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TWI848081B - 玻璃樹脂層疊體的製造方法 - Google Patents

玻璃樹脂層疊體的製造方法 Download PDF

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Publication number
TWI848081B
TWI848081B TW109109612A TW109109612A TWI848081B TW I848081 B TWI848081 B TW I848081B TW 109109612 A TW109109612 A TW 109109612A TW 109109612 A TW109109612 A TW 109109612A TW I848081 B TWI848081 B TW I848081B
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TW
Taiwan
Prior art keywords
film
glass
resin
adhesive layer
resin film
Prior art date
Application number
TW109109612A
Other languages
English (en)
Other versions
TW202043820A (zh
Inventor
佐藤啓介
村重毅
稲垣淳一
岸敦史
Original Assignee
日商日東電工股份有限公司
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Application filed by 日商日東電工股份有限公司 filed Critical 日商日東電工股份有限公司
Publication of TW202043820A publication Critical patent/TW202043820A/zh
Application granted granted Critical
Publication of TWI848081B publication Critical patent/TWI848081B/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
    • B32B17/10825—Isostatic pressing, i.e. using non rigid pressure-exerting members against rigid parts
    • B32B17/10862—Isostatic pressing, i.e. using non rigid pressure-exerting members against rigid parts using pressing-rolls
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/76—Making non-permanent or releasable joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Quality & Reliability (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Polarising Elements (AREA)

Abstract

