TWI738770B - Method for manufacturing optical member with separate film - Google Patents

Abstract

The present invention is to provide a method for manufacturing an optical member with separate film which is capable of maintaining good adhesion between an adhesive layer and its adjacent member, even if it undergoes bending caused by a flexible display.

The method for manufacturing optical member with separate film of the present invention comprises the following steps: coating step that an active energy ray-curable type adhesive composition is coated on an elongated separate film to form a coating layer; exposure step that continuously transporting a separate film having a coating layer, while patterning exposure of the coating layer by irradiation with active energy ray to form a separate film having a coating layer comprises first exposed area and a second area having a smaller exposure amount than the first area; sticking step that while continuously conveying the film after the exposure step, a long optical member is laminated on the outer surface of the adhesive layer, and the laminate is being pressed from above and below.

Description

Manufacturing method of optical component with release film

The present invention relates to a method for manufacturing an optical component with a release film including a release film, an adhesive layer, and an optical component in sequence.

Various optical components typified by polarizers etc. are sometimes used by bonding them to other components such as image display units via an adhesive layer (for example, Patent Document 1). Therefore, optical components are circulated in the market in the form of optical components with an adhesive layer preliminarily provided with an adhesive layer on one side. Generally, a peelable release film (also called a "separation film") is temporarily installed on the outer surface of the adhesive layer to protect the surface.

(Prior technical literature) (Patent Document)

[Patent Document 1] JP 2008-275722 A

As a display with both the above-mentioned optical components and image display unit, a flexible display can be set on a non-planar surface and a bending surface, and can be folded into a roll shape when carried. Can improve portability. Therefore, it is expected to be used for assembly purposes in portable devices. For optical components with adhesive layers used in flexible displays, even if the flexible displays are bent (for example, bends, bends, etc.) or bends repeatedly, the adhesive layer is required to be adjacent to the components Adhesion without peeling.

The object of the present invention is to provide a method for manufacturing an optical component with a release film, wherein the optical component with a release film is a laminate of a release film with an adhesive layer and an optical component, even for a flexible type The bending of the display can also maintain good adhesion between the adhesive layer and the adjacent components.

The present invention provides a method for manufacturing an optical component with a release film as shown below.

[1] A method of manufacturing an optical component with a release film, which includes the following steps, a coating step: coating an active energy ray-curable adhesive composition on a strip of release film to form a coating layer The step; the exposure step: one side of the release film with the coating layer is continuously transported, and the coating layer is patterned through the irradiation of active energy rays to obtain a first region containing the exposed first area and the exposure amount less than the first The step of peeling off the film of the adhesive layer in the second area of the first area; the laminating step: the film after the above-mentioned exposure step is continuously transported, while the long optical components are laminated on the outer surface of the adhesive layer, and then The step of squeezing the laminate from above and below.

[2] The manufacturing method as described in [1], in the exposure step, pattern exposure is performed by irradiation with the active energy ray through a mask.

[3] The manufacturing method according to [2], wherein the mask has a penetration portion extending along the direction of the conveying direction of the release film with the coating layer, and the penetration portion is along the direction with the coating layer. The layers of the release film are arranged in the width direction.

[4] The manufacturing method according to [2], wherein the mask is a gradation mask.

[5] The manufacturing method according to any one of [1] to [4], which further includes an aging step of winding the optical component with a release film obtained in the above bonding step into a roll Then, the step of curing the adhesive layer is carried out in a roll state.

[6] The manufacturing method according to any one of [1] to [5], in the exposure step, the active energy ray system irradiates the coating layer multiple times.

[7] The manufacturing method according to any one of [1] to [6], further comprising a surface activation step, which is a step of bonding with the adhesive layer in the optical component before the bonding step. At least one of the bonding surface and the bonding surface of the above-mentioned adhesive layer with the above-mentioned optical component is subjected to a step of energy irradiation.

[8] The manufacturing method according to any one of [1] to [7], wherein the optical component is a polarizing plate.

According to the manufacturing method of the present invention, it is possible to provide an optical component with a release film, and the optical component with a release film, for the bending in the flexible display used, is adjacent to the adhesive layer The components can also maintain good adhesion.

1‧‧‧The first feed roller

2‧‧‧The second feed roller

3‧‧‧Winding roller

10‧‧‧Peeling film

11‧‧‧Coating layer

12‧‧‧Adhesive layer

12a‧‧‧Region 1

12b‧‧‧Region 2

15‧‧‧Release film with coating layer

20‧‧‧Release film with adhesive layer

30‧‧‧Optical components

40‧‧‧Optical components with peeling film

50‧‧‧Coating device

60‧‧‧Coating roller

70‧‧‧Drying means

80‧‧‧Exposure device (active energy ray irradiation device)

81‧‧‧Mask

81a‧‧‧ Lens Hood

81b‧‧‧Halftone mask

82, 83‧‧‧Halftone masked area

85‧‧‧Slit

90‧‧‧Laminating roller

Fig. 1 is a schematic diagram showing an example of the manufacturing method of the release film-attached optical component of the present invention and the manufacturing apparatus used in it.

Fig. 2 is a schematic cross-sectional view showing an example of a release film having a coating layer.

Fig. 3 is a schematic cross-sectional view showing an example of a release film with an adhesive layer.

Fig. 4 is a schematic diagram showing an example of the bending state of the flexible display.

Fig. 5 is a schematic plan view showing a state in which active energy rays are irradiated on the coating layer through the mask.

Fig. 6 is a schematic plan view showing an example of the arrangement pattern of the first area and the second area in the adhesive layer.

Fig. 7 is a schematic cross-sectional view showing an example of an active energy ray irradiation method using a mask.

Fig. 8 is a schematic cross-sectional view showing another example of an active energy ray irradiation method using a mask.

Fig. 9 is a schematic plan view showing another example of the arrangement pattern of the first area and the second area in the adhesive layer.

Fig. 10 is a schematic plan view showing another example of the arrangement pattern of the first area and the second area in the adhesive layer.

Fig. 11 is a schematic plan view showing another example of the arrangement pattern of the first area and the second area in the adhesive layer.

Fig. 12 is a schematic plan view showing another example of the arrangement pattern of the first area and the second area in the adhesive layer.

Fig. 13 is a schematic cross-sectional view showing an example of an optical module with a release film.

The method of manufacturing an optical component with a release film of the present invention includes the following steps: a coating step: a step of coating an active energy ray-curable adhesive composition on a strip of release film to form a coating layer ; Exposure step: one side continuously conveys the release film with the coating layer, while the above-mentioned coating layer is patterned through the irradiation of active energy rays to obtain a first area including the exposed first area, and the exposure amount is less than the first area The step of peeling off the film of the adhesive layer in the second area; laminating step: then continuously transport the film after the exposure step, while laminating long optical components on the outer surface of the adhesive layer, and then laminating The body is squeezed from above and below.

The method of manufacturing an optical component with a release film of the present invention may further include other steps than the above. Hereinafter, each step will be described with reference to the drawings. In addition, in the following, the release film having the adhesive layer bonded to the film intermediate of the optical component is also referred to as "the release film with the adhesive layer".

[Coating Step]

This step is a step of forming the coating layer 11 by applying the active energy ray-curable adhesive composition on the release film 10 to obtain the release film 15 having the coating layer 11 (refer to Figures 1 and 2) . The coating system of the active energy ray-curable adhesive composition can be performed using the coating device 50.

