stretched to be supported by a resin base material, thereby being able to be stretched without causing problems such as breakage caused by stretching.

(Protective film (polarizer protective film)) The material constituting the protective film is preferably one having excellent transparency, mechanical strength, thermal stability, moisture blocking property, and isotropic property. Examples include polyester polymers such as polyethylene terephthalate and polyethylene naphthalate; cellulose polymers such as cellulose diacetate and cellulose triacetate; acrylic acid such as polymethyl methacrylate Polymers; styrene polymers such as polystyrene and acrylonitrile-styrene copolymer (AS resin); and polycarbonate polymers. In addition, the following polymers can be cited as examples of the polymer forming the protective film: polyethylene, polypropylene, polyolefins having a cyclic or even norbornene structure, and polyolefin-based polymerization such as an ethylene-propylene copolymer Polymers, vinyl chloride-based polymers, nylon-based polymers such as nylon and aromatic polyamines, fluorene-based polymers, fluorene-based polymers, polyether fluorene-based polymers, polyetheretherketone-based polymers, Polyphenylene sulfide-based polymer, vinyl alcohol-based polymer, vinylidene chloride-based polymer, ethylene butyral-based polymer, aryl ester-based polymer, polyoxymethylene-based polymer, epoxy-based polymer, or the above-mentioned polymerization Blends of substances.

In addition, the protective film may contain one or more of any appropriate additives. Examples of the additives include ultraviolet absorbers, antioxidants, lubricants, plasticizers, release agents, coloring inhibitors, flame retardants, nuclear agents, antistatic agents, pigments, and colorants. The content of the thermoplastic resin in the protective film is preferably 50 to 100% by weight, preferably 50 to 99% by weight, more preferably 60 to 98% by weight, and even more preferably 70 to 97% by weight. When the content of the thermoplastic resin in the transparent protective film is 50% by weight or less, there is a possibility that the thermoplastic resin cannot sufficiently exhibit the originally high transparency and the like.

The protective film may be a retardation film, a brightness enhancement film, a diffusion film, or the like.

The protective film may be provided with a functional layer such as a hard coating layer, an anti-reflection layer, an anti-adhesion layer, a diffusion layer, and an anti-glare layer on the side of the protective film not adjoining the polarizer. In addition, the functional layers such as the hard coat layer, the anti-reflection layer, the anti-adhesion layer, the diffusion layer, and the anti-glare layer may be provided in addition to the transparent protective film itself, or may be separated from the transparent protective film and formed as other individuals.

(Intermediary layer) The protective film and the polarizer are laminated via an intermediary layer such as an adhesive layer, an adhesive layer, and an undercoat layer (primer layer). At this time, it is desirable to use an interposer to laminate the two without an air gap. The adhesive layer is formed of an adhesive. The type of the adhesive is not particularly limited, and various types can be used. The above-mentioned adhesive layer is not particularly limited as long as it is optically transparent, and various forms such as water-based, solvent-based, hot-melt adhesive, and active energy ray-curable types can be used as the adhesive, but the water-based adhesive is ideal. Agent or active energy ray hardening type adhesive. Examples of the water-based adhesive include isocyanate-based adhesives, polyvinyl alcohol-based adhesives, gelatin-based adhesives, vinyl-based latex-based adhesives, and water-based polyesters. The water-based adhesive is usually used as an adhesive composed of an aqueous solution, and usually contains 0.5 to 60% by weight of a solid content. The active energy ray-curable adhesive is an adhesive that cures with active energy rays such as an electron beam and ultraviolet (radical-curable, cation-curable). For example, an electron beam-curable and ultraviolet-curable adhesive can be used. As the active energy ray-curable adhesive, for example, a photoradical-curable adhesive can be used. When a photoradical-curable active energy ray-curable adhesive is used as an ultraviolet-curable, the adhesive contains a radical polymerizable compound and a photopolymerization initiator.

In addition, when the polarizer and the protective film are laminated, an easy-adhesion layer may be provided between the transparent protective film and the adhesive layer. The easy-adhesion layer can be formed by using various resins having, for example, a polyester skeleton, a polyether skeleton, a polycarbonate skeleton, a polyurethane skeleton, a polysiloxane, a polyamide skeleton, and a polyimide. Skeleton, polyvinyl alcohol skeleton, etc. These polymer resins can be used singly or in combination of two or more kinds. In addition, other additives may be added in the formation of the easy-adhesion layer. Specifically, stabilizers such as an adhesion-imparting agent, an ultraviolet absorber, an antioxidant, and a heat-resistant stabilizer can be further used.

The adhesive layer is formed of an adhesive. For the adhesive, various adhesives can be used, and examples thereof include rubber-based adhesives, acrylic-based adhesives, siloxane-based adhesives, urethane-based adhesives, vinyl alkyl ether-based adhesives, and polyvinylpyrrole. Pyridone-based adhesives, polypropylene amidamine-based adhesives, cellulose-based adhesives, and the like. The adhesive base polymer can be selected according to the type of the aforementioned adhesive. Among the above-mentioned adhesives, an acrylic adhesive is preferably used because it has excellent optical transparency, exhibits adhesive properties such as appropriate wettability, cohesiveness, and adhesiveness, and is excellent in weather resistance and heat resistance.