本玻璃樹脂層疊體的製造方法係一種具有將玻璃膜和樹脂膜夾在對上述樹脂膜進行按壓的第1輥和與上述第1輥相對配置且對上述玻璃膜進行按壓的第2輥之間、並藉由粘合劑層使上述玻璃膜和上述樹脂膜粘合在一起的步驟的玻璃樹脂層疊體的製造方法，當使上述第1輥的表面層的彈性率為P1並使上述樹脂膜的彈性率為P2時，彈性率P1相對於彈性率P2之比P1/P2滿足3×10-3 ≦P1/P2≦1.0。

Description

玻璃樹脂層疊體的製造方法
本發明涉及玻璃樹脂層疊體的製造方法。
近年，畫面上安裝了觸控感應器功能的液晶單元廣泛應用於從移動電話到資訊顯示器的各種領域。
作為一例，可列舉出將具有感應器功能的膜或玻璃層疊在偏光板之上，並將被稱為前板的鋼化玻璃藉由用於填充感應器表面的段差(台階)的粘接劑層配置在最表層的顯示面板。此外，最近還出現了一種從薄化和輕量化的觀點出發將觸控感應器埋入液晶單元的玻璃基板內的被稱為內嵌式(In-cell)的液晶面板。
另一方面，鋼化玻璃的薄化也在進行中，但鋼化玻璃如果為300μm以下，則由於玻璃的壓縮應力而會發生自毀，故薄化受到限制。在這種情況下，盡管已經研究了使用樹脂來提高前板的硬度，但事實是不能獲得足夠的硬度。
因此，薄玻璃膜作為液晶單元的前板引起了人們的注意。該玻璃膜例如藉由粘合劑層與包括偏光板的樹脂膜進行層疊。由於需要更薄的產品等，故粘合劑層傾向於更薄。先前技術文獻 專利文獻
專利文獻1：國際公開第2013/175767號
本發明欲解決之課題
然而，就玻璃膜和樹脂膜的層疊而言，例如，係夾在上下相鄰配置的兩個輥之間進行的。此時，如果異物附著在與樹脂膜相接的一側的輥的表面上，則剛性較高的玻璃膜基本上不發生變形，主要是剛性較低的樹脂膜發生變形。
為此，樹脂膜的與玻璃膜相接的一側有時會出現與異物的形狀相應的凹凸，導致空氣進入凹部內，進而生成氣泡缺損。尤其是在粘合劑層的厚度較薄的情況下，氣泡缺損的發生較為顯著。作為產品，氣泡缺損的個數越少越好。
本發明是鑑於上述問題而提出的，其目的在於，提供一種當藉由粘合劑層對玻璃膜和樹脂膜進行層疊時，即使在粘合劑層較薄的情況下，與先前相比也可抑制氣泡缺損的發生的玻璃樹脂層疊體的製造方法。用於解決課題之手段
本玻璃樹脂層疊體的製造方法係一種具有將玻璃膜和樹脂膜夾在對上述樹脂膜進行按壓的第1輥和與上述第1輥相對配置且對上述玻璃膜進行按壓的第2輥之間、並藉由粘合劑層使上述玻璃膜和上述樹脂膜粘合在一起的步驟的玻璃樹脂層疊體的製造方法，當將上述第1輥的表面層的彈性率設為P1並將上述樹脂膜的彈性率設為P2時，彈性率P1相對於彈性率P2之比P1/P2滿足3×10-3 ≦P1/P2≦1.0。本發明之效果
根據公開的技術，能夠提供一種當藉由粘合劑層對玻璃膜和樹脂膜進行層疊時，即使在粘合劑層較薄的情況下，與先前相比也可抑制氣泡缺損的發生的玻璃樹脂層疊體的製造方法。
以下，參照附圖對用於實施發明的形態(方式)進行說明。各圖中，存在對相同構成部分賦予相同符號，並對重複說明進行省略的情況。
(玻璃樹脂層疊體) 首先，對作為製造對象的玻璃樹脂層疊體進行說明。圖1是玻璃樹脂層疊體的例示剖面圖，圖1(a)示出了層疊前的玻璃膜和樹脂膜，圖1(b)示出了層疊後的玻璃膜和樹脂膜(即，玻璃樹脂層疊體)。
玻璃樹脂層疊體1具有玻璃膜10和樹脂膜20。玻璃膜10藉由樹脂膜20的粘合劑層21與樹脂膜20粘合在一起。
就玻璃膜10而言，對其並無特別限定，可根據使用目的採用適當的玻璃膜。玻璃膜10按照組成(成分)進行分類時，例如可列舉出蘇打石灰玻璃、硼酸玻璃、鋁矽酸玻璃、石英玻璃等。此外，按照鹼成分進行分類時，可列舉出無鹼玻璃和低鹼玻璃。上述玻璃的鹼金屬成分(例如，Na2 O、K2 O、Li2 O)的含有量優選為15重量%以下，較佳為10重量%以下。
玻璃膜10的厚度優選為50μm~150μm，較佳為60μm~140μm，更佳為70μm~130μm，尤佳為80μm~120μm。在這樣的範圍內，可進行靈活性較優且基於輥到輥工藝的加工，並可獲得玻璃膜不易破裂且生產性優異的玻璃樹脂層疊體1。