(1) Peeling film

The release film 10 is generally a thermoplastic resin film, preferably a thermoplastic resin film having light transmittance (optically transparent is more preferable). Specific examples of thermoplastic resins include: polyolefin resins such as chain polyolefin resins (polyethylene resins, polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.); such as polyolefin resins; Fluorine-containing polyolefin resins of vinyl fluoride, polyvinylidene fluoride, and polyfluorinated ethylene; such as polyester resins such as polyethylene terephthalate resins and polyethylene naphthalate resins Resins; (meth)acrylic resins such as methyl methacrylate resins; cellulose resins such as cellulose acetate resins such as cellulose triacetate [TAC] and cellulose diacetate; polycarbonate resins; Polyvinyl alcohol-based resin; polyvinyl acetate-based resin; polyarylate-based resin; polyimide-based resin; polystyrene-based resin; polyamide-based resin; polyether-based resin; These mixtures and copolymers. In this specification, "(meth)acrylic acid" means acrylic and/or methacrylic acid, and "(meth)" when referred to as (meth)acrylate etc. also has the same meaning.

As for the release film 10, it is possible to use a mold release treatment on the surface on the side where the adhesive layer is laminated. Examples of mold release treatments include silicone treatment, long-chain alkyl treatment, fluorine treatment, and the like. The thickness of the release film 10 is, for example, about 5 to 200 m, preferably 10 to 150 m, and more preferably 15 to 100 m.

(2) Active energy ray hardening adhesive composition

The active energy ray-curable adhesive composition is an adhesive composition that undergoes a curing reaction by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. The active energy ray-curable adhesive composition is preferably an ultraviolet-curable adhesive composition. A preferable example of the ultraviolet curable adhesive composition is a (meth)acrylic ultraviolet curable adhesive composition mainly composed of a (meth)acrylic compound. In the present invention, any of conventionally known active energy ray-curable adhesive compositions can be used. The active energy ray-curable adhesive composition may be solvent-based, solvent-free, water-dispersible, and the like.

An example of an active energy ray-curable adhesive composition includes one or more types of polymerizable monomers having at least one active energy ray-curable site in the molecule (hereinafter, also referred to as "polymerizable monomers") The adhesive composition. The active energy ray-curable site is, for example, an ethylenic double bond. A preferable active energy ray-curable adhesive composition is a (meth)acrylic adhesive composition mainly composed of a (meth)acrylic compound. In this case, a polymerizable monomer is preferable It is an active energy ray-curable (meth)acrylic monomer. A preferred example of the active energy ray-curable (meth)acrylic monomer is a (meth)acrylic monomer having a (meth)acryloyl group, and its specific example is represented by the following formula (I) The (meth)acrylate.

In the above formula (I), R ¹ represents a hydrogen atom or a methyl group, and R ² represents an alkyl group with 1 to 14 carbons which may be substituted by an alkoxy group with 1 to 10 carbons, or an alkyl group with 1 to 10 carbons which may be substituted with an alkoxy group having 1 to 10 carbons. Alkoxy substituted aralkyl with 7 to 21 carbons. R ² is preferably an alkyl group having 1 to 14 carbons which may be substituted by an alkoxy group having 1 to 10 carbons. The (meth)acrylate type represented by the formula (I) may be used singly, or two or more types may be used in combination.

Specific examples of the (meth)acrylate represented by formula (I) include: for example, methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, n-octyl acrylate, and lauryl acrylate. Linear alkyl acrylate; such as isobutyl acrylate, 2-ethylhexyl acrylate, and isooctyl acrylate whose alkyl part is branched alkyl acrylate; such as methyl methacrylate, ethyl methacrylate Ester, propyl methacrylate, n-butyl methacrylate, n-octyl methacrylate, lauryl methacrylate, the alkyl part of which is linear alkyl methacrylate; such as isobutyl methacrylate, The alkyl part of 2-ethylhexyl methacrylate and isooctyl methacrylate is branched alkyl methacrylate.

When R ² is an alkyl group substituted with an alkoxy group, that is, when R ² is an alkoxy alkyl group, specific examples of the (meth)acrylate represented by formula (I) include: 2-methoxy acrylate Ethyl ethyl, ethoxy methyl acrylate, 2-methoxy ethyl methacrylate, ethoxy methyl methacrylate, etc. Specific examples of the (meth)acrylate represented by formula (I) when R ² is an aralkyl group having 7 to 21 carbon atoms include benzyl acrylate, benzyl methacrylate, and the like.

The (meth)acrylic mono-system having a (meth)acryloyl group may include a methacrylate having an alicyclic structure in the molecule. The carbon number of the alicyclic structure is generally 5 or more, preferably about 5 to 7. Specific examples of (meth)acrylates having an alicyclic structure include: isobornyl (meth)acrylate, cyclohexyl (meth)acrylate, dicyclopentyl (meth)acrylate, and (meth)acrylate Cyclododecyl acrylate, methylcyclohexyl (meth)acrylate, trimethylcyclohexyl (meth)acrylate, tributylcyclohexyl (meth)acrylate, cyclohexyl (meth)acrylate Phenyl ester, α-ethoxycyclohexyl acrylate, etc.

The above-mentioned polymerizable single system may include a polymerizable monomer having a polar functional group. The polymerizable single system with polar functional group is preferably a (meth)acrylic monomer. In terms of polar functional groups, in addition to free carboxyl groups, hydroxyl groups, and amino groups, heterocyclic groups such as ethoxy groups can be exemplified.

Specific examples of polymerizable monomers with polar functional groups include: polymerizable monomers with free carboxyl groups such as (meth)acrylic acid and β-carboxyethyl (meth)acrylate; such as (meth)acrylic acid 2 -Hydroxyethyl, 3-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-(2-hydroxyethoxy)ethyl (meth)acrylate, (meth)acrylic acid 2- or 3-chloro-2-hydroxypropyl ester, diethylene glycol mono(meth)acrylate polymerizable monomers with hydroxyl groups; such as acryloyl mopholin, vinyl caprolactam, N- Vinyl-2-pyrrolidone, vinyl pyridine, methyl tetrahydrofuran (meth)acrylate, methyl tetrahydrofuran acrylate modified by caprolactone, 3,4-epoxycyclohexyl methyl (meth)acrylate , (Meth) glycidyl acrylate, 2,5-dihydrofuran is a polymerizable monomer with a heterocyclic group; such as (meth) acrylate, N,N-di A polymerizable monomer having an amino group which is different from a heterocyclic ring such as methylamino ethyl and dimethylaminopropyl (meth)acrylate. The polymerizable single system having a polar functional group may be used singly, or two or more of them may be used in combination.

Among the above, the polymerizable monomer system having a polar functional group preferably contains a polymerizable monomer having a hydroxyl group and/or a polymerizable monomer having a free carboxyl group.

In addition to the polymerizable monomers exemplified above, the above-mentioned polymerizable monomers may include, for example, the phenoxyethyl-containing (meth)acrylate represented by the following formula (II) having an aryloxyalkyl group (Meth)acrylate,

In the above (II), R ³ represents a hydrogen atom or a methyl group, n represents an integer of 1 to 8, and R ⁴ represents a hydrogen atom, an alkyl group, an aralkyl group, or an aryl group. When R ⁴ is an alkyl group, its carbon number can be about 1 to 9; if it is an aralkyl group, its carbon number can be about 7 to 11; if it is an aryl group, its carbon number can be about 6 to 10.

In the formula (II), ^{the alkyl group having 1 to 9 carbon atoms constituting R 4} may include methyl, butyl, nonyl, etc.; the aralkyl group having 7 to 11 carbon atoms may include such as benzyl, Phenylethyl, naphthylmethyl, etc.; aryl groups with 6 to 10 carbon atoms include, for example, phenyl, tolyl, naphthyl and the like.

Specific examples of the phenoxyethyl-containing (meth)acrylate represented by formula (II) include: 2-phenoxyethyl (meth)acrylate, 2-(2-benzene) (meth)acrylate Oxyethoxy) ethyl ester, nonylphenol (meth)acrylate modified by ethylene oxide, 2-(o-phenylphenoxy)ethyl (meth)acrylate, etc. The phenoxyethyl-containing (meth)acrylate system may be used individually by 1 type, and may use 2 or more types together. Among them, the (meth)acrylates containing phenoxyethyl groups include 2-phenoxyethyl (meth)acrylate, 2-(o-phenylphenoxy)ethyl (meth)acrylate, and / Or 2-(2-phenoxyethoxy)ethyl (meth)acrylate is preferred.

