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TWI862694B - Manufacturing method of optical member - Google Patents

Manufacturing method of optical member Download PDF

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Publication number
TWI862694B
TWI862694B TW109133668A TW109133668A TWI862694B TW I862694 B TWI862694 B TW I862694B TW 109133668 A TW109133668 A TW 109133668A TW 109133668 A TW109133668 A TW 109133668A TW I862694 B TWI862694 B TW I862694B
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Taiwan
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laminated structure
face
aforementioned
rotary blade
laminated
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TW109133668A
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Chinese (zh)
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TW202128321A (en
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芦田丈行
内藤達也
藤井幹士
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日商住友化學股份有限公司
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    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0016—Abrading

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polarising Elements (AREA)
  • Laminated Bodies (AREA)
  • Milling Processes (AREA)

Abstract

A manufacturing method of optical member includes a cutting step of cutting a laminated structure 2 with a pair of rotary blades b1 and b2; the laminated structure 2 includes a plurality of laminated bodies 4 which contain a plurality of optical films, wherein the laminated structure 2 is a cuboid or a cube and end faces of the laminated structure 2 are parallel to a laminated direction. The laminated structure 2 is held by a clamp 12 contacting upper and lower surfaces thereof. The rotary blade b1 is in contact with an end face f1 of the laminated structure 2, and the rotary blade b2 is in contact with the other end face f2 of the laminated structure 2. The opposite end faces f1 and f2 are cut by the rotary blades b1 and b2 at approximately the same time. In the process of cutting all the end faces of the laminated structure 2 with the rotary blades, positions where the rotary blades b1 and b2 are arranged will be changed, and the clamp 12 always does not rotate relative to a rotation axis a12 which is substantially parallel to the lamination direction of the lamination bodies 4.

Description

光學構件的製造方法 Manufacturing method of optical component

本發明係關於光學構件的製造方法。 The present invention relates to a method for manufacturing an optical component.

作為光學構件的一種的偏光板，係用於液晶顯示器、有機EL顯示器、智慧型手機、智慧型手錶或車輛的儀表板等之圖像顯示裝置。偏光板係偏光片膜及保護膜等之複數的光學膜的積層體。隨著圖像顯示裝置的精密化或小型化，偏光板的形狀及尺寸也被要求高精確度。 Polarizing plates, a type of optical component, are used in image display devices such as liquid crystal displays, organic EL displays, smart phones, smart watches, or vehicle instrument panels. Polarizing plates are laminated bodies of multiple optical films such as polarizing films and protective films. As image display devices become more sophisticated or miniaturized, the shape and size of polarizing plates are also required to be highly accurate.

例如，日本特開2004-148419號公報揭示將彼此積層之複數的積層體所構成的積層構造體的端面(剖面)以旋轉刀切削，藉此提高各積層體的形狀及尺寸的精確度。 For example, Japanese Patent Publication No. 2004-148419 discloses cutting the end face (cross section) of a laminated structure composed of a plurality of laminated bodies stacked on each other with a rotary cutter, thereby improving the accuracy of the shape and size of each laminated body.

當上述的積層構造體藉由旋轉刀加工時，在積層構造體於積層體之積層方向上被夾鉗(clamp)固定的狀態下，旋轉刀被抵靠於積層構造體的端面使端面被切削。為了以高精確度加工構成積層構造體的各積層體，需要精密地控制旋轉刀相對於積層構造體之端面的相對位置及相對移動速度。然而，在積層構造體之端面被切削的過程中，由於旋轉刀對於積層構 造體之端面所施加的力，在積層構造體之端面中之旋轉刀所相接的部分容易產生力矩(moment)。由於旋轉刀所施加的力或力矩，而使積層構造體的一部分或整體從預定的位置偏離，或積層構造體的一部分或整體繞著大致平行於積層體之積層方向的旋轉軸線旋轉，而使積層構造體扭歪。由於上述之積層構造體的位置偏移或扭歪，將難以精密地控制旋轉刀相對於積層構造體之端面的相對位置及相對移動速度。基於以上的理由，以使用旋轉刀之以往的切削方法而言，難以精密地切削積層構造體的端面，且難以提高各積層體之形狀及尺寸的精確度。偏光板以外的光學構件亦要依據其用途而精確地加工。 When the above-mentioned laminated structure is processed by a rotary cutter, the rotary cutter is pressed against the end face of the laminated structure while the laminated structure is fixed by a clamp in the laminated direction of the laminated structure, so that the end face is cut. In order to process each laminated structure with high precision, it is necessary to precisely control the relative position and relative movement speed of the rotary cutter relative to the end face of the laminated structure. However, during the process of cutting the end face of the laminated structure, due to the force applied by the rotary cutter to the end face of the laminated structure, a moment is easily generated in the portion of the end face of the laminated structure where the rotary cutter contacts. Due to the force or torque applied by the rotating blade, part or the whole of the laminated structure deviates from the predetermined position, or part or the whole of the laminated structure rotates around a rotation axis roughly parallel to the lamination direction of the laminated structure, causing the laminated structure to twist. Due to the positional deviation or twisting of the laminated structure, it is difficult to precisely control the relative position and relative movement speed of the rotating blade relative to the end face of the laminated structure. For the above reasons, it is difficult to precisely cut the end face of the laminated structure and to improve the accuracy of the shape and size of each laminated structure using the previous cutting method using a rotating blade. Optical components other than polarizing plates must also be precisely processed according to their use.

因此，上述的技術性課題在偏光板以外之光學構件的製造上亦有可能發生。 Therefore, the above technical issues may also occur in the manufacturing of optical components other than polarizing plates.

本發明之目的係提供一種形狀及尺寸之精確度優異之光學構件的製造方法。 The purpose of the present invention is to provide a method for manufacturing an optical component with excellent shape and size accuracy.

本發明之一型態之光學構件的製造方法，係具備：以一對旋轉刀切削積層構造體的切削步驟；積層構造體係包含彼此積層的複數層積層體，積層體係包含彼此積層的複數層光學膜，積層構造體係大致長方體或大致立方體，積層構造體之各端面係大致平行於積層體的積層方向，積層構造體的上表面及下表面係大致垂直於積層方向，積層構造體係藉由與積層構造體之上表面和下表面相接的夾鉗所挾持，旋轉刀係沿著積層方向延伸，旋轉刀的側面係大致平行於積層構造體的端面，旋轉刀的旋轉軸線係大致平行於旋轉刀的側面，一方之旋轉刀的側面係與積層構造體之相對向之兩個端面中之一方的端面相接，另一方之旋轉刀的側面係與積層構造 體之相對向之兩個端面中之另一方的端面相接，積層構造體之相對向的二個端面係被一對旋轉刀大致同時地切削，在以旋轉刀切削積層構造體之所有端面的過程中，設置一對旋轉刀的位置會變更，且在以旋轉刀切削積層構造體之所有端面的過程中，夾鉗係始終相對於大致平行於積層方向的旋轉軸線不旋轉。 A method for manufacturing an optical component of one embodiment of the present invention comprises: a step of cutting a laminated structure with a pair of rotating cutters; the laminated structure comprises a plurality of laminated layers stacked on each other, the laminated structure comprises a plurality of optical films stacked on each other, the laminated structure is substantially rectangular or substantially cubic, and each of the laminated structures is substantially rectangular. The end face is substantially parallel to the stacking direction of the stacking structure, the upper surface and the lower surface of the stacking structure are substantially perpendicular to the stacking direction, the stacking structure is clamped by clamps connected to the upper surface and the lower surface of the stacking structure, the rotating knife extends along the stacking direction, and the side face of the rotating knife is substantially parallel to the end face of the stacking structure , the rotation axis of the rotary cutter is roughly parallel to the side surface of the rotary cutter, the side surface of one rotary cutter is in contact with one of the two opposite end surfaces of the laminated structure, and the side surface of the other rotary cutter is in contact with the other of the two opposite end surfaces of the laminated structure. The two opposite end surfaces of the laminated structure are cut by a pair of rotary cutters roughly at the same time. In the process of cutting all the end surfaces of the laminated structure with the rotary cutter, the position of the pair of rotary cutters will change, and in the process of cutting all the end surfaces of the laminated structure with the rotary cutter, the clamp will always not rotate relative to the rotation axis roughly parallel to the lamination direction.