玻璃膜10在波長550nm下的透光率優選為85%以上。玻璃膜10在波長550nm下的折射率優選為1.4~1.65。
玻璃膜10的密度優選為2.3g/cm3 ~3.0g/cm3 ，較佳為2.3g/cm3 ~2.7g/cm3 。只要係位於該範圍內的玻璃膜，即可提供有助於圖像顯示的輕量化的玻璃樹脂層疊體1。
就玻璃膜10的成形方法而言，對其並無特別限定，可根據使用目的採用適當的成形方法。通常，玻璃膜10可藉由如下方法製作，即，使包含二氧化矽、氧化鋁等的主原料、芒硝、氧化銻等的消泡劑、及碳等的還原劑的混合物在1400℃~1600℃左右的溫度下進行熔融(融化)，並將其成形為薄板狀，然後再進行冷卻，由此可製作玻璃膜10。作為玻璃膜10的成形方法，例如可列舉出槽下拉法、熔融法、浮式法等。就藉由該些方法而成形為板狀的玻璃膜而言，為了進行薄化或提高平滑性，根據需要，還可使用氟酸等的溶劑對其進行化學研磨。
樹脂膜20依次具備粘合劑層21、偏光板22、粘接劑層28、及離型膜29。但樹脂膜20還可具備其他層。例如，樹脂膜20可在偏光板22和粘接劑層28之間具備相位差層，但並不限定於此。
需要說明的是，粘合劑層21也可設置在玻璃膜10上。此情況下，樹脂膜20依次具備偏光板22、粘接劑層28、及離型膜29，根據需要還可具備其他層。
樹脂膜20的彈性率優選為0.1GPa~8.0GPa，較佳為0.2GPa~7.0GPa，更佳為0.3GPa~5.0GPa。本說明書中，彈性率可藉由精密万能試験機(Autograph)並在下述條件下進行測定。
[彈性率測定方法] 測定溫度：23℃ 樣品尺寸：寬2cm，長15cm 卡盤間距離：10cm 拉伸速度：10mm/min。
需要說明的是，本說明書中，粘接劑層是指，常溫下具有粘接性，藉由較輕的壓力即可粘接於被粘接體的層。故，即使在將粘接於粘接劑層上的被粘接體進行了剝離的情況下，粘接劑層也可保持具有實用性的粘接力。另一方面，粘合劑層是指，藉由存在於物質之間而可對物質進行結合的層。故，在將粘合於粘合劑層上的被粘合體進行了剝離的情況下，粘合劑層並不具有實用性的粘合力。
偏光板22配置在粘合劑層21的與玻璃膜10粘合的一側的相反側。偏光板22具有偏光片221、第1保護膜222、及第2保護膜223。第1保護膜222配置在偏光片221的粘合劑層21側，第2保護膜223配置在偏光片221的粘接劑層28側。
離型膜29藉由粘接劑層28配置在第2保護膜223的與偏光片221相反的一側。
以下，對樹脂膜20的各構成要素進行更詳細的說明。
[粘合劑層] 就粘合劑層21而言，對其並無特別限定，可根據使用目的採用適當的粘合劑。作為粘合劑，例如可列舉出聚酯(Polyester)類粘合劑、聚氨酯(Polyurethane)類粘合劑、聚乙烯醇(Polyvinyl alcohol)類粘合劑、及環氧(Epoxy)類粘合劑。其中，可獲得尤其良好的密著(密接)性的環氧類粘合劑為優選。
在粘合劑層21為熱硬化性粘合劑的情況下，藉由加熱硬化(固化)，可表現出耐剝離性。此外，在粘合劑層21為紫外線硬化性等的光硬化性粘合劑的情況下，藉由照射紫外線等的光以進行硬化，可表現出耐剝離性。另外，在粘合劑層21為可濕硬化性粘合劑的情況下，由於可與空氣中的水分等進行反應而進行硬化，故藉由放置也可進行硬化，由此可表現出耐剝離性。
粘合劑層21例如可使用市場上銷售的粘合劑，也可將各種硬化性樹脂溶解或分散於溶媒(溶劑)，藉此調製粘合劑溶液(或分散液)。
粘合劑層21的厚度優選為8μm以下，較佳為0.1μm~8μm，更佳為0.1μm~5μm，尤佳為0.1μm~2μm。在這樣的範圍內，可獲得可撓性較佳且耐穿刺性優異的玻璃樹脂層疊體1。此外，粘合劑層21越薄，玻璃樹脂層疊體1也越薄，故可滿足產品的薄化的要求。