Another example of the polymerizable monomer of the (meth)acrylic monomer is a (meth)acrylamide-based monomer. Specific examples of (meth)acrylamide-based monomers include: N-methylol(meth)acrylamide, N-(2-hydroxyethyl)(meth)acrylamide, N-(3 -Hydroxypropyl)(meth)acrylamide, N-(4-hydroxybutyl)(meth)acrylamide, N-(5-hydroxypentyl)(meth)acrylamide, N-( 6-Hydroxyhexyl)(meth)acrylamide, N,N-dimethyl(meth)acrylamide, N,N-diethyl(meth)acrylamide, N-isopropyl(meth)acrylamide, N-isopropyl(meth)acrylamide, N,N-diethyl(meth)acrylamide, Yl)acrylamide, N-(3-dimethylaminopropyl)(meth)acrylamide, N-(1,1-dimethyl-3-oxobutyl)(methyl) Allylamide, N-[2-(2-Pendant oxy-1-imidazolidinyl)ethyl](meth)acrylamide, 2-propenylamino-2-methyl-1-propanesulfon Acid, N-(methoxymethyl)acrylamide, N-(ethoxymethyl)(meth)acrylamide, N-(propoxymethyl)(meth)acrylamide, N -(1-Methylethoxymethyl)(meth)acrylamide, N-(1-methylpropoxymethyl)(meth)acrylamide, N-(2-methylpropoxy) (Methyl)(meth)acrylamide [alias: N-(isobutoxymethyl)(meth)acrylamide], N-(butoxymethyl)(meth)acrylamide, N-(1,1-Dimethylethoxymethyl)(meth)acrylamide, N-(2-methoxyethyl)(meth)acrylamide, N-(2-ethoxy Ethyl)(meth)acrylamide, N-(2-propoxyethyl)(meth)acrylamide, N-[2-(1-methylethoxy)ethyl](former Base) acrylamide, N-[2-(1-methylpropoxy)ethyl](meth)acrylamide, N-[2-(2-methylpropoxy)ethyl](formula Yl)acrylamide [alias: N-(2-isobutoxyethyl)(meth)acrylamide], N-(2-butoxyethyl)(meth)acrylamide, N- [2-(1,1-Dimethylethoxy)ethyl](meth)acrylamide and the like.

The (meth)acrylamide-based single system may be used singly, or two or more of them may be used in combination.

The above-mentioned polymerizable single system may contain other polymerizable monomers other than the (meth)acrylic monomer. With regard to other polymerizable monomers, for example, styrene-based monomers, vinyl-based monomers, and the like can be mentioned. The polymerizable single system may contain one or more other polymerizable monomers.

Specific examples of styrene monomers include: styrene; such as methyl styrene, dimethyl styrene, trimethyl styrene, ethyl styrene, diethyl styrene, triethyl styrene, propylene Alkyl styrene, butyl styrene, hexyl styrene, heptyl styrene, octyl styrene; such as fluorostyrene, chlorostyrene, bromostyrene, dibromostyrene, iodostyrene Halostyrene; Nitrostyrene, Acetylstyrene, Methoxystyrene, Divinylbenzene, etc.

Specific examples of vinyl monomers include: fatty acid vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, and vinyl laurate; such as vinyl chloride and vinyl bromide. Vinyl halide; vinylidene halides such as vinylidene chloride; nitrogen-containing aromatic vinyl such as vinyl pyridine, vinyl pyrrolidone, and vinyl carbazole; such as butadiene, isoprene, and chloroprene The co-active diene monomer; acrylonitrile, methacrylonitrile, etc.

The above-mentioned polymerizable single system may include a monomer having two or more ethylenic double bonds in the molecule, such as active energy ray-curable sites. An example of this multifunctional monomer is a (meth)acrylic monomer having two or more (meth)acrylic groups in the molecule.

Specific examples of (meth)acrylic monomers having two or more (meth)acrylic groups in the molecule include: 1,4-butanediol di(meth)acrylate, 1,6-hexane Glycol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethyl Glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, tricyclodecanediyl dimethanol di(meth)acrylate, polyethylene Glycol di(meth)acrylate, neopentyl glycol di(meth)acrylate, bisphenol A diglycidyl ether (meth)acrylic acid adduct, polyester di(meth) Acrylate, ethylene oxide or propylene oxide adduct of bisphenol A, dihydric alcohol di(meth)acrylate, hydrogenated bisphenol A, ethylene oxide or propylene oxide adduct Dihydric alcohol di(meth)acrylate, tricyclodecane dimethanol di(meth)acrylate, cyclohexane dimethanol di(meth)acrylate have 2 (meth)acrylic acid in the molecule Group monomers; such as trimethylolpropane tri(meth)acrylate, trimethylolpropane trioxyethyl (meth)acrylate, neopentylerythritol tri(meth)acrylate, tri(meth)acrylate 2-Hydroxyethyl) trimeric isocyanate di(meth)acrylate, tricyclodecane dimethanol di(meth)acrylate, monomers with 3 (meth)acrylic groups in the molecule; such as neopentyl Tetraol tetra(meth)acrylate is a monomer with 4 (meth)acrylic acid groups in the molecule; adding the diglycidyl ether of bisphenol A to the epoxy group of (meth)acrylate ( Meth) acrylate and the like.

(Meth) acrylic active energy ray curable adhesive composition. The active energy ray curable component may be composed only of the above-mentioned polymerizable monomers, but preferably contains one type in addition to the polymerizable monomers Or two or more (meth)acrylic polymers and/or oligomers.

The (meth)acrylic polymer and/or oligomer may be a (co)polymer obtained by copolymerizing one or two or more of the above-mentioned polymerizable monomers. The (meth)acrylic polymer and/or oligomer preferably has one or two or more structural units derived from the (meth)acrylate represented by the above formula (I) as the main component, Among 100 parts by weight of all the structural units, it is more preferable to include 50 parts by weight or more of the structural unit, more preferably 60 parts by weight or more, and particularly preferably 70 parts by weight or more. Among them, the (meth)acrylate represented by the above formula (I) preferably contains n-butyl acrylate.

The (meth)acrylic polymer and/or oligomer system preferably contains a structural unit derived from the above-mentioned polymerizable monomer having a polar functional group. The content of the structural unit is generally 0.1 to 20 parts by weight, preferably 0.4 to 10 parts by weight in 100 parts by weight of all the structural units. The (meth)acrylic polymer and/or oligomer itself may have active energy ray-curable sites such as ethylenic double bonds.

The weight average molecular weight Mw of the (meth)acrylic polymer in terms of standard polystyrene by gel permeation chromatography (GPC) can be, for example, 50,000 to 800,000. The active energy ray-curable adhesive composition system may include one or more (meth)acrylic polymers with Mw of 50,000 to 800,000. The active energy ray-curable adhesive composition may further include a (meth)acrylic polymer or oligomer with a Mw of less than 50,000.

When the active energy ray-curable adhesive composition contains the above-mentioned polymerizable monomer, and a (meth)acrylic polymer and/or oligomer, these may be included as a partial polymer of the above-mentioned polymerizable monomer.