積層構造體的上表面及下表面各者可為大致長方形，大致同時被切削的二個端面可大致平行於積層構造體的上表面及下表面各者的長邊。 The upper surface and the lower surface of the laminated structure may each be roughly rectangular, and the two end surfaces that are cut roughly at the same time may be roughly parallel to the long sides of the upper surface and the lower surface of the laminated structure.

在切削步驟中，一對之旋轉刀可沿著積層構造體之相對向的兩個端面移動。 During the cutting step, a pair of rotating cutters can move along two opposite end faces of the laminated structure.

在切削步驟中，夾鉗可沿著與積層構造體之相對向的兩個端面大致平行的方向移動。 During the cutting step, the clamp can move in a direction roughly parallel to the two opposite end faces of the laminated structure.

積層體可包含至少一黏著劑層。 The laminate may include at least one adhesive layer.

旋轉刀可為端銑刀(end mill)。 The rotary cutter can be an end mill.

依據本發明，係提供一種形狀及尺寸之精確度優異之光學構件的製造方法。 According to the present invention, a method for manufacturing an optical component with excellent shape and size accuracy is provided.

2:積層構造體 2: Layered structure

4:積層體 4: Laminated body

6a:第一保護片 6a: First protective film

6b:第二保護片 6b: Second protective sheet

8a~8e:光學膜 8a~8e: Optical film

10a,10b:光學膜(黏著劑層) 10a, 10b: Optical film (adhesive layer)

12:夾鉗 12: Clamps

12a:第一研磨墊 12a: First polishing pad

12b:第二研磨墊 12b: Second polishing pad

a1:第一旋轉刀的旋轉軸線 a1: Rotation axis of the first rotary cutter

a2:第二旋轉刀的旋轉軸線 a2: Rotation axis of the second rotary knife

a12:大致平行於積層體之積層方向的旋轉軸線 a12: The rotation axis roughly parallel to the stacking direction of the stack

b1:第一旋轉刀 b1: First rotary knife

b2:第二旋轉刀 b2: Second rotary knife

f1:第一端面 f1: first end face

f2:第二端面 f2: second end face

f3:第三端面 f3: The third end face

f4:第四端面 f4: the fourth end face

s1,s2:側面 s1,s2: side

tf:上表面 tf: upper surface

p1~p4:位置 p1~p4: Location

uf:下表面 uf: lower surface

圖1係積層構造體、夾鉗及旋轉刀的示意側視圖。 Figure 1 is a schematic side view of the laminated structure, clamps and rotary cutter.

圖2係構成圖1所示之積層構造體之各積層體的剖面圖，圖2所示之剖面係大致平行於積層體的積層方向。 FIG2 is a cross-sectional view of each layered structure constituting the layered structure shown in FIG1. The cross-section shown in FIG2 is roughly parallel to the layering direction of the layered structure.

圖3係顯示積層構造體的上表面，和切削步驟中抵接於積層構造體之端面之旋轉刀的示意圖。 FIG3 is a schematic diagram showing the upper surface of the laminated structure and the rotating cutter abutting against the end surface of the laminated structure during the cutting step.

圖4(a)係繞著大致平行於積層構造體之積層方向之旋轉軸線旋轉之積層構造體的俯視圖，圖4(b)係已扭歪之積層構造體的俯視圖。 FIG4(a) is a top view of a layered structure rotated about a rotation axis roughly parallel to the layered direction of the layered structure, and FIG4(b) is a top view of a distorted layered structure.

以下參照圖式來說明本發明的較佳實施型態。在圖式中，對於相等的構成要素係賦予相等的符號。本發明不限定於下述實施型態。各圖所示之X、Y和Z，係指彼此正交的三個座標軸。各圖中的XYZ座標軸各者所示的方向係各圖共通。 The preferred embodiment of the present invention is described below with reference to the drawings. In the drawings, equal symbols are given to equal components. The present invention is not limited to the following embodiments. X, Y and Z shown in each figure refer to three coordinate axes that are orthogonal to each other. The directions shown by the XYZ coordinate axes in each figure are common to each figure.

本實施型態之光學構件的製造方法係可例如為偏光板(包含反射型偏光板)、相位差膜、亮度提升膜、附帶防眩功能的膜、附帶表面反射防止功能的膜、反射膜、半穿透反射膜或視野角補償膜的製造方法。 The manufacturing method of the optical component of this embodiment can be, for example, a method for manufacturing a polarizing plate (including a reflective polarizing plate), a phase difference film, a brightness enhancement film, a film with an anti-glare function, a film with a surface reflection prevention function, a reflective film, a semi-transmissive reflective film, or a viewing angle compensation film.

本實施型態之光學構件之製造方法的概要係如圖1至圖3所示。本實施型態之光學構件的製造方法係具備以一對旋轉刀(第一旋轉刀b1和第二旋轉刀b2)切削積層構造體2的切削步驟。在切削步驟中，積層構造體2之相對向的二個端面(第一端面f1和第二端面f2)係以一對旋轉刀大致同時(即並行地)被切削。積層構造體2及切削步驟的詳細內容係如以下所述。 The outline of the manufacturing method of the optical component of this embodiment is shown in Figures 1 to 3. The manufacturing method of the optical component of this embodiment has a cutting step of cutting the laminated structure 2 with a pair of rotary blades (first rotary blade b1 and second rotary blade b2). In the cutting step, the two opposite end faces (first end face f1 and second end face f2) of the laminated structure 2 are cut by a pair of rotary blades at approximately the same time (i.e., in parallel). The details of the laminated structure 2 and the cutting step are described below.

積層構造體2係包含彼此積層的複數層積層體4，各積層體4係包含彼此積層的複數層光學膜。積層構造體2中之積層體4的積層方向(Z軸方向)係與各積層體4中之光學膜的積層方向相同。所謂光學膜係指構成光學構件的膜狀(層狀)構件。光學膜係可例如為選自由偏光片膜、保護膜、 黏著劑(pressure sensitive adhesive，又稱壓敏性接著劑)層、離型膜、光學補償層、硬塗(hard coat)層、接觸式感測器(touch sensor)層、帶電防止層和防污層所構成之群的至少一種膜(層)。積層構造體2的積層構造並無限定。 The laminated structure 2 includes a plurality of laminated layers 4 laminated on each other, and each laminated layer 4 includes a plurality of optical films laminated on each other. The lamination direction (Z-axis direction) of the laminated layers 4 in the laminated structure 2 is the same as the lamination direction of the optical films in each laminated layer 4. The so-called optical film refers to a film-like (layer-like) component constituting an optical component. The optical film may be, for example, at least one film (layer) selected from the group consisting of a polarizer film, a protective film, an adhesive (pressure sensitive adhesive, also known as a pressure sensitive adhesive) layer, a release film, an optical compensation layer, a hard coat layer, a touch sensor layer, an antistatic layer, and an antifouling layer. The layered structure of the layered structure 2 is not limited.