粘合劑層21的彈性率優選為0.5GPa~15GPa，較佳為0.8GPa~10GPa，更佳為1GPa~5GPa。在這樣的範圍內，能獲得可撓性優異且耐穿刺性較佳的玻璃樹脂層疊體1。
需要說明的是，圖1(a)的狀態(層疊前)下的粘合劑層21並未硬化，如圖1(b)所示在樹脂膜20上層疊了玻璃膜10後粘合劑層21進行了硬化，由此可獲得將玻璃膜10和樹脂膜20粘合在一起的玻璃樹脂層疊體1。關於藉由粘合劑層21將玻璃膜10和樹脂膜20粘合在一起的玻璃樹脂層疊體1的製造方法，將在後面進行詳述。
[偏光板] 偏光板22的厚度優選為5μm~300μm，較佳為10μm~250μm，更佳為25μm~200μm，尤佳為25μm~100μm。
偏光板22的彈性率優選為1GPa以上，較佳為1GPa~10GPa，更佳為2GPa~7GPa，尤佳為2GPa~5GPa。在這樣的範圍內，可獲得耐穿刺性優異的玻璃樹脂層疊體1。
就偏光板22的形狀而言，對其並無特別限定，可根據使用目的採用適當的形狀，作為一例，可列舉出具有長邊和短邊的矩形形狀。在偏光板22為矩形形狀的情況下，優選為，偏光板22所具有的偏光片221的吸收軸方向與偏光板22的長邊或短邊大致平行。需要說明的是，本說明書中，「大致平行」的概念是指，不僅包括嚴密平行的情況，還包括兩線之夾角為±10°(優選為±5°)的情況。
[偏光片] 就偏光片221的厚度而言，對其並無特別限定，可根據使用目採用適當的厚度。偏光片221的厚度通常為1μm~80μm左右。作為偏光片221，可使用較薄的偏光片，此情況下，偏光片221的厚度優選為20μm以下，較佳為15μm以下，更佳為10μm以下，尤佳為6μm以下。
偏光片221優選在波長380nm~780nm內的任意波長下顯示吸收二色性。偏光片的單體透射率優選為40.0%以上，較佳為41.0%以上，更佳為42.0%以上，尤佳為43.0%以上。偏光片221的偏光度優選為99.8%以上，較佳為99.9%以上，更佳為99.95%以上。
偏光片221優選為碘類偏光片。具體而言，上述偏光片可由包含碘的聚乙烯醇類樹脂(以下稱「PVA類樹脂」)膜構成。
作為形成PVA類樹脂膜的PVA類樹脂，對其並無特別限定，可根據使用目的採用適當的樹脂，例如可列舉出聚乙烯醇和乙烯-乙烯醇共聚物(Ethylene-vinyl alcohol copolymer)。
聚乙烯醇可藉由對聚醋酸乙烯(Polyvinyl acetate)進行皂化(Saponification)而獲得。乙烯-乙烯醇共聚物可藉由對乙烯-乙酸乙烯酯共聚物(Ethylene-vinyl acetate copolymer)進行皂化而獲得。PVA類樹脂的皂化度通常為85摩爾%~100摩爾%，優選為95.0摩爾%~99.95摩爾%，較佳為99.0摩爾%~99.93摩爾%。皂化度可基於JIS K 6726-1994求得。藉由使用這樣的皂化度的PVA類樹脂，可獲得耐久性較優的偏光片。然而，如果皂化度過高，則可能發生膠凝。
就PVA類樹脂的平均聚合度而言，對其並無特別限定，可根據使用目的進行適當的選擇。PVA類樹脂的平均聚合度例如為1000~10000，較佳為1200~5000，更佳為1500~4500。需要說明的是，平均聚合度可基於JIS K 6726-1994求得。
作為偏光片221的製造方法，例如可列舉出使PVA類樹脂膜單體延伸並進行染色的方法(I)、使具有樹脂基材和聚乙烯醇類樹脂層的層疊體(i)延伸並進行染色的方法(II)等。方法(I)為業界周知的慣用方法，故省略其詳細說明。
方法(II)優選包括使具有樹脂基材和在該樹脂基材的單側形成的聚乙烯醇類樹脂層的層疊體(i)延伸並進行染色，從而在該樹脂基材上製作偏光片的步驟。層疊體(i)可藉由在樹脂基材上塗敷包含聚乙烯醇類樹脂的塗敷液並進行乾燥而形成。此外，層疊體(i)也可藉由將聚乙烯醇類樹脂層轉寫(轉錄)在樹脂基材上而形成。該製造方法(II)的詳細內容例如記載於(日本)特開2012-73580號公報，該公報作為參考援引於本說明書。