The active energy ray-curable adhesive composition generally contains a photopolymerization initiator. Specific examples of the photopolymerization initiator include: acetophenone, 2,2-diethoxyacetophenone, p-dimethylaminoacetophenone, methoxyacetophenone, 2,2-di Acetophenones such as methoxy-2-phenylacetophenone and 2-hydroxy-2-cyclohexylacetophenone; diphenyl ketone, 2-chlorodiphenyl ketone, p,p'-dichloro Diphenyl ketone, p,p'-bis(diethylamino)diphenyl ketone, N,N'-tetramethyl-4,4'-diaminodiphenyl ketone, 4-(2- Hydroxyethoxy) phenyl (2-hydroxy-2-propyl) ketone, 2-hydroxy-2-methyl-1-phenyl-propan-1-one and other ketones; benzoin, benzoin Benzoin ethers such as methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, etc.; thioxanthone, 2-chlorothioxanthone, 2- Thioxanthones such as methyl thioxanthone; Phosphine oxides such as bis-phosphonyl phosphine oxide and benzyl phosphine oxide; Ketals such as benzophenone dimethyl ketal; Camphor -2,3-dione, phenanthrenequinone and other quinones. A photopolymerization initiator system may be used individually by 1 type, and may use 2 or more types together.

The content of the photopolymerization initiator is generally 0.01 to 10 parts by weight, preferably 0.05 to 5 parts by weight, relative to 100 parts by weight of active energy ray curable components such as the above-mentioned polymerizable monomers.

The active energy ray-curable adhesive composition may further contain a crosslinking agent. The crosslinking agent is a compound having two or more polar functional groups in the molecule that can react with the reactive functional group possessed by the active energy ray curable component, etc., to crosslink the active energy ray curable component Compound. Specific examples include isocyanate-based compounds, epoxy-based compounds, aziridine-based compounds, and metal chelate-based compounds. Among these, isocyanate-based compounds, epoxy-based compounds, and aziridine-based compounds have two or more functional groups that can react with the polar functional groups in the active energy ray-curable component in the molecule. A crosslinking agent system may be used individually by 1 type, and may use 2 or more types together.

The isocyanate compound is a compound having at least two isocyanate groups (-NCO) in the molecule. Specific examples of isocyanate compounds include: toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, diphenylmethane diisocyanate, hydrogenated diisocyanate Phenylmethane diisocyanate, naphthalene diisocyanate, triphenylmethane triisocyanate, hydrogenated diphenylmethane diisocyanate; biuret and trimer isocyanate of these isocyanate compounds; in these isocyanate compounds, such as ethyl Adducts derived from the reaction of glycol, propylene glycol, neopentyl glycol, trimethylolpropane, castor oil, glycerin and trimethylolpropane polyol; these isocyanate compounds become dimers and trimers Wait.

The epoxy compound is a compound having at least two epoxy groups in the molecule. Specific examples of epoxy compounds include: bisphenol A type epoxy resin, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, glycerin diglycidyl ether, triglyceride Glycidyl ether, 1,6-hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, N,N-diglycidyl aniline, N,N,N', N'-tetraepoxypropyl-m-xylenediamine, 1,3-bis(N,N'-diglycidylaminomethyl)cyclohexane, etc.

The aziridine-based compound is also called ethyleneimine, and is a compound having at least two 3-membered ring skeletons composed of one nitrogen atom and two carbon atoms in the molecule. Specific examples of aziridine compounds include: diphenylmethane-4,4'-bis(1-aziridine carboxyamide), toluene-2,4-bis(1-aziridine carboxyamide) , Triethylenemelamine, m-phthaloyl bis-1-(2-methylaziridine), tri-1-aziridinyl phosphine oxide, hexamethylene-1,6-bis (1-aziridine carboxyamide), trimethylolpropane-tris-β-aziridinyl propionate, tetramethylolmethane-tris-β-aziridinyl propionate, etc.

Specific examples of metal chelate compounds include: aluminum, iron, copper, zinc, tin, titanium, nickel, antimony, magnesium, vanadium, chromium, zirconium and other polyvalent metals mixed with acetone and ethyl acetate. Position of the compound and so on.

Relative to 100 parts by weight of the active energy ray-curable component, the crosslinking agent is generally contained in a ratio of 0.05 to 10 parts by weight, preferably 0.1 to 5 parts by weight.

The active energy ray-curable adhesive composition system may further contain an ionic compound as an antistatic agent. The ionic compound is, for example, a compound having an inorganic cation or an organic cation, and an inorganic anion or an organic anion. An ionic compound system may be used individually by 1 type, and may use 2 or more types together.

Regarding inorganic cations, for example ^{, alkali metal ions such as lithium cation [Li +} ], sodium cation [Na ⁺ ], potassium cation [K ⁺ ], and beryllium cation [Be ²⁺ ], magnesium cation [Mg ²⁺ ], calcium cation [Ca ²⁺ ] alkaline earth metal ions, etc.

Organic cations include, for example, imidazolium cations, pyridinium cations, pyrrolidinium cations, ammonium cations, sulfonium cations, and phosphonium cations.

Among the above-mentioned cationic components, the organic cationic components have excellent compatibility in the adhesive composition. Among the organic cation components, pyrrolidinium cations and imidazolium cations are advantageous from the viewpoint of antistatic properties.

Inorganic anions aspect, for example, include: chlorine anions [Cl ^-], bromine anion [Br ^-], iodide anion [I ^-], tetrachloroaluminate anion [AlCl ₄ ^-], heptachlor aluminum anions [Al ₂ Cl ^_7--], tetrafluoroborate anion [BF ₄ ^-], hexafluorophosphate anions [PF ₆ ^-], perchlorate anion [ClO ₄ ^-], nitrate anions [NO ₃ ^-], hexafluoroarsenate anion [AsF ₆ ^-], hexafluoroantimonate anion [SbF ₆ ^-], niobium hexafluorophosphate anion [NbF ₆ ^-], six tantalum fluoride anion [TaF ₆ ^-], dicyanimide ion [(CN) ₂ N ^- ] Wait.

Organic anion regard include, for example: acetate anion [CH ₃ COO ^-], trifluoroacetate anion [CF ₃ COO ^-], methanesulfonate anion [CH ₃ SO ₃ ^-], triflate anion [CF ₃ SO ₃ ^-], - toluenesulfonic acid anion _{[p-CH 3 C 6 H} 4 SO 3 -], bis (sulfo-fluoro-acyl) imide anion ^{_{[(FSO 2) 2 N -}} ], bis (trifluoromethyl methanesulfonamide acyl) imide anion _{[(CF 3 SO 2) 2} N -], tris (trifluoromethanesulfonyl acyl) methide anion _{[(CF 3 SO 2) 3} C -], dimethylphosphinic anion ^{_{[(CH 3) 2 POO -}} ], ( poly) hydrogen fluoride anion ^{_{[F (HF) n -]}} (n is about 1 to 3), thiocyanate anion [SCN ^-], perfluoro butane sulfonate anion ^{_{[C 4 F 9 SO 3 -}} ], bis (pentafluoroethane sulfonyl acyl) imide anion _{[(C 2 F 5 SO 2} ) 2 N -], perfluoro butyrate anion [C ₃ F ₇ COO ^-], (trifluoromethanesulfonyl acyl) (carbonyl trifluoromethanesulfonyl) imide anion _{[(CF 3 SO 2) (} CF 3 CO) N -], -1,3- perfluoropropane disulfonate anion ^[- _{O 3 S (CF 2) 3} SO 3 -], carbonate anion [CO ₃ ^2-] and the like. Among the above-mentioned anion components, an anion component containing a fluorine atom is advantageous from the viewpoint of antistatic properties.

Specific examples of the ionic compound can be appropriately selected from the combination of the above-mentioned cationic components and anionic components. When classifying examples of ionic compounds having organic cations from the structure of organic cations, the following can be cited.

