JP2019184912A - Manufacturing method of machined optical laminate having adhesive layer - Google Patents

Manufacturing method of machined optical laminate having adhesive layer Download PDF

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JP2019184912A
JP2019184912A JP2018077467A JP2018077467A JP2019184912A JP 2019184912 A JP2019184912 A JP 2019184912A JP 2018077467 A JP2018077467 A JP 2018077467A JP 2018077467 A JP2018077467 A JP 2018077467A JP 2019184912 A JP2019184912 A JP 2019184912A
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adhesive layer
pressure
sensitive adhesive
optical
cutting
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JP7018349B2 (en
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弘明 麓
Hiroaki Fumoto
弘明 麓
史枝 片山
Fumie Katayama
史枝 片山
勝則 高田
Katsunori Takada
勝則 高田
寳田翔
Sho Takarada
翔 寳田
直孝 樋口
Naotaka Higuchi
直孝 樋口
裕加 山本
Yuka Yamamoto
裕加 山本
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Nitto Denko Corp
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Nitto Denko Corp
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Priority to JP2018077467A priority Critical patent/JP7018349B2/en
Priority to KR1020207029196A priority patent/KR102652292B1/en
Priority to CN201980025511.XA priority patent/CN111971598B/en
Priority to PCT/JP2019/015002 priority patent/WO2019198616A1/en
Priority to TW108112684A priority patent/TW201943553A/en
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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
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/12—Trimming or finishing edges, e.g. deburring welded corners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/13—Surface milling of plates, sheets or strips
    • 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
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/04—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B23/08—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/325—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polycycloolefins
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J201/00—Adhesives based on unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
    • C09J7/38—Pressure-sensitive adhesives [PSA]
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Polarising Elements (AREA)
  • Surface Treatment Of Optical Elements (AREA)
  • Milling Processes (AREA)
  • Laminated Bodies (AREA)

Abstract

To provide a method of easily manufacturing a machined optical laminate having an adhesive layer while suppressing a crack in an optical film without causing a malfunction.SOLUTION: An optical laminate having an adhesive layer includes an optical film, a first adhesive layer arranged on one side of the optical film, a first separator arranged on an opposite side to the optical film of the first adhesive layer, a second adhesive layer arranged on the other side of the optical film and a second separator arranged on an opposite side to the optical film of the second adhesive layer. A manufacturing method of a machined optical laminate having an adhesive layer includes: laminating a plurality of optical laminates each having an adhesive layer to form a work-piece 1; and contacting, onto an outer peripheral surface of the work-piece, a cutting blade of cutting means 20 having a revolving shaft extending in a lamination direction of the work-piece and the cutting blade configured to serve as an outermost diameter of a main body revolving centering the revolving shaft, so as to cut the outer peripheral surface of the work-piece.SELECTED DRAWING: Figure 4

Description

本発明は、切削加工された粘着剤層付光学積層体の製造方法に関する。   The present invention relates to a method for producing a cut optical laminate with an adhesive layer.

携帯電話、ノート型パーソナルコンピューター等の画像表示装置には、画像表示を実現し、および／または当該画像表示の性能を高めるために、種々の光学積層体（例えば、偏光板）が使用されている。近年、自動車のインストゥルメントパネルやスマートウォッチなどにも光学積層体の使用が望まれており、光学積層体の形状を所望の形状に加工することが望まれている。しかし、光学積層体を加工する場合には、クラックが発生しやすいという問題がある。特に、矩形以外に加工（異形加工、非直線加工）する場合には、クラックが顕著なものとなる。   Various optical laminates (for example, polarizing plates) are used in image display devices such as mobile phones and notebook personal computers in order to realize image display and / or enhance the performance of the image display. . In recent years, it has been desired to use an optical laminate for automobile instrument panels, smart watches, and the like, and it is desired to process the optical laminate into a desired shape. However, when processing an optical laminated body, there exists a problem that it is easy to generate | occur | produce a crack. In particular, when processing other than a rectangle (deformation processing, non-linear processing), cracks become prominent.

特開２００４−１１４２０５号公報JP 2004-114205 A

本発明は上記従来の課題を解決するためになされたものであり、その主たる目的は、光学フィルムのクラックを抑制し、不具合を生じることなく、切削加工された粘着剤層付光学積層体を簡便に製造し得る方法を提供することにある。   The present invention has been made in order to solve the above-described conventional problems, and its main purpose is to suppress the cracking of the optical film and to easily cut the optical layered body with the adhesive layer that has been cut without causing defects. It is to provide a method that can be manufactured.