[第1和第2保護膜] 作為第1保護膜222和第2保護膜223，對其並無特別限定，可根據使用目的採用適當的樹脂膜。作為第1保護膜222和第2保護膜223的形成材料，例如可列舉出聚對苯二甲酸乙二酯(PET)等的聚酯類樹脂、三醋酸纖維素(TAC)等的纖維素類樹脂、降冰片烯(Norbornene)類樹脂等的環烯烴(Cycloolefin)類樹脂、聚乙烯(Polyethylene)、聚丙烯(Polypropylene)等的烯烴(Olefin)類樹脂、(甲基)丙烯酸((Meth) acrylic)類樹脂等。這些當中，優選為聚對苯二甲酸乙二酯(PET)。需要說明的是，「(甲基)丙烯酸類樹脂」是指，丙烯酸類樹脂和/或甲基丙烯酸類樹脂。
作為(甲基)丙烯酸類樹脂，例如可使用具有戊二醯亞胺(Glutarimide)結構的(甲基)丙烯酸類樹脂。具有戊二醯亞胺結構的(甲基)丙烯酸類樹脂(以下也稱戊二醯亞胺樹脂)例如記載於(日本)特開2006-309033號公報、特開2006-317560號公報、特開2006-328329號公報、特開2006-328334號公報、特開2006-337491號公報、特開2006-337492號公報、特開2006-337493號公報、特開2006-337569號公報、特開2007-009182號公報、特開2009-161744號公報、及特開2010-284840號公報。該些內容作為參考援引於本說明書。
可藉由任意的適當的粘合劑層使第1保護膜222和第2保護膜223與偏光片221層疊。就偏光片221的製作時所使用的樹脂基材而言，可在第1保護膜222和第2保護膜223與偏光片221層疊前或層疊後被剝離。
第1保護膜222和第2保護膜223的厚度優選為4μm~250μm，較佳為5μm~150μm，更佳為10μm~100μm，尤佳為10μm~50μm。
第1保護膜222和第2保護膜223的彈性率為1GPa以上，優選為1GPa~10GPa，較佳為1.8GPa~7GPa，更佳為2GPa~5GPa。在這樣的範圍內，可獲耐穿刺性優異的玻璃樹脂層疊體1。
[粘接劑層] 粘接劑層28可藉由任意的適當的粘接劑而形成。作為粘接劑，例如可使用將丙烯酸類聚合物、矽樹脂類聚合物、聚酯、聚氨酯、聚醯胺、聚醚、氟類橡膠類等的聚合物作為基礎聚合物的粘接劑。優選使用丙烯酸類粘接劑。其理由為，丙烯酸類粘接劑的光學透明性較優，顯示了適度的潤濕性、凝聚性、及粘合性的粘接特性，並具有優異的耐候性、耐熱性等。由碳數為4~12的丙烯酸類聚合物製成的丙烯酸類粘接劑尤佳。
粘接劑層28的厚度優選為1μm~100μm，較佳為3μm~80μm，更佳為3μm~50μm。在這樣的範圍內，當將玻璃樹脂層疊體1貼附在液晶單元等的光學元件上以製作光學層疊體時，能獲得可撓性優異且耐穿刺性較佳的光學層疊體。
[離型膜] 離型膜29例如可藉由聚對苯二甲酸乙二酯(PET)、聚乙烯(PE)、聚丙烯(PP)等的樹脂而形成。離型膜29的厚度優選為5μm~125μm，較佳為20μm~75μm，更佳為30μm~50μm。就離型膜29而言，在將玻璃樹脂層疊體1貼附於液晶單元等的光學元件之前，從與粘接劑層28之間的界面處被剝離。
(玻璃樹脂層疊體的製造方法) 接下來，就玻璃樹脂層疊體的製造方法而言，著眼於將玻璃膜10和樹脂膜20夾在對樹脂膜20進行按壓的輥和對玻璃膜10進行按壓的輥之間並藉由粘合劑層21使玻璃膜10和樹脂膜20粘合在一起的步驟，由此對該製造方法進行說明。
圖2是在樹脂膜上層疊玻璃膜的步驟的說明圖。圖2中，樹脂膜20懸掛在輥110、120、及130上，並沿箭頭方向被搬送。樹脂膜20例如可藉由輥到輥(roll-to-roll)的方式而被進行搬送。沿上下方向與輥110相對的位置處配置有輥140。