圖1及圖3所示之積層構造體2係大致長方體。惟積層構造體亦可為大致立方體。積層構造體2係具有第一端面f1、第二端面f2、第三端面f3及第四端面f4。第一端面f1和第二端面f2係彼此相對向而且大致平行。第三端面f3和第四端面f4係彼此相對向而且大致平行。第一端面f1、第二端面f2、第三端面f3及第四端面f4各者係大致平行於光學膜的積層方向(Z軸方向)。積層構造體2的上表面tf及下表面uf各者，係大致垂直於積層方向(Z軸方向)。相對向之第一端面f1及第二端面f2各者的形狀及尺寸係彼此大致相同。相對向之第三端面f3及第四端面f4各者的形狀及尺寸係彼此大致相同。上表面tf及下表面uf各者係大致長方形。第一端面f1及第二端面f2各者係大致平行於積層構造體2的上表面tf及下表面uf各者的長邊(Y軸方向)。第三端面f3及第四端面f4係分別大致平行於積層構造體2的上表面tf及下表面uf各者的短邊(X軸方向)。第一研磨墊(pad)12a係與積層構造體2的上表面tf相接，第二研磨墊12b係與積層構造體2的下表面uf相接。積層構造體2係藉由由第一研磨墊12a及第二研磨墊12b所構成之夾鉗12，在積層方向(Z軸方向)上被挾持及固定。切削步驟中所研磨之積層構造體2的各端面係從第一研磨墊12a及第二研磨墊12b之間向外側突出。 The laminated structure 2 shown in FIG. 1 and FIG. 3 is a roughly rectangular parallelepiped. However, the laminated structure may also be a roughly cubical body. The laminated structure 2 has a first end face f1, a second end face f2, a third end face f3 and a fourth end face f4. The first end face f1 and the second end face f2 are opposite to each other and are roughly parallel. The third end face f3 and the fourth end face f4 are opposite to each other and are roughly parallel. The first end face f1, the second end face f2, the third end face f3 and the fourth end face f4 are each roughly parallel to the lamination direction (Z-axis direction) of the optical film. The upper surface tf and the lower surface uf of the laminated structure 2 are each roughly perpendicular to the lamination direction (Z-axis direction). The shapes and sizes of the first end face f1 and the second end face f2 that are opposite to each other are roughly the same. The shapes and sizes of the third end face f3 and the fourth end face f4 facing each other are substantially the same. The upper surface tf and the lower surface uf are substantially rectangular. The first end face f1 and the second end face f2 are substantially parallel to the long sides (Y-axis direction) of the upper surface tf and the lower surface uf of the multilayer structure 2. The third end face f3 and the fourth end face f4 are substantially parallel to the short sides (X-axis direction) of the upper surface tf and the lower surface uf of the multilayer structure 2, respectively. The first polishing pad 12a is connected to the upper surface tf of the multilayer structure 2, and the second polishing pad 12b is connected to the lower surface uf of the multilayer structure 2. The laminated structure 2 is clamped and fixed in the laminated direction (Z-axis direction) by a clamp 12 composed of a first polishing pad 12a and a second polishing pad 12b. Each end surface of the laminated structure 2 polished in the cutting step protrudes outward from between the first polishing pad 12a and the second polishing pad 12b.

如圖1所示，積層構造體2係由第一保護片(sheet)6a、複數層積層體4及第二保護片6b所構成。複數層積層體4係在第一保護片6a及第二保護片6b之間積層。相鄰之一對積層體4係彼此未被接著而可分離。第一保 護片6a及積層體4亦可彼此未被接著而可分離。第二保護片6b及積層體4亦可彼此未被接著而可分離。第一保護片6a及第二保護片6b各者亦可為聚苯乙烯(polystyrene)等樹脂。 As shown in FIG1 , the laminate structure 2 is composed of a first protective sheet 6a, a plurality of laminates 4, and a second protective sheet 6b. The plurality of laminates 4 are laminated between the first protective sheet 6a and the second protective sheet 6b. A pair of adjacent laminates 4 are not connected to each other and can be separated. The first protective sheet 6a and the laminate 4 can also be not connected to each other and can be separated. The second protective sheet 6b and the laminate 4 can also be not connected to each other and can be separated. The first protective sheet 6a and the second protective sheet 6b can also be resins such as polystyrene.

如圖2所示，各積層體4係包含積層的複數層光學膜8a、8b、8c、8d、8e、10a及10b。積層體4的積層構造並無限定。積層體4的積層構造亦可與完成後之光學構件的積層構造相同。例如，當光學構件為偏光板時，積層體4的積層構造係可與偏光板的積層構造相同。換言之，積層體4各者亦可為偏光板。例如，光學膜8a係可為偏光片膜。光學膜8b係可為第一保護膜。光學膜8c係可為第二保護膜。光學膜10a係可為第一黏著劑層，光學膜10b係可為第二黏著劑層。換言之，積層構造體2係可包含黏著劑層作為光學膜。光學膜8d係可為第一離型膜。光學膜8e係可為第二離型膜。第一保護膜(8b)係可直接形成於偏光片膜(8a)之一方的表面。第一保護膜(8b)係可藉由紫外線硬化樹脂等接著劑而貼合於偏光片膜(8a)之一方的表面。第二保護膜(8c)係可直接形成於偏光片(8a)之另一方的表面。第二保護膜(8c)係可藉由紫外線硬化樹脂等接著劑而貼合於偏光片膜(8a)之另一方的表面。 As shown in FIG2 , each laminate 4 includes a plurality of laminated optical films 8a, 8b, 8c, 8d, 8e, 10a and 10b. The laminated structure of the laminate 4 is not limited. The laminated structure of the laminate 4 may also be the same as the laminated structure of the optical component after completion. For example, when the optical component is a polarizing plate, the laminated structure of the laminate 4 may be the same as the laminated structure of the polarizing plate. In other words, each laminate 4 may also be a polarizing plate. For example, the optical film 8a may be a polarizer film. The optical film 8b may be a first protective film. The optical film 8c may be a second protective film. The optical film 10a can be a first adhesive layer, and the optical film 10b can be a second adhesive layer. In other words, the laminated structure 2 can include an adhesive layer as an optical film. The optical film 8d can be a first release film. The optical film 8e can be a second release film. The first protective film (8b) can be directly formed on the surface of one side of the polarizer film (8a). The first protective film (8b) can be attached to the surface of one side of the polarizer film (8a) by means of an adhesive such as an ultraviolet curing resin. The second protective film (8c) can be directly formed on the surface of the other side of the polarizer (8a). The second protective film (8c) can be attached to the surface of the other side of the polarizer film (8a) by means of an adhesive such as an ultraviolet curing resin.

偏光片膜係可為經由延伸、染色及交聯等步驟所製作之膜狀的聚乙烯醇(polyvinyl alcohol)(PVA)系樹脂。偏光片膜的厚度係可例如為1μm以上50μm以下。偏光片膜的縱幅及橫幅各者係可例如為30mm以上600mm以下。積層體4的厚度係可為例如10μm以上1200μm以下。 The polarizer film can be a film-shaped polyvinyl alcohol (PVA) resin produced by stretching, dyeing and cross-linking. The thickness of the polarizer film can be, for example, 1 μm to 50 μm. The length and width of the polarizer film can be, for example, 30 mm to 600 mm. The thickness of the laminate 4 can be, for example, 10 μm to 1200 μm.