本発明の切削加工された粘着剤層付光学積層体の製造方法は、粘着剤層付光学積層体を複数枚重ねてワークを形成すること；および、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること；を含む。該粘着剤層付光学積層体は、光学フィルムと、該光学フィルムの一方の側に配置された第１の粘着剤層と、該第１の粘着剤層の該光学フィルムと反対側に配置された第１のセパレーターと、該光学フィルムの他方の側に配置された第２の粘着剤層と、該第２の粘着剤層の該光学フィルムと反対側に配置された第２のセパレーターと、を含み、該第１の粘着剤層および該第２の粘着剤層の少なくとも１つの２５℃における貯蔵弾性率Ｇ’は１．０×１０５（Ｐａ）〜２．５×１０５（Ｐａ）であり、かつ、該少なくとも１つの粘着剤層の厚みは５０μｍ以上である。
本発明の別の切削加工された粘着剤層付光学積層体の製造方法においては、該粘着剤層付光学積層体が、光学フィルムと、該光学フィルムの一方の側に該光学フィルム側から順に配置された第３の粘着剤層、光学機能フィルム、第１の粘着剤層および第１のセパレーターと、該光学フィルムの他方の側に該光学フィルム側から順に配置された第２の粘着剤層および第２のセパレーターと、を含み、該第１の粘着剤層、前記第２の粘着剤層および該第３の粘着剤層の少なくとも１つの２５℃における貯蔵弾性率Ｇ’が１．０×１０５（Ｐａ）〜２．５×１０５（Ｐａ）であり、かつ、該少なくとも１つの粘着剤層の厚みが５０μｍ以上である。
１つの実施形態においては、上記製造方法は、上記ワークの外周面を非直線的に切削することを含む。
１つの実施形態においては、上記切削手段はエンドミルである。
１つの実施形態においては、上記光学フィルムは偏光子または偏光板である。
１つの実施形態においては、上記光学機能フィルムは、セルロース系樹脂、シクロオレフィン系樹脂およびアクリル系樹脂から選択される少なくとも１つを含む。
１つの実施形態においては、上記光学機能フィルムの破断強度は３５Ｎ以下である。
１つの実施形態においては、上記切削手段は、上記切削刃を２枚以上有する。
１つの実施形態においては、上記非直線的な切削は、上記粘着剤層付光学積層体を平面視した場合に曲線部を含む凹部を形成することを含む。
１つの実施形態においては、上記曲線部の半径は５ｍｍ以下である。 The manufacturing method of the optical laminated body with the adhesive layer by which the cutting process of this invention was carried out forms a workpiece | work by laminating | stacking a plurality of optical laminated bodies with an adhesive layer; and the rotating shaft extended in the lamination direction of this workpiece | work, Cutting the outer peripheral surface of the workpiece by bringing the cutting blade of a cutting means having a cutting blade configured as the outermost diameter of the main body rotating about the rotation axis into contact with the outer peripheral surface of the workpiece; Including. The optical layered body with the pressure-sensitive adhesive layer is disposed on the side opposite to the optical film of the optical film, the first pressure-sensitive adhesive layer disposed on one side of the optical film, and the first pressure-sensitive adhesive layer. A first separator, a second pressure-sensitive adhesive layer disposed on the other side of the optical film, a second separator disposed on the opposite side of the second pressure-sensitive adhesive layer from the optical film, The storage elastic modulus G ′ at 25 ° C. of at least one of the first pressure-sensitive adhesive layer and the second pressure-sensitive adhesive layer is 1.0 × 10 5 (Pa) to 2.5 × 10 5 (Pa) And the thickness of the at least one pressure-sensitive adhesive layer is 50 μm or more.
In another method for producing an optical laminate with a pressure-sensitive adhesive layer according to the present invention, the optical laminate with a pressure-sensitive adhesive layer comprises an optical film and one side of the optical film in order from the optical film side. The 3rd adhesive layer, optical function film, 1st adhesive layer, and 1st separator which were arrange | positioned, and the 2nd adhesive layer arrange | positioned in order from this optical film side on the other side of this optical film And at least one of the first pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer, and the third pressure-sensitive adhesive layer has a storage elastic modulus G ′ at 25 ° C. of 1.0 ×. 10 5 (Pa) to 2.5 × 10 5 (Pa), and the thickness of the at least one pressure-sensitive adhesive layer is 50 μm or more.
In one embodiment, the manufacturing method includes cutting the outer peripheral surface of the workpiece non-linearly.
In one embodiment, the cutting means is an end mill.
In one embodiment, the optical film is a polarizer or a polarizing plate.
In one embodiment, the optical functional film includes at least one selected from a cellulose resin, a cycloolefin resin, and an acrylic resin.
In one embodiment, the breaking strength of the optical function film is 35 N or less.
In one embodiment, the cutting means has two or more cutting blades.
In one embodiment, the non-linear cutting includes forming a concave portion including a curved portion when the optical layered body with an adhesive layer is viewed in plan.
In one embodiment, the radius of the above-mentioned curve part is 5 mm or less.