需要說明的是，圖2中盡管示出了3個用於對樹脂膜20進行搬送的輥，但這僅為一例，可根據需要適當地確定輥的個數。
玻璃膜10沿箭頭方向被搬送，並在輥110和輥140之間被層疊在樹脂膜20上。此時，輥140對玻璃膜10進行按壓，輥110對樹脂膜20進行按壓。
據此，可在樹脂膜20上對玻璃膜10進行層疊。此時，粘合劑層21並未硬化。粘合劑層21在輥110和輥140的搬送方向(箭頭方向)的下游側所配置的未圖示的硬化步驟中進行硬化，由此可製成玻璃樹脂層疊體1。需要說明的是，硬化前和硬化後，粘合劑層21的厚度基本上沒有變化。
這裡，對當使用先前的方法的情況下在樹脂膜20上層疊玻璃膜10時可能會發生的問題進行說明。圖3是對在樹脂膜上層疊玻璃膜時的先前存在的問題進行說明的圖。
圖3中，取代圖2所示的輥110使用了輥110X。輥110X為鐵製。即，輥110X中相當於輥110的表面層的部分由鐵形成。
如圖3所示，有時異物F會附著在輥110X上。此情況下，當在樹脂膜20上層疊玻璃膜10時，樹脂膜20的輥110X側與異物F相接(接觸)，但此時，剛性較高的鐵製的輥110X和玻璃膜10基本上不會發生變形，主要是剛性較低的樹脂膜20進行變形。為此，在樹脂膜20的與玻璃膜10相接的一側會出現與異物F的形狀相應的凹凸，導致空氣進入凹部內，從而產生氣泡缺損B。
氣泡缺損B具有人的眼睛能觀察到的大小(size)。為此，在玻璃樹脂層疊體1被應用於顯示裝置等的產品的情況下，就這樣的氣泡缺損而言，只允許存在一定個數(數量)以下的這樣的氣泡缺損，優選儘可能為零。因此，為了解決先前存在的這樣的問題，本實施方式中提出了可抑制氣泡缺損B的發生的對策。以下參照圖4和圖5對其進行說明。
圖4是對抑制氣泡缺損的發生的方法進行說明的圖，放大地示出了圖2的輥110和140的附近的部分。如參照圖3所說明的那樣，以往，使用鐵製輥的情況較多，本實施方式中，輥110的表面層由彈性率低於鐵的材料形成。需要說明的是，表面層是指，從輥110的表面開始沿中心方向深入至1mm左右的內側的區域。
作為彈性率低於鐵的材料，對其並無特別限定，例如可列舉出聚對苯二甲酸乙二酯(PET)、聚乙烯(PE)、聚丙烯(PP)等的樹脂、矽樹脂橡膠、聚氨酯橡膠、丁腈橡膠等的橡膠等。這些當中，柔軟性優異的矽樹脂橡膠(Silicone rubber)尤佳。
圖5是圖4的A部分的放大圖。圖5中，異物F的存在導致樹脂膜20和輥110的表面層發生了變形。
這裡，與樹脂膜20的表面垂直的方向的異物F的壓縮前的長度為t，考慮到在樹脂膜20上層疊玻璃膜10時的壓縮，壓縮後的異物F的長度可為Δｌ=√t。這是基於本發明的發明人的經驗而獲得的知識。
此外，壓縮後的異物F的長度Δｌ中，樹脂膜20側的長度為Δｌp，輥110側的長度為Δｌr。此時，如果將樹脂膜20的彈性率設為Ep，並將輥110的表面層的彈性率設為Er，則根據異物F的兩側的应变和彈性率的關係，可導出以下的公式(1)。
[公式1] 此外，根據上述說明還可知，Δｌp、Δｌr、Δｌ、及√t的關係由以下的公式(2)所示。
[公式2] 藉由公式(1)和公式(2)，對具體的數值例進行探討(研究)。這裡，作為目標的異物F的壓縮前的長度t為20~100μm左右。其理由為，如果存在這樣大小的異物F，則容易產生可被人眼觀察到的氣泡缺損B。這裡，作為一例，t=100μm。
這裡，在作為輥110的表面層的材料而假定使用了聚對苯二甲酸乙二酯(PET)的情況下，其彈性率為5GPa左右。樹脂膜20的彈性率也為5GPa左右，故根據公式(1)和公式(2)計算Δｌp後可知，Δｌp=5μm。即，異物F進入樹脂膜20內的量大約為5μm左右。此時，並未硬化的粘合劑層21柔軟性較高，故，如果粘合劑層21的厚度為5μm以上，則粘合劑層21會吸收Δｌp，據此，如圖4所示，樹脂膜20的與玻璃膜10相接的一側不會發生變形。即，不會出現如圖3所示的氣泡缺損B。