The undercoat layer (primer layer) is formed to improve the adhesion between the polarizer and the protective film. The material constituting the primer layer is not particularly limited as long as it exhibits a certain degree of strong adhesion to both the base film and the polyvinyl alcohol-based resin layer. For example, a thermoplastic resin excellent in transparency, thermal stability, elongation, and the like can be used. Examples of the thermoplastic resin include acrylic resins, polyolefin resins, polyester resins, polyvinyl alcohol resins, and mixtures thereof.

(Surface protection film) The first and second surface protection films are provided on one side of the polarizing film (the surface on which the adhesive layer is not laminated) in the optical film to protect optical functional films such as the polarizing film. As the base film of the first and second surface protection films, from the viewpoints of inspection and management, etc., a film material having an isotropic or nearly isotropic property is selected. Examples of the film material include polyester resins such as polyethylene terephthalate films, cellulose resins, acetate resins, polyether fluorene resins, polycarbonate resins, polyamide resins, Polyimide-based resin, polyolefin-based resin, and acrylic-based transparent polymer. Among them, polyester resins are preferred. The base film may be a laminate of one or more film materials, and an extension of the film may also be used. The thickness of the base film is preferably 10 μm to 150 μm, and more preferably 20 to 100 μm.

In addition to the first and second surface protection films, in addition to using the base film as a self-adhesive film, those having the base film and an adhesive layer can also be used. From the viewpoint of protecting optical functional films such as polarizing films, those having an adhesive layer are preferably used as the first and second surface protective films.

The adhesive layer for laminating the first and second surface protection films can be appropriately selected and used, for example, from a (meth) acrylic polymer, a silicone polymer, a polyester, or a polyurethane. Polymers such as esters, polyamides, polyethers, fluorine-based and rubber-based polymers are used as adhesives for the base polymer. From the viewpoints of transparency, weather resistance, heat resistance, and the like, an acrylic adhesive having an acrylic polymer as a base polymer is preferred. The thickness of the adhesive layer (dry film thickness) is determined by the required adhesive force. It is usually about 1 to 100 μm, and preferably 5 to 50 μm.

In addition, the first and second surface protection films may be provided on the opposite side of the surface on which the adhesive layer is provided, with a release treatment layer using a low-adhesion material such as polysiloxane treatment, long-chain alkyl treatment, or fluorine treatment.

<Adhesive Layer> An appropriate adhesive can be used for the formation of the first adhesive layers 12 and 22, and the type is not particularly limited. Examples of the adhesive include a rubber-based adhesive, an acrylic-based adhesive, a polysiloxane-based adhesive, a urethane-based adhesive, a vinyl alkyl ether-based adhesive, a polyvinyl alcohol-based adhesive, and a polymer. Vinyl pyrrolidone-based adhesives, polypropylene amidamine-based adhesives, cellulose-based adhesives, and the like.

Among these adhesives, those which are excellent in optical transparency, exhibit proper adhesion properties such as wettability, cohesiveness, and adhesiveness, and are excellent in weather resistance and heat resistance are also suitable. As those exhibiting these characteristics, an acrylic adhesive is preferably used.

The first method for forming the adhesive layers 12 and 22 can be produced, for example, by the following method: applying the aforementioned adhesive to a release film (separator, etc.) subjected to a peeling treatment, and drying and removing a polymerization solvent, etc. After forming the adhesive layer, the method is transferred to a polarizer (or a transparent protective film); or the aforementioned adhesive is applied to the polarizer (or a transparent protective film), and the polymerization solvent is dried and removed to form an adhesive on the polarizer Layer methods, etc. In addition, when the adhesive is applied, one or more solvents other than the polymerization solvent may be appropriately added.

A silicone release liner should be used as the release film after the release treatment. In the step of applying the adhesive of the present invention to such a lining material and drying it to form an adhesive layer, a suitable and appropriate method may be adopted as a method of drying the adhesive according to the purpose. It is preferable to use a method of drying the coating film by heat. The heating and drying temperature is preferably 40 ° C to 200 ° C, more preferably 50 ° C to 180 ° C, and even more preferably 70 ° C to 170 ° C. By setting the heating temperature to the above range, an adhesive having excellent adhesive properties can be obtained.

The appropriate drying time can be used as the drying time. The drying time is preferably 5 seconds to 20 minutes, more preferably 5 seconds to 10 minutes, and even more preferably 10 seconds to 5 minutes.

Various methods can be used for forming the first adhesive layers 12 and 22. Specifically, for example, a roll coating method, a contact sizing roller coating method, a gravure coating method, a reverse coating method, a roll brush method, a spray coating method, a dip roll coating method, a bar coating method, a knife coating method, a gas coating method, etc. A knife coating method, a curtain coating method, a lip mold coating method, an extrusion coating method using a mold coater, and the like.

The thickness of the first adhesive layers 12 and 22 is not particularly limited, and is, for example, about 1 to 100 μm. It is preferably 2 to 50 μm, preferably 2 to 40 μm, and more preferably 5 to 35 μm.

<Release Film> The first release film 11, 21 is a protective adhesive layer until it is actually used. The constituent materials of the release film include, for example, plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and non-woven cloth, meshes, foamed sheets, and metals. A suitable monolithic body, such as a foil or a laminated body thereof, is preferably a plastic film from the viewpoint of excellent surface smoothness.