本発明によれば、粘着剤層付光学積層体を複数枚重ねてワークを形成し、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削することを含む粘着剤層付光学積層体の製造方法において、光学積層体に含まれる粘着剤層のうちの少なくとも1つの貯蔵弾性率を所定範囲とし、かつ、厚みを所定値以上とすることにより、光学積層体に含まれる光学フィルムのクラックを抑制し、不具合を生じることなく、切削加工された粘着剤層付光学積層体を簡便に製造することができる。このような効果は、特に、ワークの外周面を非直線的に加工する場合に顕著である。より詳細には以下のとおりである。粘着剤層付光学積層体を複数枚重ねてワークを形成し、当該ワークを所望の形状（例えば、矩形以外の形状）に加工する場合、当該加工方法としては、レーザー加工、打ち抜き加工、切削刃を切削面に横方向から当接させる加工方法（例えば、エンドミル加工）等が候補として挙げられる。しかし、レーザー加工は得られる光学積層体の光学特性に悪影響を与える場合があり、打ち抜き加工は形状精度が不十分である。そこで、エンドミル加工を試みたところ、光学フィルムにクラックが発生するという課題が新たに発見された。本発明者らは、当該新たな課題について試行錯誤を繰り返した結果、粘着剤層付光学積層体に含まれる粘着剤層のうちの少なくとも1つの貯蔵弾性率を所定範囲とし、かつ、厚みを所定値以上とすることにより、当該少なくとも1つの粘着剤層が切削時に切削端面に塗り広げられ、切削手段による光学フィルムへのダメージを吸収し、クラックを抑制できることを見出した。すなわち、本発明は、粘着剤層付光学積層体を切削加工するという技術において新たに生じた課題を解決したものである。   According to the present invention, a workpiece is formed by stacking a plurality of optical layered bodies with adhesive layers, and is configured as an outermost diameter of a main body that rotates about the rotation axis and a rotation axis that extends in the lamination direction of the workpiece. In a method for producing an optical laminate with an adhesive layer, the method comprising: bringing a cutting blade of a cutting means having a cutting blade into contact with the outer peripheral surface of the workpiece and cutting the outer peripheral surface of the workpiece; By setting the storage elastic modulus of at least one of the pressure-sensitive adhesive layers to be in a predetermined range, and by setting the thickness to a predetermined value or more, the cracks of the optical film contained in the optical laminate are suppressed, without causing a problem, The cut optical laminated body with the pressure-sensitive adhesive layer can be easily produced. Such an effect is particularly remarkable when the outer peripheral surface of the workpiece is processed non-linearly. More details are as follows. When forming a workpiece by stacking a plurality of optical laminates with adhesive layers and processing the workpiece into a desired shape (for example, a shape other than a rectangle), the processing methods include laser processing, punching, cutting blade A candidate is a processing method (for example, end mill processing) in which the surface is brought into contact with the cutting surface from the lateral direction. However, laser processing may adversely affect the optical properties of the resulting optical laminate, and punching has insufficient shape accuracy. Therefore, when end milling was attempted, a problem that a crack occurred in the optical film was newly discovered. As a result of repeating trial and error for the new problem, the present inventors set the storage elastic modulus of at least one of the pressure-sensitive adhesive layers included in the optical layered body with the pressure-sensitive adhesive layer within a predetermined range and a predetermined thickness. It has been found that when the value is equal to or greater than the value, the at least one pressure-sensitive adhesive layer is spread on the cutting end face during cutting, absorbs damage to the optical film by the cutting means, and can suppress cracks. That is, this invention solves the problem which arose newly in the technique of cutting an optical laminated body with an adhesive layer.

本発明の製造方法に用いられ得る粘着剤層付光学積層体の一例を説明する概略断面図である。It is a schematic sectional drawing explaining an example of the optical laminated body with an adhesive layer which can be used for the manufacturing method of this invention. 本発明の製造方法に用いられ得る粘着剤層付光学積層体の別の例を説明する概略断面図である。It is a schematic sectional drawing explaining another example of the optical laminated body with an adhesive layer which can be used for the manufacturing method of this invention. 本発明の製造方法により得られ得る切削加工された粘着剤層付光学積層体の形状の一例を示す概略平面図である。It is a schematic plan view which shows an example of the shape of the cut optical laminated body with an adhesive layer which can be obtained with the manufacturing method of this invention. 本発明の製造方法における切削加工を説明するための概略斜視図である。It is a schematic perspective view for demonstrating the cutting process in the manufacturing method of this invention. 本発明の製造方法における切削加工に用いられる切削手段の構造を説明するための概略図である。It is the schematic for demonstrating the structure of the cutting means used for the cutting in the manufacturing method of this invention. （ａ）〜（ｃ）は、本発明の製造方法における切削加工の一連の手順を説明する概略平面図である。(A)-(c) is a schematic plan view explaining the series of procedures of the cutting process in the manufacturing method of this invention.

以下、図面を参照して本発明の具体的な実施形態について説明するが、本発明はこれらの実施形態には限定されない。なお、見やすくするために図面は模式的に表されており、さらに、図面における長さ、幅、厚み等の比率、ならびに角度等は、実際とは異なっている。   Hereinafter, specific embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. Note that the drawings are schematically shown for ease of viewing, and the ratios of length, width, thickness, etc., angles, and the like in the drawings are different from actual ones.