第一保護膜及第二保護膜若為具有透光性的熱可塑性樹脂即可。構成第一保護膜及第二保護膜各者的樹脂，係可例如為鏈狀聚烯烴 (polyolefine)系樹脂、環狀烯烴聚合物(olefin polymer)系樹脂(COP系樹脂)、纖維素酯(cellulose ester)系樹脂(三醋酸纖維素(triacetyl cellulose)等)、聚酯(polyester)系樹脂、聚碳酸酯(polycarbonate)系樹脂、甲基丙烯酸(methacrylic)系樹脂、聚苯乙烯(polystyrene)系樹脂，或此等混合物或是共聚物。第一保護膜的組成係可與第二保護膜的組成相同。第一保護膜的組成亦可與第二保護膜的組成不同。第一保護膜的厚度係可為例如5μm以上90μm以下。第二保護膜的厚度亦可為例如5μm以上90μm以下。 The first protective film and the second protective film may be made of a light-transmitting thermoplastic resin. The resin constituting each of the first protective film and the second protective film may be, for example, a chain polyolefin resin, a cyclic olefin polymer resin (COP resin), a cellulose ester resin (triacetyl cellulose, etc.), a polyester resin, a polycarbonate resin, a methacrylic resin, a polystyrene resin, or a mixture or a copolymer thereof. The composition of the first protective film may be the same as that of the second protective film. The composition of the first protective film may also be different from that of the second protective film. The thickness of the first protective film can be, for example, greater than 5 μm and less than 90 μm. The thickness of the second protective film can also be, for example, greater than 5 μm and less than 90 μm.

第一黏著劑層及第二黏著劑層各者係可為由黏著劑所構成的層。第一黏著劑層及第二黏著劑層各者係可為光學用透明黏著(Optically Clear Adhesive，OCA)膜。例如，第一黏著劑層及第二黏著劑層各者係可由丙烯(acrylic)系感壓型黏著劑、橡膠系感壓型黏著劑、矽酮(silicone)系感壓型黏著劑或氨基甲酸酯(urethane)系感壓型黏著劑等黏著劑所構成。第一黏著劑層的組成係可與第二黏著劑層的組成不同。第一黏著劑層的厚度係可例如為2μm以上500μm以下。第二黏著劑層的厚度亦可例如為2μm以上500μm以下。 The first adhesive layer and the second adhesive layer may each be a layer composed of an adhesive. The first adhesive layer and the second adhesive layer may each be an optically clear adhesive (OCA) film. For example, the first adhesive layer and the second adhesive layer may each be composed of an adhesive such as an acrylic pressure-sensitive adhesive, a rubber pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, or a urethane pressure-sensitive adhesive. The composition of the first adhesive layer may be different from the composition of the second adhesive layer. The thickness of the first adhesive layer may be, for example, greater than 2 μm and less than 500 μm. The thickness of the second adhesive layer may also be, for example, greater than 2 μm and less than 500 μm.

構成第一離型膜及第二離型膜各者的樹脂，係可與構成第一保護膜或第二保護膜之上述的樹脂相同。第一離型膜的組成係可與第二離型膜的組成相同。第一離型膜的組成亦可與第二離型膜的組成不同。第一離型膜的厚度係可例如為5μm以上200μm以下。第二離型膜的厚度亦可為例如5μm以上200μm以下。 The resin constituting each of the first release film and the second release film may be the same as the above-mentioned resin constituting the first protective film or the second protective film. The composition of the first release film may be the same as the composition of the second release film. The composition of the first release film may also be different from the composition of the second release film. The thickness of the first release film may be, for example, greater than 5 μm and less than 200 μm. The thickness of the second release film may also be, for example, greater than 5 μm and less than 200 μm.

第一旋轉刀b1及第二旋轉刀b2各者係沿著積層體4的積層方向(Z軸方向)延伸。第一旋轉刀b1的側面s1係相對於積層構造體2的各端 面大致平行。第二旋轉刀b2的側面s2亦相對於積層構造體2的各端面大致平行。第一旋轉刀b1的旋轉軸線a1係大致平行於第一旋轉刀b1的側面s1。第二旋轉刀b2的旋轉軸線a2係大致平行於第二旋轉刀b2的側面s2。 The first rotary blade b1 and the second rotary blade b2 each extend along the lamination direction (Z-axis direction) of the laminated body 4. The side surface s1 of the first rotary blade b1 is roughly parallel to each end surface of the laminated structure 2. The side surface s2 of the second rotary blade b2 is also roughly parallel to each end surface of the laminated structure 2. The rotation axis a1 of the first rotary blade b1 is roughly parallel to the side surface s1 of the first rotary blade b1. The rotation axis a2 of the second rotary blade b2 is roughly parallel to the side surface s2 of the second rotary blade b2.

第一旋轉刀b1係具有形成於其側面s1的刀(刀口(edge))。藉由將繞著旋轉軸線a1旋轉之第一旋轉刀b1的側面s1抵靠於積層構造體2的端面，以切削積層構造體2的端面。第二旋轉刀b2亦具有形成於其側面s2的刀(刀口)。藉由將繞著旋轉軸線a2之第二旋轉刀b2的側面s2抵靠於積層構造體2的端面，以切削積層構造體2的端面。積層體4之積層方向(Z軸方向)上之各旋轉刀的寬度，係可為積層方向上之積層構造體2的寬度以上。 The first rotary blade b1 has a blade (edge) formed on its side surface s1. The side surface s1 of the first rotary blade b1 rotating around the rotation axis a1 is pressed against the end surface of the laminated structure 2 to cut the end surface of the laminated structure 2. The second rotary blade b2 also has a blade (edge) formed on its side surface s2. The side surface s2 of the second rotary blade b2 rotating around the rotation axis a2 is pressed against the end surface of the laminated structure 2 to cut the end surface of the laminated structure 2. The width of each rotary blade in the laminated direction (Z-axis direction) of the laminated structure 4 can be greater than the width of the laminated structure 2 in the laminated direction.

第一旋轉刀b1及第二旋轉刀b2各者係可為端銑刀。然而，第一旋轉刀b1及第二旋轉刀b2各者不限定於端銑刀。例如，第一旋轉刀b1及第二旋轉刀b2各亦可為側面配置有刨刀的旋轉刀。 Each of the first rotary cutter b1 and the second rotary cutter b2 may be an end milling cutter. However, each of the first rotary cutter b1 and the second rotary cutter b2 is not limited to an end milling cutter. For example, each of the first rotary cutter b1 and the second rotary cutter b2 may also be a rotary cutter with a planer disposed on the side.

在切削步驟中，大致平行於積層構造體2之上表面tf及下表面uf各者之長邊(Y軸方向)的第一端面f1及第二端面f2各者係藉由以下的方法切削。 In the cutting step, the first end face f1 and the second end face f2 which are roughly parallel to the long sides (Y-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2 are cut by the following method.

如圖3(a)所示，第一旋轉刀b1的側面s1係與積層構造體2的第一端面f1相接，同時切削第一端面f1的整體。第二旋轉刀b2的側面s2係和與第一端面f1相對向的第二端面f2相接，同時切削第二端面f2的整體。 As shown in Figure 3(a), the side surface s1 of the first rotary blade b1 is connected to the first end surface f1 of the laminated structure 2, and the first end surface f1 is cut as a whole. The side surface s2 of the second rotary blade b2 is connected to the second end surface f2 opposite to the first end surface f1, and the second end surface f2 is cut as a whole.