The plastic film is not particularly limited as long as it is a film capable of protecting the aforementioned adhesive layer, and examples thereof include polyethylene films, polypropylene films, polybutene films, polybutadiene films, polymethylpentene films, and polymer films. Vinyl chloride film, vinyl chloride copolymer film, polyethylene terephthalate film, polybutylene terephthalate film, polyurethane film, ethylene-vinyl acetate copolymer film, and the like.

The thickness of the first release films 11 and 21 is usually about 5 to 200 μm, and preferably about 5 to 100 μm. If necessary, release and antifouling treatments using polysiloxane-based, fluorine-based, long-chain alkyl-based or fatty acid ammonium-based release agents, silica powder, etc., as well as coating and kneading types , Anti-static treatment such as evaporation type. In particular, by appropriately applying a peeling treatment such as a siloxane treatment, a long-chain alkyl treatment, or a fluorine treatment to the surface of the release film, the peelability from the adhesive layer can be further improved.

(Embodiment 2: Both-side optical film group) The both-side optical film group of Embodiment 2 consists of a 1st optical film group and a 2nd optical film group. Since the first optical film group is the same as the first optical film group of the first embodiment, description thereof is omitted. The second optical film group will be described with reference to FIG. 2. The second optical film group includes a rolled second optical film 3 and a single-piece second optical film 4.

The upper side of FIG. 2 is an enlarged view of a side surface, a plane, and a partial cross section of the rolled second optical film 3. The lower part of FIG. 2 shows an enlarged sectional view of a side surface, a plane, and a part of the single-piece second optical film 4. The roll-shaped second optical film 3 is sequentially laminated with a second release film 31, a second adhesive layer 32, a second optical function film 33, and a third surface protection film 34. The strip-shaped optical film 30 having the width b which has been output from the rolled second optical film 3 is cut by the cutting means C at a predetermined interval a while retaining the second release film 31. The symbol s is a slit formed by the above-mentioned cutting of the optical film 30.

In addition, the single-piece second optical film 4 is sequentially laminated with a second release film 41, a second adhesive layer 42, a second optical function film 43, a third surface protection film 44, and a fourth surface protection film 45. The dimensions of the single-piece second optical film 4 are horizontal a and vertical b.

In this embodiment, the second release film 31 and the second release film 41 have the same structure. The second adhesive layer 32 and the second adhesive layer 42 have the same structure. The second optical function film 33 has the same structure as the second optical function film 43. The third surface protection film 34 and the third surface protection film 44 have the same structure as the fourth surface protection film 45. The so-called "same structure" should be substantially the same (for example, the manufacturing quality is the same), and not only the material and thickness are completely the same.

In this embodiment, the third surface protection film 34 (or 44) has a third base film and a third adhesive layer, and is laminated on the second optical function film 33 (or 43) through the third adhesive layer. In addition, in another embodiment, the third surface protection film 34 (or 44) may be a self-adhesive film.

In this embodiment, the fourth surface protective film 45 includes a fourth base film and a fourth adhesive layer, and is laminated on the third surface protective film 34 through the fourth adhesive layer. In addition, in another embodiment, the fourth surface protection film 45 may be a self-adhesive film.

(Relationship of Interlayer Peeling Forces) Also, the interlayer peeling force of the third surface protective film 34 and the second optical function film 33 is structurally greater than the interlayer peeling force of the fourth surface protective film 45 and the third surface protective film 44. Thereby, the 4th surface protection film 45 can be peeled relatively smoothly.

The magnitude relationship of the peeling force between the layers in the single-piece second optical film 4 is as follows. The interlayer peeling force A1 between the second release film 41 and the second adhesive layer 42 is set as the interlayer peeling force B1 between the second adhesive layer 42 and the second optical function film 43, the second optical function film 43 and the third surface When the interlayer peeling force C1 of the protective film 44 and the interlayer peeling force D1 of the third surface protective film 44 and the fourth surface protective film 45 are A1 <B1, A1 <C1, A <D1. And it should be A1 <D1 <C1 ≦ B1, or A1 <D1 <B1 ≦ C1. Preferably, A1 <D1 <C1 <B1. According to the relationship between the interlayer peeling forces, when the second release film is peeled off, peeling of the fourth surface protection film can be suppressed.

In the second optical film group, each member constituting the rolled second optical film and the single-piece second optical film may be the same as the optical function film, the release film, the adhesive layer, and the surface protective film described in Embodiment 1. Structure.

(Embodiment 3: Production of an optical film group) Next, the manufacturing method of a 1st optical film group and a 2nd optical film group is demonstrated. FIG. 3A is a schematic view showing a method for manufacturing the first optical film 1 in a roll form. FIG. 3B is a schematic view showing a method for manufacturing the single-piece first optical film 2.

In FIG. 3A, a roll-shaped first optical film blank 5 is prepared, which has a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated. Next, the first optical film is output from the first optical film blank 5 and is slit into three strip-shaped optical films with a predetermined width a using the slit cutting section sc. Each of the three strip-shaped optical films subjected to the slit processing is wound to produce a rolled first optical film.

Although the present embodiment is divided into three strip-shaped optical films, it is not limited thereto. In this embodiment, both ends e1 and e2 are trimmed (edge trimmed). However, trimming may be performed at either end, and both ends may be trimmed.