此外，在作為輥110的表面層的材料而假定使用了矽樹脂橡膠的情況下，其彈性率為1.5ＭPa左右。樹脂膜20的彈性率為5GPa左右，故根據公式(1)和公式(2)計算Δｌp後可知，Δｌp=3.0×10-3 μm。即，異物F進入樹脂膜20的量為3.0×10-3 μm左右(基本上沒有進入)。此時，樹脂膜20基本上不發生變形，故，即使在粘合劑層21的厚度極薄的情況下，樹脂膜20的與玻璃膜10相接的一側也不會發生變形。即，不會出現如圖3所示的氣泡缺損B。
即，在具備5μm以下的粘合劑層21的彈性率為5GPa左右的樹脂膜20上對玻璃膜10進行層疊的情況下，輥110的表面層優選由聚對苯二甲酸乙二酯(PET)、矽樹脂橡膠等的彈性率較低的材料形成。據此，即使在異物F附著於輥110的表面的情況下，也可抑制樹脂膜20的變形，進而可抑制氣泡缺損B的發生。
這樣，如果輥110的表面層的彈性率較低，則異物F導致的樹脂膜20的變形較小，藉此可抑制氣泡缺損B的發生。此外，如果異物F引起的樹脂膜20的變形較小，則粘合劑層21也不太可能有助於變形的鬆弛，從而可使用更薄的粘合劑層21。
對上述內容進行進一步的概括後可知，在玻璃樹脂層疊體的製造步驟中，當輥110的表面層的彈性率為P1，並且樹脂膜20的彈性率為P2時，只要按照彈性率P1相對於彈性率P2之比P1/P2滿足3×10-3 ≦P1/P2≦1.0的方式來選擇輥110的表面層的材料即可。這裡需要說明的是，輥110中的表面層之外的部分也可由與表面層相同的材料形成。
就上述條件而言，使玻璃膜和樹脂膜粘合在一起的粘合劑層越薄，效果發揮的越好，例如，在粘合劑層的厚度為0.1μm以上且5μm以下的情況下，效果尤其顯著。換言之，在使用厚度大於10μm那樣的粘合劑層的情況下，有時即使不滿足上述條件也可抑制氣泡缺損B的發生。但是，如果粘合劑層增厚，則會出現樹脂膜的搬送性下降的問題、粘合劑層的硬化時間變長的問題等，故優選使粘合劑層為10μm以上。
需要說明的是，以上的探討中並沒有言及輥140，但是，就輥140而言，由於剛性較高的玻璃膜10基本上不發生變形，故可認為，輥140的表面層的材質不會影響上述的探討。因此，輥140的表面層的材質可為鐵，可為樹脂，可為橡膠，還可為其他材料。
以下，列舉實施例和比較例對樹脂膜和玻璃膜的層疊進行更具體的說明，但本發明並不限定於該些實施例。
[實施例1] 實施例1中，準備一具備厚度2μm的粘合劑層的彈性率為5GPa的樹脂膜，並在上下相對的輥之間將玻璃膜層疊在樹脂膜上。之後，使粘合劑層硬化，由此製作了玻璃樹脂層疊體A。與樹脂膜相接的輥的表面層使用了彈性率5GPa的聚對苯二甲酸乙二酯(PET)。
[實施例2] 實施例2中，使粘合劑層的厚度為5μm，除此之外與實施例1相同，由此製作了玻璃樹脂層疊體B。
[實施例3] 實施例3中，使粘合劑層的厚度為10μm，除此之外與實施例1相同，由此製作了玻璃樹脂層疊體C。
[比較例1] 比較例1中，準備一具備厚度2μm的粘合劑層的彈性率為5GPa的樹脂膜，並在上下相對的輥之間將玻璃膜層疊在樹脂膜上。之後，使粘合劑層硬化，由此製作了玻璃樹脂層疊體D。與樹脂膜相接的輥的表面層使用了彈性率73GPa的鐵。
[比較例2] 比較例2中，使粘合劑層的厚度為5μm，除此之外與比較例1相同，由此製作了玻璃樹脂層疊體E。
[比較例3] 比較例3中，使粘合劑層的厚度為10μm，除此之外與比較例1相同，由此製作了玻璃樹脂層疊體F。
[評價] 針對實施例1~3和比較例1~3中製作的玻璃樹脂層疊體A~F，分別對其氣泡缺損的個數進行了目視檢查。結果示於表1和表2。需要說明的是，判定時，如果氣泡缺損的個數[/m2 ]為50個以下，則為〇(合格)，如果多於50個，則為×(不合格)。
[表1]