在切削步驟中，係大致同時地進行藉由第一旋轉刀b1切削第一端面f1及藉由第二旋轉刀b2切削第二端面f2。由於第一端面f1及第二端面f2彼此相對向，因此第一旋轉刀b1對於第一端面f1施加的壓力及第二旋轉刀b2對於第二端面f2施加的壓力容易取得平衡，且第一旋轉刀b1對於第 一端面f1施加的力矩及第二旋轉刀b2對於第二端面f2施加的力矩容易彼此抵銷，因此，積層構造體2的一部分或整體，不易在大致垂直於積層體4的積層方向(Z軸方向)的方向(XY面方向)上偏移。基於相同的理由，積層構造體2的一部分或整體，不易繞著大致平行於積層體4之積層方向(Z軸方向)的旋轉軸線a12(夾鉗的中軸線)旋轉。換言之，藉由將相對向之第一端面f1及第二端面f2大致同時地切削，抑制積層構造體2的位置偏移及扭歪。因此，可精密地控制各旋轉刀相對於積層構造體2之各端面的相對位置及相對移動速度，且可以較高的精確度切削第一端面f1及第二端面f2各者。藉由以上的機制，積層構造體2及積層體4各者的形狀及尺寸的精確度獲得提高。換言之，積層構造體2的上表面tf、下表面uf及各積層體4係以高精確度被加工。例如，第一端面f1與第二端面f2的間隔被均一地控制。此外，第一端面f1與第三端面f3的交叉角、第一端面f1與第四端面f4的交叉角、第二端面f2與第三端面f3的交叉角，及第二端面f2與第四端面f4的交叉角係被均一地控制。例如，當構成積層構造體2之積層體4的數量為100片，在積層方向(Z軸方向)上之黏著劑層之厚度相對於積層構造體2之厚度所佔之合計的比例為17%，各積層體4的厚度為190μm，切削步驟前之各積層體4之長邊的長度(Y方向上之積層體4的寬度)為155mm，切削步驟前之各積層體4之短邊的長度(X方向上之積層體4的寬度)為75mm時，切削步驟後之積層體4之短邊之長度從設計值偏移的寬度，最大為0.008mm左右，交叉角從90°偏移的幅度，最大為0.16°左右。另一方面，當第一端面f1及第二端面f2未被同時切削，第一端面f1及第二端面f2分別被一個旋轉刀切削時，積層體4之短邊 之長度從設計值偏移的寬度，最大為0.044mm左右，交叉角從90°偏移的幅度係0.29°左右。 In the cutting step, the first end face f1 is cut by the first rotary blade b1 and the second end face f2 is cut by the second rotary blade b2 at approximately the same time. Since the first end face f1 and the second end face f2 are opposite to each other, the pressure applied by the first rotary blade b1 to the first end face f1 and the pressure applied by the second rotary blade b2 to the second end face f2 are easily balanced, and the torque applied by the first rotary blade b1 to the first end face f1 and the torque applied by the second rotary blade b2 to the second end face f2 are easily offset, so that a part or the whole of the laminated structure 2 is not easily offset in the direction (XY plane direction) approximately perpendicular to the laminated direction (Z axis direction) of the laminated structure 4. For the same reason, part or all of the laminated structure 2 is not easy to rotate around the rotation axis a12 (the center axis of the clamp) which is roughly parallel to the lamination direction (Z-axis direction) of the laminated structure 4. In other words, by cutting the first end face f1 and the second end face f2 facing each other roughly at the same time, the position deviation and distortion of the laminated structure 2 are suppressed. Therefore, the relative position and relative movement speed of each rotating knife relative to each end face of the laminated structure 2 can be precisely controlled, and each of the first end face f1 and the second end face f2 can be cut with higher accuracy. Through the above mechanism, the accuracy of the shape and size of each of the laminated structure 2 and the laminated structure 4 is improved. In other words, the upper surface tf, the lower surface uf of the laminated structure 2 and each laminated body 4 are processed with high precision. For example, the interval between the first end face f1 and the second end face f2 is uniformly controlled. In addition, the intersection angle between the first end face f1 and the third end face f3, the intersection angle between the first end face f1 and the fourth end face f4, the intersection angle between the second end face f2 and the third end face f3, and the intersection angle between the second end face f2 and the fourth end face f4 are uniformly controlled. For example, when the number of laminated bodies 4 constituting the laminated structure 2 is 100, the total ratio of the thickness of the adhesive layer in the laminated direction (Z-axis direction) to the thickness of the laminated structure 2 is 17%, the thickness of each laminated body 4 is 190 μm, and the length of the long side of each laminated body 4 before the cutting step (the length of the laminated body in the Y-axis direction) is 17%. 4) is 155mm, and the length of the short side of each laminate 4 before the cutting step (the width of the laminate 4 in the X direction) is 75mm, the width of the short side of the laminate 4 after the cutting step is about 0.008mm at most from the design value, and the deviation of the crossing angle from 90° is about 0.16° at most. On the other hand, when the first end face f1 and the second end face f2 are not cut at the same time, and the first end face f1 and the second end face f2 are cut by a rotating cutter respectively, the width of the short side of the laminate 4 is about 0.044mm at most from the design value, and the deviation of the crossing angle from 90° is about 0.29°.

在垂直於積層方向(Z軸方向)之方向(XY平面方向)上，第一端面f1及第二端面f2各者的寬度係比第三端面f3及第四端面f4各者的寬度更大。垂直於積層方向(Z軸方向)之方向(XY面方向)上之端面的寬度愈大，旋轉刀愈易於施加力矩於端面。因此，假設當寬度較大之第一端面f1及第二端面f2各者僅使用一個旋轉刀非同時地進行切削時，如圖4(a)所示，由於旋轉刀(b1)施加於積層構造體2的力F，積層構造體2的整體繞著大致平行於積層方向(Z軸方向)之旋轉軸線a12(夾鉗12的中心軸線)旋轉，積層構造體2易於從預定的位置偏移，且如圖4(b)所示，構成積層構造體2的各積層體4係繞著大致平行於積層方向(Z軸方向)之旋轉軸線a12(夾鉗12的中心軸線)旋轉，而使積層構造體2易於扭歪。尤其積層方向(Z軸方向)上之積層構造體2的中央部特別易於旋轉，且構成積層構造體2之積層體4的片數愈多，則愈易於引起積層構造體2的位置偏移及扭歪。各積層體4包含第一黏著劑層及第二黏著劑層等黏著劑層作為光學膜10a及10b時，由於黏著劑層比其他光學膜更為柔軟，因此積層構造體2易於扭歪。結果，在切削步驟中，難以精密地控制第一端面f1及第二端面f2各者的形狀，且難以以較高的精確度將積層構造體2的上表面tf、下表面uf及各積層體4加工為異形。另一方面，以本實施型態之情形而言，藉由上述的機制，即可抑制在切削寬度較大之第一端面f1及第二端面f2中之積層構造體2的位置偏移及扭歪。 In the direction perpendicular to the lamination direction (Z-axis direction) (XY plane direction), the width of each of the first end face f1 and the second end face f2 is greater than the width of each of the third end face f3 and the fourth end face f4. The greater the width of the end face in the direction perpendicular to the lamination direction (Z-axis direction) (XY plane direction), the easier it is for the rotating tool to apply torque to the end face. Therefore, assuming that when the first end face f1 and the second end face f2 with a larger width are each cut non-simultaneously using only one rotating tool, as shown in Figure 4(a), due to the force F applied to the lamination direction (Z-axis direction) by the rotating tool (b1), the entire lamination structure 2 rotates around the rotation axis a1 which is roughly parallel to the lamination direction (Z-axis direction). 2 (the center axis of the clamp 12), the laminated structure 2 is easily deviated from the predetermined position, and as shown in FIG4(b), each laminated body 4 constituting the laminated structure 2 rotates around the rotation axis a12 (the center axis of the clamp 12) which is substantially parallel to the lamination direction (Z-axis direction), making the laminated structure 2 easily twisted. In particular, the central portion of the laminated structure 2 in the lamination direction (Z-axis direction) is particularly easy to rotate, and the more laminated bodies 4 constituting the laminated structure 2 are, the easier it is to cause the position of the laminated structure 2 to deviate and twist. When each laminate 4 includes adhesive layers such as the first adhesive layer and the second adhesive layer as optical films 10a and 10b, the laminate structure 2 is easily distorted because the adhesive layer is softer than other optical films. As a result, it is difficult to precisely control the shape of each of the first end face f1 and the second end face f2 in the cutting step, and it is difficult to process the upper surface tf, the lower surface uf and each laminate 4 of the laminate structure 2 into an irregular shape with high precision. On the other hand, in the case of this embodiment, the above-mentioned mechanism can suppress the positional deviation and distortion of the laminate structure 2 in the first end face f1 and the second end face f2 with a larger cutting width.