In FIG. 3B, the first surface protective film 14 side of the roll-shaped first optical film 1 (corresponding to the first optical film blank) is bonded from the second surface by a bonding means (a pair of bonding rollers R1 and R2). The second surface protective film 25 output from the protective film blank S25 is manufactured as an optical film blank S2 in which the second surface protective film 25 is laminated. Next, the optical film blank S2 on which the second surface protection film 25 is laminated is completely cut at a predetermined interval b using the cutting means FC to produce a single-piece first optical film 2. The single-piece first optical film 2 may be stored in a predetermined storage portion, or may be laminated on a carrier film. The first optical film group can be manufactured by the above method.

In another embodiment, a step of winding the optical film blank S2 and a strip-shaped first optical film output from the optical film blank S2 may be performed, and the cutting process may be performed at a predetermined interval b using the cutting means FC.

The second optical film group can be manufactured by the same steps as those in FIGS. 3A and 3B.

Furthermore, in another embodiment, the method may further include the step of cutting (half-cutting) the adhesive layer 12 at a predetermined interval and retaining the first optical function under a strip-shaped first release film 11 after the slitting process. The film and the first surface protection film are formed with a plurality of slits.

(Liquid crystal cell, liquid crystal display panel) The liquid crystal cell has a structure in which a liquid crystal layer is sealed between a pair of substrates (a first substrate (viewing side) Pa and a second substrate (back side) Pb) arranged opposite to each other. Any type of liquid crystal cell can be used, but in order to achieve high contrast, a liquid crystal cell in vertical alignment (VA) mode and in-plane switching (IPS) mode should be used. The liquid crystal display panel is a thing with a polarizing film laminated on one or both sides of the liquid crystal cell, and a driving circuit is installed as needed.

(Organic EL Unit, Organic EL Display Panel) The organic EL unit has a structure in which an electric field light-emitting layer is sandwiched between a pair of electrodes. As the organic EL unit, any type such as a top emission type, a bottom emission type, and a dual emission type can be used. The organic EL display panel is a thing in which a polarizing film is laminated on one or both sides of an organic EL unit, and a driving circuit is installed as needed.

(Embodiment 4: Remanufacturing using the first optical film group) FIG. 4 is a schematic diagram of a continuous manufacturing system for an optical display panel. In this embodiment, the roll-shaped first optical film 1 is used for manufacturing an optical display panel by a roll-to-panel method. The monolithic first optical film 2 is used to remanufacture an optical display panel having a structure in which an optical display panel manufactured using the roll-shaped first optical film 1 is judged to be defective and the first adhesive layer is peeled off. 1. An optical display panel having a first optical function film and a first surface protection film, wherein a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated on one side of an optical unit. Specifically, the first adhesive layer 22, the first optical function film 23, and the first surface protective film 24 are peeled off from the optical unit, and the panel method is used for laminating the sheet, that is, from the single-piece first optical The film 2 peels off the first release film 21 and sequentially bonds the first adhesive layer 22, the first optical function film 23, the first surface protection film 24, and the second surface protection film 25, and then the second surface protection film 25 Peel off. In this embodiment, an example in which a liquid crystal cell is an optical unit and an example in which a liquid crystal display panel is an optical display panel will be described.

The roll-shaped first optical film 1 is sequentially laminated with a first release film 11, a first adhesive layer 12, a first optical function film 13, and a first surface protection film 14. As shown in FIG. 1, the rolled first optical film 1 has a width a and has a width corresponding to the long side of the liquid crystal panel (a width substantially shorter than the long side of the liquid crystal cell P).

As shown in FIG. 4, the manufacturing system of the liquid crystal display panel of this embodiment includes: a first transporting unit 81 that transports the liquid crystal cell P to the first attaching unit 64; and a second transporting unit 82 that transports the used roll shape. The first optical film 1 is a liquid crystal cell P having an optical film attached to a first surface P1 of the liquid crystal cell P. Each conveying unit is configured to have a plurality of conveying rollers R for conveying the liquid crystal cell P by rotating around a rotation axis. The rotation axis is parallel to the orthogonal direction of the conveying direction. Moreover, in addition to a conveyance roller, you may have an adsorption | suction plate etc. by forming a group.

(Liquid crystal cell transporting step) The liquid crystal cell P is arranged from the storage portion 91 that stores the liquid crystal cell P to the first transporting portion 81 with the first surface P1 as the top surface, and the first attaching portion 64 is rotated by the rotation of the transporting roller R. delivery.

(First optical film output step, first optical film cutting step) The strip-shaped first optical film 10 output from the roll-shaped first optical film 1 is cut while adsorbing and fixing the first release film 11 side. The slit portion s is formed, and the cutting is performed without leaving the first release film 11, and the strip-shaped adhesive layer 12, the strip-shaped first optical function film 13, and the strip-shaped first The surface protection film 14 is cut into a predetermined size (corresponding to the length of the short side of the liquid crystal cell P (the substantially shorter length of the shorter side)). Examples of the cutting by the cutting unit 61 include cutting using a blade (cutting by a cutting blade) and cutting using a laser device. An example of the slit portion s after cutting is shown by an arrow in FIG. 4, but the slit is intentionally enlarged and drawn for convenience of explanation. A configuration may be adopted in which a nip roller (not shown) is arranged on the upstream side or the downstream side of the cutting section 61 to convey the first optical film 10 in the shape of a belt. The nip rollers may be arranged on the upstream side and the downstream side of the cutting portion 61.