Pyridinium salt: N-hexylpyridinium hexafluorophosphate, N-octylpyridinium hexafluorophosphate, N-octyl-4-methylpyridinium hexafluorophosphate, N-butyl-4-methyl Pyridinium hexafluorophosphate, N-decylpyridinium bis(fluorosulfonyl)imine, N-dodecylpyridinium bis(fluorosulfonyl)imine, N-tetradecylpyridinium bis(fluorosulfonyl)imide (Fluorosulfonyl)imine, N-hexadecylpyridinium bis(fluorosulfonyl)imine, N-dodecyl-4-methylpyridinium bis(fluorosulfonyl)imine, N-tetradecyl-4-methylpyridinium bis(fluorosulfonyl)imine, N-hexadecyl-4-methylpyridinium bis(fluorosulfonyl)imine, N-benzyl 2-methylpyridinium bis(fluorosulfonyl)imine, N-benzyl-4-methylpyridinium bis(fluorosulfonyl)imine, N-hexylpyridinium bis(trifluoromethyl) Sulfonyl)imine, N-octylpyridinium bis(trifluoromethanesulfonyl)imine, N-octyl-4-methylpyridinium bis(trifluoromethanesulfonyl)imine, N- Butyl-4-methylpyridinium bis(trifluoromethanesulfonyl)imide.

Imidazolium salt: 1-ethyl-3-methylimidazolium hexafluorophosphate, 1-ethyl-3-methylimidazolium p-toluenesulfonate, 1-ethyl-3-methylimidazolium bis (Fluorosulfonyl)imine, 1-ethyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imine, 1-butyl-3-methylimidazolium methanesulfonate, 1- Butyl-3-methylimidazolium bis(fluorosulfonyl)imine.

Pyrrolidinium salt: N-butyl-N-methylpyrrolidinium hexafluorophosphate, N-butyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide, N-butyl-N -Methylpyrrolidinium bis(trifluoromethanesulfonyl)imine.

Quaternary ammonium salt: tetrabutylammonium hexafluorophosphate, tetrabutylammonium p-toluenesulfonate, (2-hydroxyethyl)trimethylammonium bis(trifluoromethanesulfonyl)imide, (2 -Hydroxyethyl)trimethylammonium dimethylphosphonite.

When an example of an ionic compound having an inorganic cation is given, it is as follows.

Lithium bromide, lithium iodide, lithium tetrafluoroborate, lithium hexafluorophosphate, lithium thiocyanate, lithium perchlorate, lithium trifluoromethanesulfonate, lithium bis(fluorosulfonyl)imide, bis(trifluoromethanesulfonyl) Lithium imide, lithium bis(pentafluoroethanesulfonyl)imide, lithium tris(trifluoromethanesulfonyl)methide, lithium p-toluenesulfonate, sodium hexafluorophosphate, bis(fluorosulfonyl) Sodium imide, sodium bis(trifluoromethanesulfonyl)imide, sodium p-toluenesulfonate, potassium hexafluorophosphate, potassium bis(fluorosulfonyl)imide, bis(trifluoromethanesulfonyl) sodium Potassium amine, potassium p-toluenesulfonate.

From the standpoint of the continuity of antistatic properties, the ionic compound preferably has a melting point above 30°C, or even above 35°C. On the other hand, from the viewpoint of compatibility with active energy ray-curable components, the ionic compound preferably has a melting point below 90°C, more preferably below 70°C, and even more preferably below 50°C.

Relative to 100 parts by weight of the active energy ray hardening component, the blending ratio of the ionic compound is preferably 0.2 to 8 parts by weight, more preferably 0.2 to 5 parts by weight. The content of the ionic compound is 0.2 parts by weight or more, which is beneficial to improve the antistatic property, and the content of the ionic compound is less than 8 parts by weight, which is beneficial to improve the durability of the adhesive layer.

When the adhesive layer 12 of the peeling film 20 with the adhesive layer is attached to the optical component 30 made of glass, in order to improve the adhesion between the adhesive layer 12 and the glass, the active energy ray-curable adhesive composition can be further Contains silane compounds. The silane compound system may be used individually by 1 type, and may use 2 or more types together.

As for the silane compound, for example, vinyl trimethoxy silane, vinyl triethoxy silane, methacryloxy propyl trimethoxy silane, vinyl tris(2-methoxyethoxy) silane , N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, 3- Aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 2-(3,4-epoxy Cyclohexyl) ethyl trimethoxysilane, 3-chloropropylmethyldimethoxysilane, 3-chloropropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-Mercaptopropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethyl Oxymethyl silane, 3-glycidoxy propyl ethoxy dimethyl silane, etc.

The silane compound may be a polysiloxane oligomer type. Examples of the polysiloxane oligomer include the following.

3-Mercaptopropyltrimethoxysilane-tetramethoxysilane copolymer, 3-mercaptopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-mercaptopropyltriethoxysilane-tetramethoxysilane Mercapto propyl-containing copolymers such as 3-mercaptopropyl triethoxysilane-tetraethoxysilane copolymer; mercaptomethyltrimethoxysilane-tetramethoxysilane copolymer, mercapto group Methyltrimethoxysilane-tetraethoxysilane copolymer, mercaptomethyltriethoxysilane-tetramethoxysilane copolymer, mercaptomethyltriethoxysilane-tetraethoxysilane copolymer, etc. Mercaptomethyl-containing copolymer; 3-glycidoxypropyltrimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltrimethoxysilane-tetraethoxysilane copolymer , 3-glycidoxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropyltriethoxysilane-tetraethoxysilane copolymer, 3- Glycidoxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3- Containing glycidoxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-glycidoxypropylmethyldiethoxysilane-tetraethoxysilane copolymer, etc. Copolymer of 3-glycidoxypropyl; 3-methacryloxypropyl trimethoxysilane-tetramethoxysilane copolymer, 3-methacryloxypropyl trimethoxy Silane-tetraethoxysilane copolymer, 3-methacryloxypropyl triethoxysilane-tetramethoxysilane copolymer, 3-methacryloxypropyl triethoxy Silane-tetraethoxysilane copolymer, 3-methacryloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-methacryloxypropylmethyl Dimethoxysilane-tetraethoxysilane copolymer, 3-methacryloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-methacryloxysilane Methacryloxypropyl-containing copolymers such as propylmethyldiethoxysilane-tetraethoxysilane copolymers, etc.; 3-propenyloxypropyl trimethoxysilane-tetramethyl Oxysilane copolymer, 3-propenyloxypropyltrimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropyltriethoxysilane-tetramethoxysilane copolymer , 3-propenyloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3 -Acrylicoxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-propenyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3 -Acrylicoxypropylmethyldiethoxysilane-tetraethoxysilane copolymer and other acryloxypropyl-containing copolymers; vinyltrimethoxysilane-tetramethoxysilane copolymer Compounds, vinyl trimethoxysilane-tetraethoxysilane copolymer, vinyl triethoxysilane-tetramethoxysilane copolymer, vinyl triethoxysilane-tetraethyl Oxysilane copolymer, vinylmethyldimethoxysilane-tetramethoxysilane copolymer, vinylmethyldimethoxysilane-tetraethoxysilane copolymer, vinylmethyldiethoxy Silane-tetramethoxysilane copolymer, vinyl methyl diethoxysilane-tetraethoxysilane copolymer and other vinyl-containing copolymers; 3-aminopropyltrimethoxysilane-tetramethoxysilane Silane copolymer, 3-aminopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-aminopropyltriethoxysilane-tetramethoxysilane copolymer, 3-aminopropyl Triethoxysilane-tetraethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane- Tetraethoxysilane copolymer, 3-aminopropylmethyldiethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldiethoxysilane-tetraethoxysilane copolymer Amine group-containing copolymers, etc.

The content ratio of the silane compound is generally 0.01 to 10 parts by weight, preferably 0.05 to 5 parts by weight, relative to 100 parts by weight of the active energy ray curable component. When the content of the silane compound is 0.01 parts by weight or more, the effect of improving the adhesion between the adhesive layer 12 and the glass can be easily obtained. Furthermore, when the content is 10 parts by weight or less, the exudation of the silane compound from the adhesive layer 12 can be suppressed.