本発明の粘着剤層付光学積層体の製造方法は、粘着剤層付光学積層体を複数枚重ねてワークを形成すること；および、該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること；を含む。特に、粘着剤層付光学積層体の非直線加工（異形加工）において本発明の効果が顕著となる。   The method for producing an optical layered body with an adhesive layer according to the present invention includes forming a workpiece by stacking a plurality of optical layered bodies with an adhesive layer; and a rotation axis extending in the laminating direction of the workpiece and the rotation axis as a center. Cutting the outer peripheral surface of the workpiece by bringing the cutting blade of the cutting means having a cutting blade configured as the outermost diameter of the rotating main body into contact with the outer peripheral surface of the workpiece. In particular, the effect of the present invention is remarkable in non-linear processing (deformation processing) of the optical layered body with an adhesive layer.

Ａ．粘着剤層付光学積層体
図１は、本発明の製造方法に用いられ得る粘着剤層付光学積層体の一例を説明する概略断面図である。図示例の粘着剤層付光学積層体１００は、光学フィルム１１０と、光学フィルム１１０の一方の側に配置された第１の粘着剤層１３０と、第１の粘着剤層１３０の光学フィルム１１０と反対側に配置された第１のセパレーター１４０と、光学フィルム１１０の他方の側に配置された第２の粘着剤層１５０と、第２の粘着剤層１５０の光学フィルムと反対側に配置された第２のセパレーター１６０と、を含む。粘着剤層付光学積層体が画像表示装置に適用された場合、代表的には、第１のセパレーター１４０が視認側に配置される。粘着剤層付光学積層体の実際の使用時には第１のセパレーター１４０は剥離除去され、第１の粘着剤層１３０にカバーガラス等が貼り合わせられる。粘着剤層付光学積層体の実際の使用時には第２のセパレーター１４０もまた剥離除去され、第２の粘着剤層１５０は、粘着剤層付光学積層体を画像表示装置（実質的には、表示セル）に貼り合わせるために用いられ得る。 A. FIG. 1 is a schematic cross-sectional view illustrating an example of an optical laminate with an adhesive layer that can be used in the production method of the present invention. The optical laminated body 100 with an adhesive layer in the illustrated example includes an optical film 110, a first adhesive layer 130 disposed on one side of the optical film 110, and the optical film 110 of the first adhesive layer 130. The first separator 140 disposed on the opposite side, the second pressure-sensitive adhesive layer 150 disposed on the other side of the optical film 110, and the second pressure-sensitive adhesive layer 150 disposed on the opposite side of the optical film. A second separator 160. When the optical layered body with an adhesive layer is applied to an image display device, typically, the first separator 140 is disposed on the viewing side. During actual use of the optical layered body with the pressure-sensitive adhesive layer, the first separator 140 is peeled and removed, and a cover glass or the like is bonded to the first pressure-sensitive adhesive layer 130. During actual use of the optical layered body with the pressure-sensitive adhesive layer, the second separator 140 is also peeled and removed. Cell).

図２は、本発明の製造方法に用いられ得る粘着剤層付光学積層体の別の例を説明する概略断面図である。図示例の粘着剤層付光学積層体１０１は、光学フィルム１１０と第１の粘着剤層１３０との間に、第３の粘着剤層１８０を介して光学フィルム１１０に貼り合わせられた光学機能フィルム１７０をさらに含む。   FIG. 2 is a schematic cross-sectional view illustrating another example of an optical layered body with an adhesive layer that can be used in the production method of the present invention. The optical layered body 101 with the pressure-sensitive adhesive layer in the illustrated example is an optical functional film that is bonded to the optical film 110 via the third pressure-sensitive adhesive layer 180 between the optical film 110 and the first pressure-sensitive adhesive layer 130. 170 is further included.

光学フィルム１１０または光学機能フィルム１７０と第１の粘着剤層１３０との間には、目的に応じて任意の適切な表面処理層が設けられてもよい。表面処理層としては、例えば、ハードコート層、反射防止層、アンチグレア層、防眩層が挙げられる。   Any appropriate surface treatment layer may be provided between the optical film 110 or the optical functional film 170 and the first pressure-sensitive adhesive layer 130 depending on the purpose. Examples of the surface treatment layer include a hard coat layer, an antireflection layer, an antiglare layer, and an antiglare layer.

以下、光学フィルム１１０、第１の粘着剤層１３０、第２の粘着剤層１５０、第３の粘着剤層１８０、および光学機能フィルム１７０の具体的な構成について、簡単に説明する。   Hereinafter, specific configurations of the optical film 110, the first pressure-sensitive adhesive layer 130, the second pressure-sensitive adhesive layer 150, the third pressure-sensitive adhesive layer 180, and the optical functional film 170 will be briefly described.

光学フィルム１１０としては、切削加工（特に、非直線加工）が必要とされる用途に用いられ得る任意の適切な光学フィルムが挙げられる。光学フィルムは、単一層で構成されるフィルムであってもよく、積層体であってもよい。単一層で構成される光学フィルムの具体例としては、偏光子、位相差フィルムが挙げられる。積層体として構成される光学フィルムの具体例としては、偏光板（代表的には、偏光子と保護フィルムとの積層体）、タッチパネル用導電性フィルム、表面処理フィルム、ならびに、これらの単一層で構成される光学フィルムおよび／または積層体として構成される光学フィルムを目的に応じて適切に積層した積層体（例えば、反射防止用円偏光板、タッチパネル用導電層付偏光板）が挙げられる。   Examples of the optical film 110 include any appropriate optical film that can be used for applications that require cutting (particularly non-linear processing). The optical film may be a film composed of a single layer or a laminate. Specific examples of the optical film composed of a single layer include a polarizer and a retardation film. Specific examples of the optical film configured as a laminate include a polarizing plate (typically, a laminate of a polarizer and a protective film), a conductive film for a touch panel, a surface treatment film, and a single layer thereof. A laminate (for example, a circularly polarizing plate for antireflection, a polarizing plate with a conductive layer for touch panel) obtained by appropriately laminating an optical film constituted as a laminated body and / or an optical film constituted as a laminated body may be mentioned.