(Tension adjustment step) In the cutting process of the first optical film 10 and the post-attachment process, the first tension is provided in order to enable continuous processing without interruption over a long period of time and to adjust the tension of the film. Adjusting section 62. The first tension adjustment unit 62 is a warp mechanism and includes, for example, a tension roller mechanism using a spindle. The nip roller (not shown) may be configured to be disposed on the upstream side or the downstream side of the first tension adjustment portion 62 to transport the first optical film 10. The nip rollers may be arranged on the upstream side and the downstream side of the first tension adjustment portion 62.

(Peeling step) The first optical film 10 is wound and reversed at the first peeling portion 63 to peel the first optical film 10 from the first release film 11. The first release film 11 is taken up by a roller through a first take-up section 65. The first winding section 65 includes a roller and a rotation driving section. The rotation driving section drives the roller to rotate, and the first release film 11 is wound around the roller. A nip roller (not shown) may be configured to be disposed on the upstream side or the downstream side of the peeling section 63 to transport the first optical film 10 or the first release film 11. The nip rollers may be disposed on the upstream side and the downstream side of the peeling portion 63.

(First attaching step) The first attaching portion 64 attaches the first optical film 10 from which the first release film 11 has been peeled through the first adhesive layer 12 to the liquid crystal cell P while conveying the liquid crystal cell P. On the first side P1. The first attachment portion 64 is composed of a pair of a first roller member 64a and a second roller member 64b. Either one may be a driving roller and the other is a driven roller, or both rollers may be driving rollers. The pair of first roller members 64a and second roller members 64b sandwich the first optical film 10 and the liquid crystal cell P while sending them downstream, so that the first optical film 10 is attached to the first surface P1 of the liquid crystal cell P. Attached. The liquid crystal cell P after the first surface P1 of the liquid crystal cell P has been pasted to the single-piece first optical film 10 is transported downstream by the second transport section 82.

(First Inspection Step) The first inspection unit 70 performs an optical inspection on the liquid crystal cell P. The first inspection unit 70 includes a light source 71 disposed on one side of the liquid crystal cell P to allow light to pass through the liquid crystal cell P, and a first imaging unit 72 disposed on the opposite side of the light source through the liquid crystal cell P to the liquid crystal cell P. The transmitted light image is recorded. The first imaging unit 72 may be an area sensor or a line sensor. In addition, the first inspection unit 70 may include a second imaging unit (not shown), and image the reflected light image for inspecting the adhesion position of the first optical film 10. The image captured by the first inspection unit 70 is subjected to image analysis by the first image analysis unit 51. The control unit 50 controls the timing and the like of each component of the continuous manufacturing system.

(First determination step) The first determination unit 52 determines whether the liquid crystal cell P is a good product or a defective product based on a result of analyzing the image by the first image analysis unit 51. Examples of defective products include misalignment and air bubbles. The liquid crystal cell P determined to be a good product is recovered to the first good product recovery unit 92. The liquid crystal cell P determined as a defective product is recovered to the first defective product recovery unit 93.

(First Defective Film Peeling Step) A processing operation of regenerating a defective liquid crystal panel into a good liquid crystal panel will be described with reference to FIG. 5. As shown in FIG. 5, the first optical film 10 is removed from the liquid crystal cell P determined to be defective by the first determination unit 52. Removal can be performed manually or by a peeling device. Next, how to use a single-chip bonding apparatus to attach a single-plate-shaped first optical film 2 to the first surface P1 of the liquid crystal cell P for remanufacturing (also referred to as "heavy industry").

(First reattachment step) Next, the single-piece first optical film 2 after the first release film 21 is peeled off by the sheet-to-panel method (for example, a single-sheet bonding device) is attached to a defective product to be judged The first surface P1 of the liquid crystal cell P after the first optical film 10 is peeled off. As the single-chip bonding device, a conventional device can be used. Refer to the single-plate-shaped first optical film 2 in FIG. 1.

(Peeling step of second surface protection film) After the first re-attachment step, the second surface protection film 25 is peeled from the single-piece first optical film 2. The peeling process can be performed by a manual operation or by a peeling device. Through the above steps, a liquid crystal panel having the same laminated structure as the liquid crystal panel manufactured by the roll-to-panel method can be manufactured (remanufactured).

(Remanufacturing using the first and second optical film groups) Remanufacturing using the second optical film group can be performed in the same manner as the remanufacturing using the first optical film group. The roll-shaped second optical film 3 is used for manufacturing an optical display panel by a roll-to-panel method. The monolithic second optical film 4 is used to remanufacture an optical display panel having a structure in which an optical display panel manufactured using a rolled second optical film 3 is judged to be defective and the second adhesive layer is peeled off. For the optical display panel of the second optical function film and the third surface protection film, a second adhesive layer, a second optical function film, and a third surface protection film are sequentially laminated on one side of the optical unit. Specifically, the second adhesive layer 31, the second optical function film 32, and the third surface protection film 33 are peeled on one side of the optical unit, and the panel method is used to adhere the sheets, that is, from a single sheet to a single sheet. The second optical film 4 peels off the second release film 41 and sequentially bonds the second adhesive layer 42, the second optical function film 43, the third surface protection film 44, and the fourth surface protection film 45, and then the fourth surface The protective film 45 is peeled.