由於藉由上述的機制即可抑制積層構造體2的位置偏移及扭歪，故依據本實施型態，可使構成積層構造體2之積層體4的數量增加。藉 由增加能一併切削之積層體4的數量，使得切削步驟的所需時間縮短，且使光學構件的生產力獲得提升。再者，依據本實施型態，即使構成積層構造體2的各積層體4包含黏著劑層時，亦可易於控制積層構造體2的位置偏移及扭歪。 Since the positional deviation and distortion of the laminated structure 2 can be suppressed by the above-mentioned mechanism, the number of laminated bodies 4 constituting the laminated structure 2 can be increased according to this embodiment. By increasing the number of laminated bodies 4 that can be cut at the same time, the time required for the cutting step is shortened and the productivity of the optical component is improved. Furthermore, according to this embodiment, even if each laminated body 4 constituting the laminated structure 2 includes an adhesive layer, the positional deviation and distortion of the laminated structure 2 can be easily controlled.

如圖3所示，從第一旋轉刀b1延伸的虛線及箭號，係表示切削步驟中之第一旋轉刀b1的移動路徑及移動方向。第一旋轉刀b1之移動路徑及移動方向係可相對於積層構造體2為相對性者。換言之，可為第一旋轉刀b1本身移動，亦可為積層構造體2本身移動。如圖3所示，從第二旋轉刀b2延伸的虛線及箭號，係表示切削步驟中之第二旋轉刀b2的移動路徑及移動方向。 As shown in FIG3 , the dotted line and arrow extending from the first rotary blade b1 indicate the moving path and moving direction of the first rotary blade b1 in the cutting step. The moving path and moving direction of the first rotary blade b1 may be relative to the laminated structure 2. In other words, the first rotary blade b1 itself may move, or the laminated structure 2 itself may move. As shown in FIG3 , the dotted line and arrow extending from the second rotary blade b2 indicate the moving path and moving direction of the second rotary blade b2 in the cutting step.

第二旋轉刀b2之移動路徑及移動方向係可相對於積層構造體2為相對性者。 The moving path and moving direction of the second rotating blade b2 can be relative to the layered structure 2.

換言之，可為第二旋轉刀b2本身移動，亦可為積層構造體2本身移動。如從第一旋轉刀b1及第二旋轉刀b2各者延伸的虛線及箭號所示，在切削步驟中，第一旋轉刀b1及第二旋轉刀b2係可沿著相對向的第一端面f1及第二端面f2移動。在切削步驟中，第一旋轉刀b1及第二旋轉刀b2係可沿著相對向的第一端面f1及第二端面f2並進。藉由第一旋轉刀b1及第二旋轉刀b2並行地移動，作用於第一端面f1及第二端面f2各者上的力矩易於彼此抵銷，易於抑制積層構造體2的旋轉及扭歪。基於相同的理由，第一旋轉刀b1施加於第一端面f1的壓力，係可與第二旋轉刀b2施加於第二端面f2的壓力大致相等，而大致平行於第一端面f1之方向上之第一旋轉刀b1的移動速度，係可與大致平行於第二端面f2之方向上之第二旋轉刀b2的移動速度大致相同。 在第一端面f1及第二端面f2被切削的過程中，第一旋轉刀b1及第二旋轉刀b2的間隔係可自由地變動。藉由控制第一旋轉刀b1及第二旋轉刀b2的間隔，將第一端面f1及第二端面f2各者精密地加工。在第一端面f1及第二端面f2被切削的過程中，夾鉗12的位置係可固定。或者在第一端面f1及第二端面f2被切削的過程中，大致平行於第一端面f1及第二端面f2之方向(Y軸方向)上之第一旋轉刀b1及第二旋轉刀b2各者的位置係可固定，而夾鉗12係可沿著大致平行於第一端面f1及第二端面f2之方向(Y軸方向)移動。換言之，被夾鉗12所挾持的積層構造體2，可通過第一旋轉刀b1及第二旋轉刀b2之間。 In other words, the second rotary blade b2 itself may move, or the laminated structure 2 itself may move. As shown by the dotted lines and arrows extending from each of the first rotary blade b1 and the second rotary blade b2, in the cutting step, the first rotary blade b1 and the second rotary blade b2 may move along the first end face f1 and the second end face f2 that are opposite to each other. In the cutting step, the first rotary blade b1 and the second rotary blade b2 may move in parallel along the first end face f1 and the second end face f2 that are opposite to each other. By the first rotary blade b1 and the second rotary blade b2 moving in parallel, the moments acting on each of the first end face f1 and the second end face f2 are easily offset, and the rotation and distortion of the laminated structure 2 are easily suppressed. For the same reason, the pressure applied by the first rotary blade b1 to the first end face f1 can be roughly equal to the pressure applied by the second rotary blade b2 to the second end face f2, and the moving speed of the first rotary blade b1 in a direction roughly parallel to the first end face f1 can be roughly equal to the moving speed of the second rotary blade b2 in a direction roughly parallel to the second end face f2. During the process of cutting the first end face f1 and the second end face f2, the interval between the first rotary blade b1 and the second rotary blade b2 can be freely changed. By controlling the interval between the first rotary blade b1 and the second rotary blade b2, each of the first end face f1 and the second end face f2 is precisely processed. During the process of cutting the first end face f1 and the second end face f2, the position of the clamp 12 can be fixed. Alternatively, during the cutting process of the first end face f1 and the second end face f2, the positions of the first rotary blade b1 and the second rotary blade b2 in the direction roughly parallel to the first end face f1 and the second end face f2 (Y-axis direction) can be fixed, and the clamp 12 can be moved along the direction roughly parallel to the first end face f1 and the second end face f2 (Y-axis direction). In other words, the laminated structure 2 clamped by the clamp 12 can pass between the first rotary blade b1 and the second rotary blade b2.

光學構件的製造方法係可更具備在切削步驟前實施的加工步驟。可藉由加工步驟來形成積層構造體2及各積層體4。加工步驟中所使用的加工手段可為衝切或切斷。加工步驟中所使用的切斷手段係可為刀具或雷射(例如CO2(二氧化碳)氣體雷射或準分子雷射(excimer laser)。 The manufacturing method of the optical component may further include a processing step performed before the cutting step. The layered structure 2 and each layered body 4 may be formed by the processing step. The processing means used in the processing step may be punching or cutting. The cutting means used in the processing step may be a tool or a laser (e.g., a CO 2 (carbon dioxide) gas laser or an excimer laser).