本発明の実施形態においては、第１の粘着剤層１３０、第２の粘着剤層１５０および第３の粘着剤層１８０の少なくとも１つの２５℃における貯蔵弾性率Ｇ’は１．０×１０５（Ｐａ）〜２．５×１０５（Ｐａ）であり、かつ、当該少なくとも１つの粘着剤層の厚みは５０μｍ以上である。すなわち、粘着剤層付光学積層体に含まれる粘着剤層（図１の例では２つ、図２の例では３つ）のうち、１つの粘着剤層のみが上記の貯蔵弾性率および厚み（以下、当該要件と称する場合がある）を満足してもよく、２つの粘着剤層が当該要件を満足してもよく、３つの粘着剤層が当該要件を満足してもよい。粘着剤層付光学積層体に含まれる粘着剤層（図１の例では２つ、図２の例では３つ）の一部の粘着剤層が当該要件を満足する場合、当該要件を満足する粘着剤層は、第１の粘着剤層、第２の粘着剤層または第３の粘着剤層のいずれであってもよい。例えば、図１の実施形態においては、当該要件を満足する粘着剤層は、第１の粘着剤層、第２の粘着剤層、あるいは、第１の粘着剤層と第２の粘着剤層であり得、代表的には第１の粘着剤層である。また例えば、図２の実施形態においては、当該要件を満足する粘着剤層は、第１の粘着剤層、第２の粘着剤層、第３の粘着剤層、第１の粘着剤層と第２の粘着剤層、第１の粘着剤層と第３の粘着剤層、第２の粘着剤層と第３の粘着剤層、あるいは、第１の粘着剤層と第２の粘着剤層と第３の粘着剤層であり得、代表的には第１の粘着剤層である。粘着剤層付光学積層体に含まれる粘着剤層のうち少なくとも1つの粘着剤層の貯蔵弾性率と厚みとを組み合わせて最適化することにより、粘着剤層付光学積層体の切削加工（特に、非直線加工）において粘着剤層が切削手段による光学フィルムへのダメージを良好に吸収し得るので、光学フィルムにおけるクラックの発生を顕著に抑制することができる。当該要件を満足する粘着剤層の貯蔵弾性率は、好ましくは１．１×１０５（Ｐａ）〜２．３×１０５（Ｐａ）であり、より好ましくは１．２×１０５（Ｐａ）〜２．０×１０５（Ｐａ）である。貯蔵弾性率は、例えば、動的粘弾性測定から求められ得る。 In the embodiment of the present invention, the storage elastic modulus G ′ at 25 ° C. of at least one of the first pressure-sensitive adhesive layer 130, the second pressure-sensitive adhesive layer 150, and the third pressure-sensitive adhesive layer 180 is 1.0 × 10 5. (Pa) to 2.5 × 10 5 (Pa), and the thickness of the at least one pressure-sensitive adhesive layer is 50 μm or more. That is, of the pressure-sensitive adhesive layers (two in the example of FIG. 1 and three in the example of FIG. 2) included in the optical layered body with the pressure-sensitive adhesive layer, only one pressure-sensitive adhesive layer has the above storage elastic modulus and thickness ( Hereinafter, the requirement may be referred to), two pressure-sensitive adhesive layers may satisfy the requirement, or three pressure-sensitive adhesive layers may satisfy the requirement. When some of the pressure-sensitive adhesive layers (two in the example of FIG. 1 and three in the example of FIG. 2) included in the optical layered body with the pressure-sensitive adhesive layer satisfy the requirement, the requirement is satisfied. The pressure-sensitive adhesive layer may be any of the first pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer, or the third pressure-sensitive adhesive layer. For example, in the embodiment of FIG. 1, the pressure-sensitive adhesive layer that satisfies the requirements is a first pressure-sensitive adhesive layer, a second pressure-sensitive adhesive layer, or a first pressure-sensitive adhesive layer and a second pressure-sensitive adhesive layer. It can be typically the first pressure-sensitive adhesive layer. Further, for example, in the embodiment of FIG. 2, the pressure-sensitive adhesive layer that satisfies the requirement includes the first pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer, the third pressure-sensitive adhesive layer, the first pressure-sensitive adhesive layer, and the first pressure-sensitive adhesive layer. 2 adhesive layers, 1st adhesive layer and 3rd adhesive layer, 2nd adhesive layer and 3rd adhesive layer, or 1st adhesive layer and 2nd adhesive layer It may be a third pressure-sensitive adhesive layer, and is typically the first pressure-sensitive adhesive layer. By optimizing the combination of the storage elastic modulus and thickness of at least one pressure-sensitive adhesive layer among the pressure-sensitive adhesive layers contained in the pressure-sensitive adhesive layer-attached optical laminate, cutting of the pressure-sensitive adhesive layer-attached optical laminate (particularly, Since the pressure-sensitive adhesive layer can satisfactorily absorb damage to the optical film due to the cutting means in non-linear processing), the occurrence of cracks in the optical film can be remarkably suppressed. The storage elastic modulus of the pressure-sensitive adhesive layer that satisfies the requirement is preferably 1.1 × 10 5 (Pa) to 2.3 × 10 5 (Pa), more preferably 1.2 × 10 5 (Pa). It is -2.0 * 10 < 5 > (Pa). The storage elastic modulus can be obtained from, for example, dynamic viscoelasticity measurement.