The continuous manufacturing system of an optical display panel is configured as a system in which a roll pair using a roll-shaped second optical film 3 is further added to a roll-to-panel manufacturing method using the roll-shaped first optical film 1 Panel type manufacturing equipment. The manufacturing equipment of the roll-to-panel system using the rolled second optical film 3 can be configured substantially the same as the manufacturing equipment of the roll-to-panel system using the rolled first optical film 1. The different manufacturing equipment is described below.

The liquid crystal cell P judged by good quality in the first inspection section 70 is sent to the rear stage, and the optical cell is attached to the second surface P2 of the liquid crystal cell P using a rolled second optical film. The second conveying unit 82 is provided with an arrangement exchange unit (not shown). The arrangement exchange unit reverses the upper and lower (P1, P2) liquid crystal cells P belonging to the good product transported by the second conveyance unit 82 and reverses the liquid crystal cell P in the conveying direction. The short side and the long side of the liquid crystal cell P are swapped. A well-known mechanism can be employ | adopted for a configuration exchange part. In this embodiment, the disposition unit includes a rotation unit that absorbs the liquid crystal cell P and rotates it 90 ° horizontally, and a reversing unit that adsorbs the liquid crystal cell P and reverses its front and back surfaces.

After the process of arranging the replacement part, the liquid crystal cell P is sent to the second attachment part. It has a second cutting portion that is the same as the first cutting portion 61, a second tension adjusting portion that is the same as the first tension adjusting portion 62, a second peeling portion that is the same as the first peeling portion 63, and a first volume The second take-up section with the same take-up section.

The second cutting section is configured to hold the second optical film 30 output by the roll-shaped second optical film 3 while holding the second release film 31 side while cutting the second optical film 31 without cutting the second release film 31. The film 30 is cut into a predetermined size (corresponding to the length of the long side of the liquid crystal cell P (the length of the substantially longer side is short)). The strip-shaped second optical film 30 is sent to the second peeling section through the second tension adjusting section, and is wound and reversed at the second peeling section to peel the second optical film 30 from the second release film 31. The second release film 31 is taken up by a roller through a second take-up section.

The second attachment portion has the same structure as the first attachment portion 64. The second attaching section attaches the second optical film 30 from which the second release film 31 has been peeled off while conveying the liquid crystal cell P, to the second surface P2 of the liquid crystal cell P through the second adhesive layer 32.

The second inspection unit has the same configuration as the first inspection unit 70. The second inspection unit performs an optical inspection on the liquid crystal cell P. The second inspection unit includes a light source disposed on one side of the liquid crystal cell P to allow light to pass through the liquid crystal cell P, and an imaging unit disposed on the opposite side of the light source through the liquid crystal cell P to transmit a light image to the liquid crystal cell P. Take a picture. The second inspection unit may further include an imaging unit (not shown) for imaging a reflected light image for inspecting the adhesion position of the second optical film 30. The images captured by the second inspection unit are analyzed by the second image analysis unit.

The second determination unit determines whether the liquid crystal cell P is a good product or a defective product based on a result of analyzing the image by the second image analysis unit. Examples of defective products include misalignment and air bubbles. The liquid crystal cell P determined to be defective is collected in a second defective collection unit. On the other hand, in the case where the second determination unit is judged by the good product, the liquid crystal cell P judged by the good product is sent to the good product storage unit and stored.

The remanufacturing using the monolithic optical film 4 is the same as the above-mentioned remanufacturing using the monolithic optical film 2. That is, the second optical film 30 is removed from the liquid crystal cell P judged as defective. Next, the single-piece second optical film 4 after the second release film 31 is peeled off by the sheet-to-panel method (for example, a single-sheet laminating device) is attached to the second optical film 30 that has been judged as defective and peeled. The second surface P2 of the rear liquid crystal cell P. Next, the fourth surface protection film 45 is peeled from the single-piece second optical film 4.

(Embodiment 5: Manufacturing of an optical display panel of an optical film group using an optical film roll and a single sheet optical film) Embodiment 5 is a continuous manufacturing system of an optical display panel using an optical film group. Hereinafter, a continuous manufacturing system for an optical display panel according to the fifth embodiment will be described in detail with reference to FIG. 6.

The first optical film 10 is attached to the first surface P1 of the liquid crystal cell P using the roll-shaped first optical film 1 in the same roll-to-panel method as in the fourth embodiment (see FIG. 4). The same symbols in Fig. 4 and Fig. 6 have the same functions. The liquid crystal cell P to which the first optical film 10 is attached is inverted (P1, P2) at the arrangement exchange unit 821, and the short side and long side of the liquid crystal cell P are exchanged in the transport direction (Y).

Next, a procedure for attaching the single-piece second optical film 4 to the second surface P2 of the liquid crystal cell P will be described below. The single-piece second optical film 4 is sucked from the container 100 in which the single-piece second optical film 4 is accommodated by the suction portion 164 a of the single-piece bonding device 164 and supplied to the bonding position. The second release film 41 is peeled from the single-piece second optical film 4 by a peeling means. The adsorption surface of the adsorption part 164a is arc-shaped in cross section. The peeling means may be, for example, using an adhesive tape, bonding the adhesive tape to the surface of the second release film 41, and moving the adhesive tape by a moving mechanism to peel the second release film 41.