在藉由上述的旋轉刀切削積層構造體2之所有端面(第一端面f1、第二端面f2、第三端面f3及第四端面f4)之一連串的過程中，夾鉗12始終相對於大致平行於積層方向(Z軸方向)的旋轉軸線a12(夾鉗12的中心軸線)不旋轉。換言之，夾鉗12從開始積層構造體2之端面之切削的時點至所有端面之切削完成的時點為止不旋轉。惟夾鉗12亦可在積層構造體2的任一個端面均未被切削的時點旋轉。夾鉗12亦可在積層構造體2之所有端面的切削完成之後旋轉。假設夾鉗12在藉由旋轉刀切削積層構造體2之所有端面之一連串的過程中旋轉時，如圖4(b)所示，構成積層構造體2的各積層體4係與夾鉗12連動地繞著大致平行於積層方向(Z軸方向)的旋轉軸線a12(夾 鉗12的中心軸線)旋轉，而使積層構造體2易於扭歪。另一方面，當夾鉗12在藉由旋轉刀切削積層構造體2之所有端面的過程中始終不旋轉時，積層構造體2的扭歪被抑制。結果，可易於精密地控制積層構造體2之所有端面的形狀，且可以高精確度將積層構造體2的上表面tf、下表面uf及各積層體4加工為異形。 In a series of processes in which all the end faces (the first end face f1, the second end face f2, the third end face f3 and the fourth end face f4) of the laminated structure 2 are cut by the above-mentioned rotating cutter, the clamp 12 never rotates relative to the rotation axis a12 (the center axis of the clamp 12) which is roughly parallel to the lamination direction (Z-axis direction). In other words, the clamp 12 does not rotate from the time when the cutting of the end faces of the laminated structure 2 starts to the time when the cutting of all the end faces is completed. However, the clamp 12 can also rotate at a point in time when any end face of the laminated structure 2 has not been cut. The clamp 12 can also rotate after the cutting of all the end faces of the laminated structure 2 is completed. Assuming that the clamp 12 rotates during a series of processes in which all end faces of the laminated structure 2 are cut by a rotating blade, as shown in FIG4(b), each laminated structure 4 constituting the laminated structure 2 rotates in conjunction with the clamp 12 around a rotation axis a12 (the center axis of the clamp 12) substantially parallel to the lamination direction (Z-axis direction), and the laminated structure 2 is easily twisted. On the other hand, when the clamp 12 never rotates during the process in which all end faces of the laminated structure 2 are cut by a rotating blade, the twisting of the laminated structure 2 is suppressed. As a result, the shapes of all end faces of the laminated structure 2 can be easily and precisely controlled, and the upper surface tf, lower surface uf of the laminated structure 2 and each laminated body 4 can be processed into an irregular shape with high precision.

如上所述，在藉由旋轉刀切削積層構造體2之所有端面的過程中，夾鉗12始終不旋轉。因此，在藉由旋轉刀切削積層構造體2之所有端面的過程中，第一旋轉刀b1及第二旋轉刀b2各者所設置的位置係自如地變更。例如，圖3所示之位置p1、p2、p3及p4為在切削步驟中第一旋轉刀b1及第二旋轉刀b2各者所設置的位置。位置p1係第一端面f1與第四端面f4相交之角部。位置p2係第二端面f2與第四端面f4相交之角部。位置p3係第一端面f1與第三端面f3相交之角部。位置p4係第二端面f2與第三端面f3相交之角部。只要相對向的兩個端面被一對旋轉刀大致同時切削，則並不限定第一旋轉刀b1及第二旋轉刀b2各者所設置的位置。只要相對向的兩個端面被一對旋轉刀大致同時切削，亦不限定第一端面f1、第二端面f2、第三端面f3與第四端面f4的切削順序，且亦不限定各端面與切削各端面之旋轉刀的組合。 As described above, during the process of cutting all the end faces of the laminated structure 2 by the rotary cutter, the clamp 12 never rotates. Therefore, during the process of cutting all the end faces of the laminated structure 2 by the rotary cutter, the positions at which the first rotary cutter b1 and the second rotary cutter b2 are respectively set can be freely changed. For example, the positions p1, p2, p3 and p4 shown in FIG. 3 are the positions at which the first rotary cutter b1 and the second rotary cutter b2 are respectively set in the cutting step. Position p1 is the corner where the first end face f1 and the fourth end face f4 intersect. Position p2 is the corner where the second end face f2 and the fourth end face f4 intersect. Position p3 is the corner where the first end face f1 and the third end face f3 intersect. Position p4 is the corner where the second end face f2 and the third end face f3 intersect. As long as the two opposite end faces are cut by a pair of rotary knives at approximately the same time, the positions of the first rotary knife b1 and the second rotary knife b2 are not limited. As long as the two opposite end faces are cut by a pair of rotary knives at approximately the same time, the cutting order of the first end face f1, the second end face f2, the third end face f3 and the fourth end face f4 is not limited, and the combination of each end face and the rotary knife for cutting each end face is not limited.

例如，大致平行於積層構造體2的上表面tf及下表面uf各者的短邊(X軸方向)之第三端面f3及第四端面f4，係與第一端面f1及第二端面f2同樣地，可以一對旋轉刀(第一旋轉刀b1及第二旋轉刀b2)大致同時(即並行地)被切削。例如，第一旋轉刀b1可設置於位置p3，第二旋轉刀b2可設置於位置p1，第二旋轉刀b2可與從位置p3往位置p4之第一旋轉刀b1的移動並行地從位置p1往位置p2移動。 For example, the third end face f3 and the fourth end face f4, which are roughly parallel to the short sides (X-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, can be cut by a pair of rotary blades (first rotary blade b1 and second rotary blade b2) roughly at the same time (i.e., in parallel) as the first end face f1 and the second end face f2. For example, the first rotary blade b1 can be set at position p3, the second rotary blade b2 can be set at position p1, and the second rotary blade b2 can move from position p1 to position p2 in parallel with the movement of the first rotary blade b1 from position p3 to position p4.

第三端面f3及第四端面f4各者可使用第一旋轉刀b1或第二旋轉刀b2而非同時地被切削。例如，在切削步驟的開始時點，第一旋轉刀b1可設置於位置p2，第四端面f4可藉由從位置p2往位置p1移動之第一旋轉刀b1而被切削。在切削第四端面f4之後，可將第一旋轉刀b1設置在位置p1，且可將第二旋轉刀b2設置在位置p2。而且，可大致同時地進行藉由第一旋轉刀b1切削第一端面f1及藉由第二旋轉刀b2切削第二端面f2。在同時切削第一端面f1及第二端面f2之後，可將第一旋轉刀b1設置在位置p3，第三端面f3可藉由從位置p3往位置p4移動之第一旋轉刀b1而被切削。 The third end face f3 and the fourth end face f4 may be cut using the first rotary blade b1 or the second rotary blade b2 instead of simultaneously. For example, at the start of the cutting step, the first rotary blade b1 may be set at position p2, and the fourth end face f4 may be cut by the first rotary blade b1 moving from position p2 to position p1. After cutting the fourth end face f4, the first rotary blade b1 may be set at position p1, and the second rotary blade b2 may be set at position p2. Moreover, the first end face f1 may be cut by the first rotary blade b1 and the second end face f2 may be cut by the second rotary blade b2 at approximately the same time. After cutting the first end face f1 and the second end face f2 simultaneously, the first rotary blade b1 may be set at position p3, and the third end face f3 may be cut by the first rotary blade b1 moving from position p3 to position p4.

在切削步驟中，亦可除了第一旋轉刀b1或第二旋轉刀b2還使用其他的旋轉刀。換言之，在切削步驟中可使用三個以上的旋轉刀。 In the cutting step, other rotary knives may be used in addition to the first rotary knife b1 or the second rotary knife b2. In other words, more than three rotary knives may be used in the cutting step.

光學構件的製造方法亦可更具備形成在積層體4的積層方向上貫通積層構造體2之孔的步驟。亦可在上述之切削步驟前，形成貫通積層構造體2的孔。亦可在上述之切削步驟後，形成貫通積層構造體2的孔。形成貫通積層構造體2之孔的手段，可為衝切裝置、鑽頭(drill)等旋轉刀或雷射。雷射係可例如為CO2氣體雷射或準分子雷射。貫通積層構造體2之孔的內壁，係可藉由上述的第一旋轉刀b1或第二旋轉刀b2切削。 The manufacturing method of the optical component may also include a step of forming a hole penetrating the laminated structure 2 in the lamination direction of the laminated body 4. The hole penetrating the laminated structure 2 may be formed before the above-mentioned cutting step. The hole penetrating the laminated structure 2 may be formed after the above-mentioned cutting step. The means for forming the hole penetrating the laminated structure 2 may be a punching device, a rotary blade such as a drill, or a laser. The laser may be, for example, a CO2 gas laser or an excimer laser. The inner wall of the hole penetrating the laminated structure 2 may be cut by the above-mentioned first rotary blade b1 or the second rotary blade b2.