The active energy ray-curable adhesive composition system may contain one or more solvents (aromatic hydrocarbons, aliphatic hydrocarbons, ketones, esters, etc.), crosslinking catalysts, weathering stabilizers, and thickening Other additives such as agents, plasticizers, softeners, dyes, pigments, inorganic fillers, light-scattering particles, tackifiers, etc.

(3) Coating of active energy ray hardening adhesive composition

The method of applying the active energy ray-curable adhesive composition to the release film 10 using the coating device 50 is not particularly limited. For example, slit die method, reverse gravure coating method, micro-gravure method, dipping method, etc. can be used. Roll coating method, flexographic printing method, etc. The thickness of the coating layer 11 composed of the active energy ray-curable adhesive composition is adjusted so that the thickness of the adhesive layer 12 of the release film 20 with the adhesive layer is within the following range.

As shown in Figure 1, the coating step, more specifically, can be continuous coating of the active energy ray-curable adhesive composition on one side of the long release film 10 continuously rolled from the first feed roll 1的步。 The steps. At this time, as shown in FIG. 1, the release film 10 can be wound on one side of the coating roller 60, and the active energy ray-curable adhesive composition can be coated at the same time.

[Exposure Step]

In this step, the peeling film 15 with the coating layer 11 is continuously transported, and active energy rays are irradiated to the coating layer 11 at the same time, thereby performing pattern exposure to obtain the peeling of the adhesive layer with the adhesive layer 12 Steps of film 20 (refer to Fig. 1 and Fig. 3). Through this step, the adhesive layer-attached release film 20 having the adhesive layer 12 is continuously manufactured as an intermediate of the release-film-attached optical component. The active energy rays are preferably ultraviolet rays.

In the adhesive layer 12 irradiated with active energy rays and exposed through a pattern, an exposed first region 12a and a second region 12b whose exposure amount is smaller than the first region 12a are formed (FIG. 3). The second area 12b may be an unexposed area, but it is preferably an area where the amount of exposure is less than the exposure of the first area 12a to a certain degree, and the curing reaction proceeds to a certain degree by the irradiation of active energy rays.

The arrangement pattern of the first area 12a and the second area 12b in the adhesive layer 12 can be selected according to the bending mode of the flexible display used. An example of the bending state of the flexible display is shown in Fig. 4. Figure 4 (a) is a rollable flexible display, and Figure 4 (b) is a foldable flexible display.

The adhesive layer 12 including the first region 12a and the second region 12b is as shown in FIG. Layer 11 is formed by the method. The coating layer 11 can be irradiated with active energy rays multiple times. By appropriately selecting the slit shape and characteristics of the mask 81 used, the method of irradiating the active energy rays through the mask 81, etc., the arrangement pattern of the first region 12a and the second region 12b can be obtained as desired picture of. To present specific examples regarding the arrangement pattern of the first region 12a and the second region 12b, and the method of irradiating the active energy ray through the mask 81, they are as follows.

a) Fig. 5 is a schematic plan view showing a state where the coating layer 11 is irradiated with active energy rays via the light shield 81a. The arrow indicates the conveying direction of the release film 15 having the coating layer 11. The light-shielding mask 81a has a plurality of slits (through portions) 85 extending along the longitudinal direction (transport direction) of the release film 15 with the coating layer 11, and the plurality of slits 85 are along the film width direction arrangement. The exposure device (active energy ray irradiation device) 80 is fixed to the light shield 81a. If the active energy rays from the exposure device 80 are irradiated on the release film 15 having the coating layer 11 through the light shield 81a, the first region 12a and the second region 12b can be obtained as shown in Figure 6(a).贴剂层12。 Adhesive layer 12. This configuration pattern is beneficial to the rollable flexible display shown in Figure 4(a), with the first area 12a extending in a direction slightly perpendicular to the winding direction as shown in Figure 6(a) and The alternate arrangement of the second regions 12b can relax the stress during winding, and thereby, the adhesiveness between the adhesive layer 12 and the adjacent components can be maintained well.

b) If a mask 81 is used that leaves the center part in the width direction and the other part is used as the through part (slit), the first area 12a and the second area 12b can be obtained, for example, as shown in Fig. 6(b)之adhesive layer 12. This configuration pattern is conducive to the foldable flexible display shown in Figure 4(b). By providing the second area 12b at the position corresponding to the foldable portion, the stress during folding can be relieved, so that it can be adhered to The agent layer 12 maintains good adhesion with adjacent components.

c) When an active energy ray is irradiated once with the light shield 81a shown in FIG. On the other hand, as shown in Fig. 7, after the active energy ray is irradiated through a light shield 81a having a slit 85 (Fig. 7(a)), the entire coating layer 11 is irradiated with active energy without a mask. According to the multiple irradiation method of radiation (Figure 7(b)), the exposed area of the second area 12b can be made. The order of the steps in Fig. 7(b) and the steps in Fig. 7(a) can be reversed.

d) As shown in Fig. 8, when the active energy ray is irradiated through the halftone mask 81b, the exposed second region 12b can be formed in a single irradiation. The halftone mask 81b refers to a mask having a region 82 with a larger transmittance of active energy rays and a smaller (not zero) region 83.

e) Figures 9 to 12 show other examples of the arrangement patterns of the first area 12a and the second area 12b. The extending direction of the first area 12a and the second area 12b can be the direction of transporting the film (or the short-side direction when the optical component 40 with the release film is made into a sheet) is parallel (Figure 9) ).

The widths of the first region 12a and the second region 12b are not particularly limited, and when there are plural of them, they can be the same (Figure 10(a)) or different (Figure 10(b)). The ratio of the first region 12a occupied by the surface of the adhesive layer 12 is not particularly limited, and the distance between adjacent first regions 12a can be shortened (Figure 11 (a)) or increased (Figure 11 (b) )). As shown in FIG. 12, the first area 12a and/or the second area 12b can gradually change the exposure amount along a certain direction. If there is such a gradation, the change (poor) of the storage modulus of the adhesive layer 12 at the boundary between the first region 12a and the second region 12b can be reduced, and thus the pair of adhesive layers 12 can be obtained. Durability of bending. The first area 12a and/or the second area 12b in which the exposure amount changes successively can be formed by irradiating active energy rays through a gradient mask. The gradient mask is a mask that gradually changes the transmission of active energy rays along a certain direction.

The light source of the active energy rays irradiated on the coating layer 11 is not particularly limited. The ultraviolet light having a luminous distribution at a wavelength of 400 nm or less is preferred. Specifically, low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, and chemical Lamps, black light lamps, microwave-excited mercury lamps, metal halide lamps, LED-type ultraviolet lamps, etc.

The irradiation intensity of the active energy ray on the coating layer 11 is, for example, 1 to 1000 mW/cm ² . Furthermore, the cumulative light quantity represented as the product of the light irradiation intensity and the light irradiation time is, for example, 10 to 5000 mJ/cm ² .

The thickness of the adhesive layer 12 of the adhesive layer-attached release film 20 obtained through the exposure step is, for example, 1 to 200 μm, preferably 5 to 35 μm. If the thickness of the adhesive layer 12 is 200 μm or less, it is advantageous from the viewpoint of the thinning of the display and the irradiation efficiency of the active energy ray. In addition, if the thickness is 5 μm or more, it is advantageous to use it as a flexible display to relax the stress when it is bent, and the adhesion to the adjacent optical component becomes better.