The single-chip bonding apparatus 164 has a fixing surface 164b, and the fixing surface 164b is a side of the first surface P1 that adsorbs and fixes the liquid crystal cell P. In a state where the second release film 41 has been peeled off and the second adhesive layer 42 is exposed, the single-piece second optical film 4 is attached to the second surface P2 of the liquid crystal cell P so that the adsorption portion 164 a is rotated.

(Fourth Surface Protection Film Peeling Step) After the single-piece second optical film 4 is attached, the fourth surface protection film 45 is peeled. The peeling process can be performed by a manual operation or by a peeling device.

(Other Embodiments of Embodiment 5) In the above Embodiment 5, a single sheet of the first optical film 2 may be used instead of the roll of the first optical film 1 and attached to the liquid crystal cell in a sheet-to-panel manner, or a roll may be used. The second optical film 3 in the shape of a sheet replaces the second optical film 4 in the form of a single sheet and is attached to the liquid crystal cell in a roll-to-panel manner.

(Modifications) Embodiments 4 and 5 describe a continuous manufacturing method for using an optical film group of a roll-shaped optical film and a monolithic optical film in a liquid crystal display panel, but it is not limited to this, and can also be used in organic EL displays Continuous manufacturing method of panel.

In the fourth and fifth embodiments, the above-mentioned optical film is used as the roll-shaped optical film, but the structure of the roll-shaped optical film is not limited to this. For example, in addition to a release film, a tape-shaped optical film having a plurality of slit lines formed in the width direction (a optical film including a slit) can be used.

In the fourth and fifth embodiments, the strip-shaped optical film is cut (half-cut) in the width direction at predetermined intervals. However, from the viewpoint of improving the yield, the strip-shaped optical film is separated from the defect portion of the strip-shaped optical film. The film can also be cut in the width direction (skip cut), and the optical film containing the defect site can be cut at a smaller size (preferably the smallest possible size) than the predetermined interval (the size of the optical unit). can.

Embodiments 4 and 5 use flat rectangular liquid crystal cells and liquid crystal display panels as examples to explain, but the shapes of the liquid crystal cells and the liquid crystal display panel may be shapes having one set of opposite sides and the other set of opposite sides. Specially limited.

1‧‧‧ roll optical film
10‧‧‧ Ribbon Optical Film
11‧‧‧ Release film
12‧‧‧ Adhesive layer
13‧‧‧ Optical Functional Film
14‧‧‧The first surface protection film
2‧‧‧ Monolithic Optical Film
21‧‧‧ Release film
22‧‧‧ Adhesive layer
23‧‧‧ Optical Functional Film
24‧‧‧The first surface protection film
25‧‧‧Second surface protection film
a‧‧‧width, vertical
b‧‧‧ predetermined interval, horizontal
s‧‧‧cutting section
C‧‧‧ cutting means
sc‧‧‧Slit cutting section
e1, e2‧‧‧ end
S25‧‧‧Second surface protection film blank
S2‧‧‧Optical film blank
FC‧‧‧ Cutting means
R‧‧‧ transport roller
R1, R2‧‧‧ laminating roller
4‧‧‧ Monolithic second optical film
41‧‧‧Second Release Film
45‧‧‧ 4th surface protection film
5‧‧‧Rolled first optical film blank
50‧‧‧Control Department
51‧‧‧The first image analysis department
52‧‧‧The first judgment department
61‧‧‧cut-off section
62‧‧‧The first tension adjustment section
63‧‧‧The first peeling part
64‧‧‧ The first attaching department
64a‧‧‧1st Roller
64b‧‧‧ 2nd roller
65‧‧‧Volume 1
70‧‧‧The first inspection department
71‧‧‧light source
72‧‧‧ The first camera department
81‧‧‧The first conveying department
82‧‧‧Second Conveyor
91‧‧‧Storage Department
92‧‧‧The first good product recovery department
93‧‧‧The first defective product recovery department
P1‧‧‧The first side of the liquid crystal cell P
P2‧‧‧Second side of liquid crystal cell P
P‧‧‧LCD unit
Y‧‧‧ Conveying direction
100‧‧‧ container
164‧‧‧Single piece laminating device
164a‧‧‧Adsorption Department
164b‧‧‧Fixed surface
821‧‧‧Configuration Exchange Department

FIG. 1 is a schematic diagram showing an optical film group according to the first embodiment. FIG. 2 is a schematic diagram showing a two-sided optical film group in Embodiment 2. FIG. FIG. 3A is a schematic view showing a method for manufacturing a roll-shaped first optical film. FIG. 3B is a schematic view showing a method for manufacturing a single-piece first optical film. FIG. 4 is a schematic diagram of a continuous manufacturing system for an optical display panel according to a fourth embodiment. FIG. 5 is a diagram showing the remanufacturing steps. Fig. 6 is a schematic diagram of a continuous manufacturing system for an optical display panel according to a fifth embodiment.