光學構件的製造方法係亦可具備：在切削步驟之後，將從積層體4的積層方向(Z軸方向)觀察之積層構造體2的四個角部中之至少一個角部藉由第一旋轉刀b1或第二旋轉刀b2予以倒角的步驟。被倒角後之角部係例如可為曲面。 The manufacturing method of the optical component may also include: after the cutting step, at least one of the four corners of the laminated structure 2 observed from the laminated direction (Z-axis direction) of the laminated body 4 is chamfered by the first rotary blade b1 or the second rotary blade b2. The chamfered corner may be, for example, a curved surface.

光學構件的製造方法係可更具備：在切削步驟之後，在積層構造體2的四個端面中之至少一個端面，形成朝積層體4的積層方向(Z軸方 向)延伸之缺口部(凹坑)的步驟。例如，缺口部係可形成於寬度較窄之第三端面f3及第四端面f4中之至少一者之端面。從積層體4的積層方向(Z軸方向)觀察之缺口部的形狀並無限定。從積層體4的積層方向(Z軸方向)觀察之缺口部的形狀係例如可為大致長方形或大致正方形之四角形、三角形、其他多角形、或半圓、半橢圓、或其他曲線。 The manufacturing method of the optical component can be further equipped with: after the cutting step, a step of forming a notch (pit) extending in the lamination direction (Z-axis direction) of the laminate 4 on at least one of the four end faces of the laminate structure 2. For example, the notch can be formed on at least one of the third end face f3 and the fourth end face f4 with a narrower width. The shape of the notch observed from the lamination direction (Z-axis direction) of the laminate 4 is not limited. The shape of the notch observed from the lamination direction (Z-axis direction) of the laminate 4 can be, for example, a roughly rectangular or roughly square quadrilateral, a triangle, other polygons, or a semicircle, a semi-ellipse, or other curves.

經過以上之步驟的積層構造體2係可作為一個積層光學膜來使用。構成經過以上之步驟之積層構造體2的各積層體4係可作為光學構件來使用。 The laminated structure 2 after the above steps can be used as a laminated optical film. Each laminated body 4 constituting the laminated structure 2 after the above steps can be used as an optical component.

[產業上之可利用性] [Industrial availability]

藉由本發明之製造方法所獲得的光學構件係可利用於液晶顯示器、有機EL顯示器、智慧型手機、智慧型手錶或車輛的儀表板等圖像顯示裝置。 The optical component obtained by the manufacturing method of the present invention can be used in image display devices such as liquid crystal displays, organic EL displays, smart phones, smart watches or vehicle dashboards.

2:積層構造體 2: Layered structure

a12:大致平行於積層體之積層方向的旋轉軸線 a12: The rotation axis roughly parallel to the stacking direction of the stack

b1:第一旋轉刀 b1: First rotary knife

b2:第二旋轉刀 b2: Second rotary knife

f1:第一端面 f1: first end face

f2:第二端面 f2: second end face

f3:第三端面 f3: The third end face

f4:第四端面 f4: the fourth end face

s1,s2:側面 s1,s2: side

tf:上表面 tf: upper surface

p1~p4:位置 p1~p4: Location

Claims (6)

一種光學構件的製造方法，係具備：以一對旋轉刀切削積層構造體的切削步驟；前述積層構造體係包含彼此積層的複數層積層體，前述積層體係包含彼此積層的複數層光學膜，前述積層構造體係大致長方體或大致立方體，前述積層構造體之各端面係大致平行於前述積層體的積層方向，前述積層構造體的上表面及下表面係大致垂直於前述積層方向，前述積層構造體係藉由與前述積層構造體之前述上表面和前述下表面相接的夾鉗所挾持，前述旋轉刀係沿著前述積層方向延伸，前述旋轉刀的側面係大致平行於前述積層構造體的前述端面，前述旋轉刀的旋轉軸線係大致平行於前述旋轉刀的側面，一方之前述旋轉刀的前述側面係與前述積層構造體之相對向之兩個前述端面中之一方的前述端面相接，另一方之前述旋轉刀的前述側面係與前述積層構造體之相對向之兩個前述端面中之另一方的前述端面相接，前述積層構造體之相對向的二個前述端面係被一對前述旋轉刀大致同時地切削，在以前述旋轉刀切削前述積層構造體之所有端面的過程中，設置一對前述旋轉刀的位置會變更，且 在以前述旋轉刀切削前述積層構造體之所有端面的過程中，前述夾鉗係始終相對於大致平行於前述積層方向的旋轉軸線不旋轉。 A method for manufacturing an optical component comprises: a step of cutting a stacked structure with a pair of rotating knives; the stacked structure comprises a plurality of stacked layers, the stacked structure comprises a plurality of optical films stacked together, the stacked structure is substantially rectangular or cubic, each end face of the stacked structure is substantially parallel to the stacked edges of the stacked structure, The stacking structure is clamped by clamps connected to the upper surface and the lower surface of the stacking structure, the rotating blade extends along the stacking direction, the side surface of the rotating blade is substantially parallel to the end surface of the stacking structure, and the rotating blade rotates The axis is substantially parallel to the side surface of the rotary blade, the side surface of the rotary blade is in contact with the end surface of one of the two opposite end surfaces of the laminated structure, and the side surface of the rotary blade is in contact with the end surface of the other of the two opposite end surfaces of the laminated structure. The aforementioned end faces are cut by the pair of aforementioned rotating knives substantially simultaneously, and in the process of cutting all the end faces of the aforementioned laminated structure with the aforementioned rotating knives, the positions of the pair of aforementioned rotating knives are changed, and in the process of cutting all the end faces of the aforementioned laminated structure with the aforementioned rotating knives, the aforementioned clamps always do not rotate relative to the rotation axis substantially parallel to the aforementioned lamination direction. 如請求項1所述之光學構件的製造方法，其中，前述積層構造體的前述上表面及前述下表面各者係大致長方形，大致同時被切削的二個前述端面係大致平行於前述積層構造體的前述上表面及前述下表面各者的長邊。 The manufacturing method of an optical component as described in claim 1, wherein the upper surface and the lower surface of the laminated structure are each approximately rectangular, and the two end faces cut approximately simultaneously are approximately parallel to the long sides of the upper surface and the lower surface of the laminated structure. 如請求項1或2所述之光學構件的製造方法，其中，在前述切削步驟中，前述一對之前述旋轉刀係沿著前述積層構造體之相對向的兩個前述端面移動。 A method for manufacturing an optical component as described in claim 1 or 2, wherein, in the aforementioned cutting step, the aforementioned pair of aforementioned rotating cutters moves along the two aforementioned end faces facing each other of the aforementioned laminated structure. 如請求項1或2所述之光學構件的製造方法，其中，在前述切削步驟中，前述夾鉗係沿著與前述積層構造體之相對向的兩個前述端面大致平行的方向移動。 A method for manufacturing an optical component as described in claim 1 or 2, wherein, in the aforementioned cutting step, the aforementioned clamp moves in a direction substantially parallel to the two aforementioned end faces opposite to the aforementioned laminated structure. 如請求項1或2所述之光學構件的製造方法，其中，前述積層體係包含至少一黏著劑層。 A method for manufacturing an optical component as described in claim 1 or 2, wherein the aforementioned laminate includes at least one adhesive layer. 如請求項1或2所述之光學構件的製造方法，其中，前述旋轉刀係端銑刀。 A method for manufacturing an optical component as described in claim 1 or 2, wherein the aforementioned rotating tool is an end milling tool.
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