[Fitting Steps]

This step is a step of attaching the optical component 30 to the outer surface of the adhesive layer 12 of the release film 20 with the adhesive layer to obtain the optical component 40 with the release film (refer to FIG. 1 and FIG. 13). As shown in FIG. 13, the optical component 40 with a release film is obtained by laminating the release film 20 with an adhesive layer on the surface of the optical component 30 via the adhesive layer 12. According to the optical component 40 with release film obtained according to the present invention, the release film 10 is peeled and removed, and the flexible display formed by bonding to other optical components such as the image display unit via the exposed adhesive layer 12 will bend even if it is bent. It is also possible to maintain good adhesion between the adhesive layer and adjacent components (optical component 30 and other optical components such as the image display unit). Therefore, a flexible display using the optical component 40 with a release film obtained by the present invention can be excellent in durability and reliability.

The bonding step can be specifically carried out in the following manner. Next, the long strip of adhesive layer-attached release film 20 obtained through the exposure step is continuously transported, and the strip of optical components 30 is rolled out from the second feed roller 2 and transported continuously, and the optical components are laminated on the attached The outer surface of the adhesive layer 12 of the peeling film 20 with an adhesive layer is made into a laminated body. The optical component 40 with a release film is continuously manufactured by pressing this laminated body from top and bottom using a pair of bonding rolls 90 etc. from top to bottom. From the viewpoint of the adhesion between the adhesive layer 12 and the optical component 30, the adhesive layer-attached release film 20 obtained through the exposure step is supplied to the optical component 30 without being rolled into a roll. The bonding step is preferable, and it may be supplied to the bonding step with the optical component 30 after performing surface activation treatment or the like as needed.

FIG. 1 shows an example in which the release film 20 with an adhesive layer is attached to one side of the optical component 30, but the release film 20 with an adhesive layer may be attached to both sides of the optical component 30.

When the adhesive layer-attached release films 20 are attached to both sides of the optical component 30, the adhesive layer-attached release films 20 on both sides may be attached at the same time or may be attached step by step.

The optical component 30 is an optical component that can be incorporated into a flexible display, for example, it can be an optical film with a single-layer or multilayer structure. Specific examples of optical films include: polarizing films; optical compensation films (retardation films, etc.), anti-reflection films (sheets), light diffusion films (sheets), reflective films (sheets) and other optically functional films; polarizing films Protective film; polarizing plate; glass film (including glass sheet and glass substrate), etc. The optical component 30 is preferably a polarizing plate.

The polarizing plate may be one where a protective film is attached to at least one side of the polarizing film via an adhesive layer. The protective film can have the function of a retardation film as an optical compensation film. The polarizing plate may have a curable resin layer formed of a curable resin layered on at least one area of the polarizing film. Moreover, it is also possible to laminate other optically functional films such as retardation film and brightness enhancement film via an adhesive layer or an adhesive layer on a polarizing film, a protective film, or a cured resin layer.

It is also possible to laminate a protective film on a polarizing film, a protective film, or a cured resin layer. The protective film is a peelable film temporarily attached to the optical component for the purpose of protecting the optical component from scratches and dust on the surface. It is generally composed of a base film containing a thermoplastic resin and an adhesive layer laminated on it. .

The polarizing film is a film having the function of extracting linearly polarized light from incident natural light, and a preferred example is one that adsorbs dichroic pigments such as directional iodine or dichroic dyes on a uniaxially stretched polyvinyl alcohol resin film. The thickness of the polarizing film is not particularly limited, but is generally 2 to 35 μm.

The protective film may be a thermoplastic resin film with light transmittance (optically transparent is preferred). Specific examples of thermoplastic resins include: polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.); polyester resins (poly Ethylene phthalate resins, etc.); (meth)acrylic resins (methyl methacrylate resins, etc.); cellulose resins (such as cellulose acetate resins such as cellulose triacetate and cellulose diacetate) Etc.); polycarbonate resins; polyvinyl alcohol resins; polyvinyl acetate resins; polyarylate resins; polystyrene resins; polyether turquoise resins; poly turquoise resins; polyamide resins ; Polyimide resins; and mixtures and copolymers of these. The thickness of the protective film is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm.

The curable resin layer is formed of curable resin such as thermosetting resin or active energy ray curable resin. The curable resin may include a thermopolymerizable compound, may include a cation polymerizable compound, may include a radical polymerizable compound, or may include a plurality of these types. The thickness of the hardened resin layer is, for example, about 0.1 to 10 μm, preferably 1 to 5 μm.

When protective films are laminated on both sides of the polarizing film, the protective films may be composed of the same type of thermoplastic resin, or may be composed of different types of thermoplastic resins. Moreover, the thickness may be the same or different. When the two area layers of the polarizing film have hardened resin layers, the hardened resin layers may be composed of the same type of curable resin layers, or may be composed of different types of curable resin layers. Moreover, the thickness may be the same or different. The protective film or the hardened resin layer may have a surface treatment layer (coating layer) such as a hard coat layer, an anti-glare layer, an anti-reflection layer, a light diffusion layer, an antistatic layer, an antifouling layer, and a conductive layer. When a protective film is attached to one side of the polarizing film or a hardened resin layer is laminated, the adhesive layer 12 of the release film 20 with an adhesive layer can be directly attached to the surface of the polarizing film.

The retardation film is an optical film showing optical anisotropy. It can be a uniaxially or biaxially stretched film of a thermoplastic resin film composed of resins that can be used in the protective film, etc., by coating liquid crystal on the thermoplastic resin film A film that shows optical anisotropy by aligning a sex compound, a film that shows optical anisotropy by coating an inorganic layered compound on a thermoplastic resin film, and the like.

The protective film (or retardation film, etc.) can be bonded to the polarizing film via an adhesive layer. Regarding the adhesive for forming the adhesive layer, a water-based adhesive, an active energy ray-curable adhesive, or a thermosetting adhesive can be used, and a water-based adhesive or an active energy ray-curable adhesive is preferable.

With regard to the water-based adhesive, for example, an adhesive containing a polyvinyl alcohol-based resin aqueous solution, an aqueous two-component polyurethane-based emulsion adhesive, and the like can be cited. Among them, an aqueous adhesive containing a polyvinyl alcohol-based resin aqueous solution is suitable. For polyvinyl alcohol resins, in addition to vinyl alcohol homopolymers obtained by saponification of polyvinyl acetate, which is a homopolymer of vinyl acetate, copolymers of vinyl acetate and other monomers copolymerizable with it can also be used. Polyvinyl alcohol-based copolymers obtained by saponification treatment, or modified polyvinyl alcohol-based polymers in which the hydroxyl groups are partially modified. The aqueous adhesive may include crosslinking agents such as aldehyde compounds (glyoxal, etc.), epoxy compounds, melamine compounds, methylol compounds, isocyanate compounds, amine compounds, and polyvalent metal salts.

When using a water-based adhesive, it is preferable to perform a drying step for removing water contained in the water-based adhesive after bonding the polarizing film and the protective film. After the drying step, a aging step for aging at a temperature of about 20 to 45° C. can be set.

The active energy ray curable adhesive refers to an adhesive that is cured by irradiating active energy rays such as ultraviolet rays, visible light, X-rays, and electron beams. Examples include: curable compositions containing polymerizable compounds and photopolymerization initiators. , Curable composition containing photoreactive resin, curable composition containing binder resin and photoreactive crosslinking agent, etc. UV curable adhesive is preferred. In terms of polymerizable compounds, for example, photopolymerizable monomers such as photocurable epoxy monomers, photocurable (meth)acrylic monomers, and photocurable polyurethane monomers; derived from photopolymerizable monomers Monomer oligomers. As for the photopolymerization initiator, for example, a substance containing active species such as neutral radicals, anionic radicals, and cationic radicals generated by irradiation with active energy rays can be cited. As an active energy ray curable adhesive containing a polymerizable compound and a photopolymerization initiator, it is preferable to use: a curable composition containing a photocurable epoxy-based monomer and a photocationic polymerization initiator; including photocuring Curable composition of (meth)acrylic monomers and photo-radical polymerization initiators; including photo-curing epoxy monomers, photo-curing (meth)acrylic monomers, photo-cationic polymerization initiators It is a curable composition of an initiator and a photo-radical polymerization initiator.