1‧‧‧ roll optical film

10‧‧‧ Ribbon Optical Film

11‧‧‧ Release film

12‧‧‧ Adhesive layer

13‧‧‧ Optical Functional Film

14‧‧‧The first surface protection film

2‧‧‧ Monolithic Optical Film

21‧‧‧ Release film

22‧‧‧ Adhesive layer

23‧‧‧ Optical Functional Film

24‧‧‧The first surface protection film

25‧‧‧Second surface protection film

a‧‧‧width, vertical

b‧‧‧ predetermined interval, horizontal

s‧‧‧cutting section

C‧‧‧ cutting means

Claims (16)

An optical film group includes a roll-shaped optical film and a single-piece optical film, and the roll-shaped optical film has a structure in which a release film, an adhesive layer, an optical function film, and a first surface protection film are sequentially laminated. The sheet-shaped optical film has a structure in which the release film, the adhesive layer, the optical function film, the first surface protection film, and the second surface protection film are sequentially laminated. For example, in the optical film group of claim 1, the interlayer peeling force between the first surface protective film and the optical function film is greater than the interlayer peeling force between the second surface protective film and the first surface protective film. The optical film group according to claim 1, wherein the optical function film is a polarizing film. For example, the optical film group of claim 3, wherein the thickness of the polarizing film is 60 μm or less. The optical film group according to claim 3 or 4, wherein the polarizing film has a polarizer having a thickness of 10 μm or less. For example, the optical film group of claim 1, wherein the first surface protection film has a first base film and a first adhesive layer, and is laminated on the optical function film through the first adhesive layer. The optical film group according to claim 1, wherein the first surface protection film is a self-adhesive film. The optical film group according to claim 1, wherein the second surface protection film has a second base film and a second adhesive layer, and is laminated on the first surface protection film through the second adhesive layer. The optical film group according to claim 1, wherein the second surface protection film is a self-adhesive film. The optical film group according to claim 1, wherein the roll-shaped optical film has a width corresponding to a group of opposite sides of the optical unit; and a group of opposite sides of the single-plate optical film has a unit corresponding to the optical unit. The length of one set of opposite sides and the other set of opposite sides have a length corresponding to the other set of opposite sides of the optical unit. For example, the optical film group of claim 1, wherein the aforementioned roll-shaped optical film and the aforementioned single-plate optical film are used for manufacturing an optical display panel, and the optical display panel is sequentially laminated on one side of the aforementioned optical unit with the aforementioned adhesive Structure of the layer, the optical function film, and the first surface protection film. The optical film group according to claim 11, wherein the roll-shaped optical film is used for manufacturing the optical display panel in a roll-to-panel manner, and the single-sheet optical film is used for manufacturing the optical display panel in a sheet-to-panel manner. For example, the optical film group of claim 12, wherein the aforementioned single-plate optical film is used to remanufacture the optical display panel having the following structure: The aforementioned optical display panel manufactured by using the aforementioned roll-shaped optical film in the aforementioned roll-to-panel method Those who are judged to be defective and have peeled off the aforementioned adhesive layer, optical function film, and first surface protection film, have an adhesive layer, optical function film, and first layer sequentially laminated on one side of the aforementioned optical unit of the optical display panel. 1Surface protection film. A method for manufacturing an optical film group, as described in any one of claims 1 to 13, and the method for manufacturing the roll-shaped optical film includes the following steps: a step of preparing an optical film blank, The optical film blank has a structure in which the release film, the adhesive layer, the optical function film, and the first surface protection film are laminated in this order, and the step of manufacturing the roll-shaped optical film is performed on the optical film blank. The optical film is processed by slitting and winding to manufacture the aforementioned roll-shaped optical film. The method for manufacturing the single-sheet optical film includes the following steps: The step of manufacturing an optical film blank is based on the first step of the aforementioned optical film blank The steps of laminating the second surface protective film blank on the surface protection film side, manufacturing the optical film blank laminated with the second surface protective film, and manufacturing the single-sheet optical film are the steps of forming the second surface protective film on the laminated layer. The optical film blank is cut to produce a single sheet optical film. An optical film group on both sides includes a first optical film group and a second optical film group, wherein the first optical film group includes a roll-shaped first optical film and a single sheet of the first optical film, and the roll-shaped first optical film The film has a structure in which a first release film, a first adhesive layer, a first optical function film, and a first surface protection film are sequentially laminated, and the single-piece first optical film is sequentially laminated with the first release Structure of the film, the first adhesive layer, the first optical function film, the first surface protection film, and the second surface protection film; the second optical film group includes a rolled second optical film and a single-piece second An optical film, wherein the roll-shaped second optical film has a structure in which a second release film, a second adhesive layer, a second optical function film, and a third surface protection film are sequentially laminated, and the single-piece second optical film is The second release film, the second adhesive layer, the second optical function film, the third surface protection film, and the fourth surface protection film are laminated in this order. For example, the optical film set on both sides of the item 15, wherein the roll-shaped first optical film and the single-sheet first optical film, and the roll-shaped second optical film and the single-sheet second optical film are used for manufacturing An optical display panel with the above structure: the first adhesive layer, the first optical function film, and the first surface protection film are sequentially laminated on one side of the optical unit, and the other area layer of the optical unit has the first 2 adhesive layer, the second optical function film, and the third surface protection film.