当該要件を満足する粘着剤層の厚みは、好ましくは７０μｍ〜２５０μｍであり、より好ましくは８０μｍ〜２００μｍであり、さらに好ましくは１００μｍ〜１５０μｍである。   The thickness of the pressure-sensitive adhesive layer that satisfies the requirement is preferably 70 μm to 250 μm, more preferably 80 μm to 200 μm, and further preferably 100 μm to 150 μm.

当該要件を満足する粘着剤層を構成する粘着剤としては、光学用途に使用可能な粘着性および透明性を有し、かつ、上記所望の貯蔵弾性率を有する限り、任意の適切な粘着剤を採用することができる。具体例としては、アクリル系粘着剤、ゴム系粘着剤、シリコーン系粘着剤、ポリエステル系粘着剤、ウレタン系粘着剤、エポキシ系粘着剤、およびポリエーテル系粘着剤が挙げられる。粘着剤のベース樹脂を形成するモノマーの種類、数、組み合わせおよび配合比、ならびに、架橋剤の配合量、反応温度、反応時間等を調整することにより、上記所望の貯蔵弾性率を有する粘着剤を調製することができる。粘着剤のベース樹脂は、単独で用いてもよく、２種以上を組み合わせて用いてもよい。透明性、加工性および耐久性などの観点から、アクリル系粘着剤が好ましい。粘着剤の詳細は、例えば、特開２０１４−１１５４６８号公報に記載されており、当該公報の記載は本明細書に参考として援用されている。   As the pressure-sensitive adhesive constituting the pressure-sensitive adhesive layer satisfying the requirements, any suitable pressure-sensitive adhesive can be used as long as it has adhesiveness and transparency that can be used for optical applications and has the desired storage elastic modulus. Can be adopted. Specific examples include acrylic adhesives, rubber adhesives, silicone adhesives, polyester adhesives, urethane adhesives, epoxy adhesives, and polyether adhesives. By adjusting the type, number, combination and blending ratio of the monomers forming the base resin of the pressure-sensitive adhesive, the amount of the crosslinking agent, the reaction temperature, the reaction time, etc., the pressure-sensitive adhesive having the desired storage elastic modulus is obtained. Can be prepared. The base resin of the pressure-sensitive adhesive may be used alone or in combination of two or more. From the viewpoints of transparency, processability and durability, an acrylic pressure-sensitive adhesive is preferred. Details of the pressure-sensitive adhesive are described in, for example, Japanese Patent Application Laid-Open No. 2014-115468, and the description of the publication is incorporated herein by reference.

当該要件を満足する粘着剤層以外の粘着剤層を構成する粘着剤としては、業界で周知慣用の粘着剤を用いることができる。   As a pressure-sensitive adhesive constituting the pressure-sensitive adhesive layer other than the pressure-sensitive adhesive layer that satisfies the requirements, a pressure-sensitive adhesive commonly used in the industry can be used.

当該要件を満足する粘着剤層以外の粘着剤層が第１の粘着剤層１３０である場合には、第１の粘着剤層は表面保護フィルムの粘着剤層であり得る。すなわち、第１のセパレーター１４０の代わりに任意の適切な基材（樹脂フィルム）が採用され得、粘着剤層付光学積層体の実際の使用時には、基材と粘着剤層とが一体として（表面保護フィルムとして）剥離除去されてもよい。   When the pressure-sensitive adhesive layer other than the pressure-sensitive adhesive layer satisfying the requirement is the first pressure-sensitive adhesive layer 130, the first pressure-sensitive adhesive layer can be the pressure-sensitive adhesive layer of the surface protective film. That is, any appropriate base material (resin film) can be adopted instead of the first separator 140, and the base material and the pressure-sensitive adhesive layer are integrated (surface) when the optical laminate with the pressure-sensitive adhesive layer is actually used. It may be peeled off (as a protective film).