[表2] 如表1所示，在與樹脂膜相接的輥的表面層由聚對苯二甲酸乙二酯(PET)形成的情況下，不管粘合劑層的厚度為2μm、5μm、及10μm中的哪一個，氣泡缺損的個數都位於容許範圍內。尤其是，如果粘合劑層的厚度為5μm以上，則氣泡缺損的個數為0，是非常好的結果。
需要說明的是，根據前述的研究結果還可預測到，如果與樹脂膜相接的輥的表面層由矽樹脂橡膠形成，則粘合劑層的厚度即使為2μm或小於2μm，氣泡缺損的個數也大約零。
另一方面，如表2所示，在與樹脂膜相接的輥的表面層使用了鐵的情況下，如果粘合劑層的厚度為10μm，則氣泡缺損的個數為0，但如果粘合劑層的厚度為2μm和5μm，則氣泡缺損的個數就超出了容許範圍。即，由此可知，在使用厚度為5μm以下的較薄的粘合劑層的情況下，與樹脂膜相接的輥的表面層需要使用聚對苯二甲酸乙二酯(PET)或彈性率更低的材料(矽樹脂橡膠等)。
如此，根據本實施例和比較例的結果可知，在玻璃樹脂層疊體的製造步驟中，當使與樹脂膜相接的輥的表面層的彈性率為P1，並使樹脂膜的彈性率為P2時，藉由按照彈性率P1相對於彈性率P2之比P1/P2滿足3×10-3 ≦P1/P2≦1.0的方式來選擇與樹脂膜相接的輥的表面層的材料，可抑制氣泡缺損的發生。
此外，還確認到了，就上述條件而言，使玻璃膜和樹脂膜粘合在一起的粘合劑層越薄，效果發揮的越好，在粘合劑層的厚度為5μm以下的情況下，效果尤其顯著。
需要說明的是，以上盡管以具有偏光板的樹脂膜為例進行了說明，但是，就上述條件而言，在具有使用相對的兩個輥並藉由粘合劑層將玻璃膜和樹脂膜粘合在一起的步驟的玻璃樹脂層疊體的製造方法中都是有效的，並不限定於具有偏光板的樹脂膜。作為具有偏光板的樹脂膜之外的例子，例如可列舉出PET膜、PEN膜等。
以上，對優選實施方式等進行了詳細說明，但並不限定於上述實施方式等，只要不脫離申請專利範圍內記載的技術範圍，還可對上述實施方式等進行各種各樣的變形和置換。
本國際申請主張基於2019年3月29日申請的日本國專利申請第2019-066162號的優先權，並將日本國專利申請第2019-066162號的內容全部援引於本國際申請。
1:玻璃樹脂層疊體 10:玻璃膜 20:樹脂膜 21:粘合劑層 22:偏光板 28:粘接劑層 29:離型膜 110,120,130,140:輥 221:偏光片 222:第1保護膜 223:第2保護膜
[圖1(a)、(b)]玻璃樹脂層疊體的例示剖面圖。 [圖2]在樹脂膜上層疊玻璃膜的步驟的說明圖。 [圖3]在樹脂膜上層疊玻璃膜時的先前的問題的說明圖。 [圖4]抑制氣泡缺損的發生的方法的說明圖。 [圖5]圖4的A部分的放大圖。
10:玻璃膜
20:樹脂膜
110:輥
120:輥
130:輥
140:輥

Claims (3)

  1. 一種玻璃樹脂層疊體的製造方法，其特徵在於，具有：將玻璃膜和樹脂膜夾在對上述樹脂膜進行按壓的第1輥和與上述第1輥相對配置且對上述玻璃膜進行按壓的第2輥之間，並藉由粘合劑層使上述玻璃膜和上述樹脂膜粘合在一起的步驟，其中，上述粘合劑層的厚度為5μm以下，當使上述第1輥的表面層的彈性率為P1，並使上述樹脂膜的彈性率為P2時，彈性率P1相對於彈性率P2之比P1/P2滿足3×10-3≦P1/P2≦1.0，上述第1輥的表面層由彈性率低於鐵的彈性率的材料形成，上述第1輥的表面層係從上述第1輥的表面開始沿中心方向深入至1mm的內側的區域，上述第1輥的表面層由選自由聚對苯二甲酸乙二酯、聚乙烯、或聚丙烯所組成之群的樹脂形成。
  2. 如請求項1所述的玻璃樹脂層疊體的製造方法，其特徵在於，上述樹脂膜包含偏光板，該偏光板配置在上述粘合劑層的與上述玻璃膜粘合的一側的相反側。
  3. 如請求項2所述的玻璃樹脂層疊體的製造方法，其特徵在於，上述偏光板具有偏光片和保護膜。
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