When using an active energy ray curable adhesive, after bonding the polarizing film and the protective film, a drying step can be carried out as needed (but the active energy ray curable adhesive can be a solvent-free adhesive that contains substantially no solvent components. Agent), followed by a curing step of curing the active energy ray-curable adhesive by irradiating active energy rays. The light source of active energy rays is not particularly limited. Ultraviolet rays with a luminous distribution below 400nm wavelength are preferred. Specifically, low-pressure mercury lamps, medium-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, chemical lamps, black light lamps, and microwave excitation can be used. Mercury lamps, metal halide lamps, etc.

Before lamination of the protective film, in order to improve the adhesion, corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, saponification treatment, and bottoming can be applied to the bonding surface of at least any one of the polarizing film and the protective film. Surface activation treatment of lacquer layer formation treatment.

When protective films are attached to both sides of the polarizing film, the adhesive used to attach the protective films may be the same type of adhesive or different types of adhesives.

[Other steps]

(1) Drying step

The manufacturing method of the present invention may include a drying step of drying (solvent volatilization) the coating layer 11 of the release film 15 with the coating layer 11 between the coating step and the exposure step. This drying step is generally performed when the coating layer 11 (active energy ray curable adhesive composition) contains a solvent. The drying step refers to FIG. 1, and the long release film 15 having the coating layer 11 obtained through the coating step can be continuously conveyed continuously and carried out by (introducing) the drying means 70.

The drying means 70 is not particularly limited as long as it can volatilize the solvent, and it is, for example, a drying furnace (heating furnace). In addition to heating means, the drying furnace may further include pressure reduction means. Drying conditions such as the amount of hot air supplied into the drying furnace, the temperature and pressure in the drying furnace, and the like are appropriately set in consideration of the type of solvent contained in the coating layer 11, smoothness, and dew condensation. The drying temperature (for example, the temperature in the drying furnace) is generally 50 to 120°C, preferably 60 to 110°C.

(2) Surface activation step

The manufacturing method of the present invention may further include a surface activation step before the bonding step, more specifically, between the exposure step and the bonding step, on the bonding surface of the optical component 30 and the adhesive layer 12 and bonding At least one surface of the bonding surface of the agent layer 12 and the optical component 30 is irradiated with energy. The surface activation treatment in the surface activation step can be corona treatment, plasma treatment, ultraviolet radiation treatment, flame treatment, saponification treatment, etc.

When both the bonding surface of the optical component 30 and the adhesive layer 12 and the bonding surface of the adhesive layer 12 and the optical component 30 are subjected to surface activation treatment, the surface activation treatment is performed by the adhesive layer 12 and the optical component From the viewpoint of adhesion of 30, it is preferable that the time until the release film 20 with the adhesive layer reaches the bonding step after the exposure step is the same as the time until the optical component 30 after the surface activation treatment reaches the bonding step. , Or implementation at approximately the same time. Furthermore, from the viewpoint of the adhesiveness between the adhesive layer 12 and the optical component 30, the time from energy irradiation in the surface activation step until the laminated body is squeezed using a pair of bonding rolls 90 and the like in the bonding step. It is preferably less than 5 seconds. The surface activation treatment can be performed multiple times on the above-mentioned bonding surface.

(3) Winding step and curing step

The manufacturing method of the present invention may include a winding step of winding the long strip of release film-attached optical component 40 obtained through the laminating step on the winding roller 3 into a roll to form a film roll (refer to Figure 1). Furthermore, the manufacturing method of the present invention may also include a curing step of curing (ageing) the adhesive layer 12 in a rolled state after the winding step. By implementing the curing step to promote the hardening reaction of the adhesive layer 12, the adhesive force of the adhesive layer 12 can be improved. Moreover, by curing the adhesive layer 12 in the state of being in close contact with the optical component 30 (hardening reaction of the adhesive), the interaction with the optical component 30 (including chemical reaction) and the wetting of the optical component 30 by the adhesive are improved. Therefore, the adhesion between the adhesive layer 12 and the optical component 30 can be further improved. The aging temperature is, for example, 20 to 45°C.

(4) Bonding steps with other optical components

The manufacturing method of the present invention may include a peeling step of removing the peeling film 10 from the optical component 40 with a peeling film, and bonding other optical components to the surface of the adhesive layer 12 exposed through the peeling step. The bonding step (the second bonding step). After the peeling step and before the second bonding step, corona treatment, plasma treatment, ultraviolet irradiation treatment, flame treatment, saponification treatment, etc. may be applied to at least any of the bonding surfaces of the adhesive layer 12 and the other optical components. Surface treatment such as primer layer formation treatment.

The above-mentioned other optical components can be incorporated into the optical components of the flexible display, for example, an image display unit. The image display unit is, for example, a flexible liquid crystal unit, an organic EL display element, etc. The optical laminate system obtained through the bonding step (the second bonding step), when the above-mentioned other optical component is an image display unit, has an image display unit/adhesive layer 12/optical component 30 (for example, polarized light The layer composition of the board). In the flexible display including the optical laminate of this structure, the stress generated in the adhesive layer 12 in the bending state can be relieved. Therefore, even if the display is bent, the adhesive layer is adjacent to it. The components (optical component 30 and other optical components mentioned above) can also maintain good adhesion.

1‧‧‧The first feed roller

2‧‧‧The second feed roller

3‧‧‧Winding roller

10‧‧‧Peeling film

15‧‧‧Release film with coating layer

20‧‧‧Release film with adhesive layer

30‧‧‧Optical components

40‧‧‧Optical components with peeling film

50‧‧‧Coating device

60‧‧‧Coating roller

70‧‧‧Drying means

80‧‧‧Exposure device (active energy ray irradiation device)

81‧‧‧Mask

90‧‧‧Laminating roller

Claims (8)

A method for manufacturing an optical component with a release film, including the following steps, a coating step: the step of coating an active energy ray-curable adhesive composition on a strip of release film to form a coating layer; Exposure step: while continuously conveying the release film with the above-mentioned coating layer, while pattern-exposing the above-mentioned coating layer by active energy ray irradiation, a first area including the exposed first area and the exposure amount is smaller than the first area The step of peeling off the film of the adhesive layer in the second area; laminating step: then continuously transport the film after the above-mentioned exposure step, while laminating long optical components on the outer surface of the adhesive layer, and then The laminate is pressed from above and below. In the manufacturing method described in the first item of the patent application, in the above-mentioned exposure step, pattern exposure is performed through the above-mentioned active energy ray through a mask. The manufacturing method according to claim 2, wherein the mask has a penetrating portion extending along the direction of the conveying direction of the release film having the coating layer, and the penetrating portion is along the coating layer. The release film of the cloth layer is arranged in the width direction. The manufacturing method described in item 2 of the scope of patent application, wherein the above-mentioned mask is a gradation mask. The manufacturing method described in any one of items 1 to 4 in the scope of the patent application, which further includes a maturing step, and the maturing step is performed by the above The optical component with the release film obtained in the bonding step is wound into a roll, and then the step of curing the adhesive layer is performed in the roll state. In the manufacturing method described in any one of items 1 to 4 in the scope of patent application, in the exposure step, the active energy ray system irradiates the coating layer multiple times. The manufacturing method described in any one of items 1 to 4 in the scope of the patent application, which further includes a surface activation step, which is prior to the bonding step, attaching the optical component to the adhesive layer At least one of the bonding surface and the bonding surface of the above-mentioned adhesive layer with the above-mentioned optical component is subjected to a step of energy irradiation. The manufacturing method according to any one of items 1 to 4 in the scope of the patent application, wherein the above-mentioned optical component is a polarizing plate.

Images