光学機能フィルム１７０は、必要に応じて設けられる構成要素である。光学機能フィルムは、目的に応じた所望の光学機能を粘着剤層付光学積層体に付与するために設けられる。光学機能フィルムとしては、例えば、偏光子または偏光板の保護フィルム、反射防止フィルム、アンチグレアフィルム、偏光サングラスを介して視認する場合の視認性を改善するためのフィルムが挙げられる。偏光サングラスを介して視認する場合の視認性を改善するためのフィルムとしては、例えば、（楕）円偏光機能を有するフィルム（例えば、λ／４板）、超高位相差フィルム（例えば、２０００ｎｍ以上の面内位相差を有するフィルム）が挙げられる。   The optical function film 170 is a component provided as necessary. The optical function film is provided in order to impart a desired optical function according to the purpose to the optical layered body with an adhesive layer. Examples of the optical functional film include a polarizer or polarizing plate protective film, an antireflection film, an antiglare film, and a film for improving visibility when viewed through a polarized sunglasses. As a film for improving the visibility when viewed through polarized sunglasses, for example, a film having an (elliptical) circular polarization function (for example, λ / 4 plate), an ultrahigh retardation film (for example, 2000 nm or more) Film having in-plane retardation).

光学機能フィルム１７０は、１つの実施形態においては、樹脂フィルムで構成され得る。樹脂フィルムを構成する樹脂としては、例えば、セルロース系樹脂、シクロオレフィン系樹脂およびアクリル系樹脂が挙げられる。これらは、単独で用いてもよく、組み合わせて用いてもよい。   In one embodiment, the optical functional film 170 may be formed of a resin film. Examples of the resin constituting the resin film include a cellulose resin, a cycloolefin resin, and an acrylic resin. These may be used alone or in combination.

光学機能フィルム１７０の破断強度は、好ましくは３５Ｎ以下であり、より好ましくは５Ｎ〜３０Ｎであり、さらに好ましくは７Ｎ〜２８Ｎである。本発明の実施形態によれば、このような低い破断強度を有する光学機能フィルムを用いた場合であっても、クラックを良好に抑制することができる。破断強度は、代表的には、ＪＩＳ Ｋ ７１６１に準拠して測定され得る。   The breaking strength of the optical functional film 170 is preferably 35N or less, more preferably 5N to 30N, and further preferably 7N to 28N. According to the embodiment of the present invention, cracks can be satisfactorily suppressed even when an optical functional film having such a low breaking strength is used. The breaking strength can typically be measured according to JIS K 7161.

上記の実施形態は適宜組み合わせられ得る。したがって、本明細書は、上記の光学フィルム、第１の粘着剤層、第２の粘着剤層、第３の粘着剤層、および光学機能フィルム（存在する場合）のすべての組み合わせを記載していると解されるべきである。これらのいずれの組み合わせに対しても本発明が適用され得ることは、当業者に自明である。   The above embodiments can be combined as appropriate. Therefore, this specification describes all combinations of the optical film, the first pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer, the third pressure-sensitive adhesive layer, and the optical functional film (if present). Should be understood. It is obvious to those skilled in the art that the present invention can be applied to any combination of these.

以下、一例として図３に示すような平面形状の粘着剤層付光学積層体の製造方法における各工程を説明する。   Hereafter, each process in the manufacturing method of an optical laminated body with a planar shape as shown in FIG. 3 as an example is demonstrated.

Ｂ．ワークの形成
図４は、切削加工を説明するための概略斜視図であり、本図にワーク１が示されている。図４に示すように、粘着剤層付光学積層体を複数枚重ねたワーク１が形成される。粘着剤層付光学積層体は、ワーク形成に際し、代表的には任意の適切な形状に切断されている。具体的には、粘着剤層付光学積層体は矩形形状に切断されていてもよく、矩形形状に類似する形状に切断されていてもよく、目的に応じた適切な形状（例えば、円形）に切断されていてもよい。ワーク１は、互いに対向する外周面（切削面）１ａ、１ｂおよびそれらと直交する外周面（切削面）１ｃ、１ｄを有している。ワーク１は、好ましくは、クランプ手段（図示せず）により上下からクランプされている。ワークの総厚みは、好ましくは８ｍｍ〜２０ｍｍであり、より好ましくは９ｍｍ〜１５ｍｍであり、さらに好ましくは約１０ｍｍである。このような厚みであれば、クランプ手段による押圧または切削加工時の衝撃による損傷を防止し得る。粘着剤層付光学積層体は、ワークがこのような総厚みとなるように重ねられる。ワークを構成する粘着剤層付光学積層体の枚数は、例えば１０枚〜５０枚であり得る。クランプ手段（例えば、治具）は、軟質材料で構成されてもよく硬質材料で構成されてもよい。軟質材料で構成される場合、その硬度（ＪＩＳ Ａ）は、好ましくは６０°〜８０°である。硬度が高すぎると、クランプ手段による押し跡が残る場合がある。硬度が低すぎると、治具の変形により位置ずれが生じ、切削精度が不十分となる場合がある。 B. Formation of Workpiece FIG. 4 is a schematic perspective view for explaining the cutting process, and the work 1 is shown in this drawing. As shown in FIG. 4, a work 1 is formed in which a plurality of optical laminates with adhesive layers are stacked. The optical layered body with the pressure-sensitive adhesive layer is typically cut into any appropriate shape when forming a workpiece. Specifically, the optical layered body with an adhesive layer may be cut into a rectangular shape, may be cut into a shape similar to the rectangular shape, and has an appropriate shape (for example, a circle) according to the purpose. It may be cut. The workpiece 1 has outer peripheral surfaces (cutting surfaces) 1a and 1b facing each other and outer peripheral surfaces (cutting surfaces) 1c and 1d orthogonal to them. The workpiece 1 is preferably clamped from above and below by clamping means (not shown). The total thickness of the workpiece is preferably 8 mm to 20 mm, more preferably 9 mm to 15 mm, and even more preferably about 10 mm. If it is such thickness, the damage by the impact at the time of the press by a clamp means or a cutting process can be prevented. The optical laminate with the pressure-sensitive adhesive layer is overlaid so that the workpiece has such a total thickness. The number of the optical laminated body with an adhesive layer which comprises a workpiece | work may be 10-50 sheets, for example. The clamping means (for example, a jig) may be made of a soft material or a hard material. When composed of a soft material, the hardness (JIS A) is preferably 60 ° to 80 °. If the hardness is too high, there may be a case where a mark is left by the clamping means. If the hardness is too low, displacement may occur due to deformation of the jig, and cutting accuracy may be insufficient.

Ｃ．切削加工
次に、ワーク１の外周面を、切削手段２０により切削する。切削は、上記のとおり、切削手段の切削刃をワーク１の外周面に当接させることにより行われる。切削は、ワークの外周面の全周にわたって行ってもよく、所定の位置のみに行ってもよい。以下の図示例においては、切削は、ワークの外周面の全周にわたって行われる。図３に示すような平面視形状の粘着剤層付光学積層体を作製する場合には、ワークの外周を直線的に切削するとともに、ワークの外周の２つの隅部に面取り部４ａ、４ｂを形成し、面取り部４ａ、４ｂが形成された外周面の中央部に凹部（曲線部を含む凹部）４ｃを形成する。切削加工は、代表的には図４および図５に示すように、いわゆるエンドミル加工である。すなわち、切削手段（エンドミル）２０の側面を用いて、ワーク１の外周面の所定の位置を切削する。切削手段（エンドミル）２０としては、代表的にはストレートエンドミルが用いられ得る。 C. Next, the outer peripheral surface of the workpiece 1 is cut by the cutting means 20. Cutting is performed by bringing the cutting blade of the cutting means into contact with the outer peripheral surface of the workpiece 1 as described above. Cutting may be performed over the entire circumference of the outer peripheral surface of the workpiece, or may be performed only at a predetermined position. In the following illustrated example, cutting is performed over the entire circumference of the outer peripheral surface of the workpiece. When producing an optical layered product with a pressure-sensitive adhesive layer having a plan view shape as shown in FIG. Then, a concave portion (a concave portion including a curved portion) 4c is formed at the center of the outer peripheral surface where the chamfered portions 4a and 4b are formed. The cutting is typically so-called end milling as shown in FIGS. That is, a predetermined position on the outer peripheral surface of the workpiece 1 is cut using the side surface of the cutting means (end mill) 20. As the cutting means (end mill) 20, a straight end mill can be typically used.

具体的には、切削手段２０は、図５に示すように、ワーク１の積層方向（鉛直方向）に延びる回転軸２１と、回転軸２１を中心として回転する本体の最外径として構成される切削刃２２と、を有する。図示例では、切削刃２２は、回転軸２１に沿ってねじれた最外径として構成されている。切削刃２２は、刃先２２ａと、すくい面２２ｂと、逃がし面２２ｃと、を含む。切削刃２２の刃数は、目的に応じて適切に設定され得る。図示例における切削刃は３枚の構成であるが、刃数は連続した１枚であってもよく、２枚であってもよく、４枚であってもよく、５枚以上であってもよい。好ましくは、刃数は２枚以上である。刃数が２枚以上であれば、粘着剤の削りカスの逃がし面２２ｃへの付着が抑制されるので、結果として、ブロッキングが抑制され得る。これは、通常の粘着剤層を含む光学積層体の切削加工とは逆の傾向である。すなわち、通常の粘着剤層を含む光学積層体の切削加工では、刃数が多いと削りカスがすくい面２２ｂにたまってしまい、切削不良を起こす場合が多い。一方、本発明のように粘着剤層付光学積層体が柔らかい粘着剤層を含む場合には、刃数が多い方が粘着剤層付光学積層体（の粘着剤層）の弾性回復が抑制され、粘着剤の削りカスの逃がし面２２ｃへの付着が抑制される。その結果、逃がし面の粘着剤の削りカスと粘着剤層付光学積層体（の粘着剤層）との接触が抑制されるので、結果として、削りカスに起因するブロッキングが抑制され得る。より詳細には以下のとおりである：一般的には、刃数が少ない方がすくい面における粘着剤の削りカスの排出性が良好である一方で、１枚の刃あたりの切削抵抗が大きく、粘着剤層の弾性回復が大きくなるので、逃がし面に粘着剤の削りカスが付着しやすくなる。通常の粘着剤層を含む光学積層体の切削加工においては、すくい面における粘着剤の削りカスの排出性の影響の方が大きいので、刃数が少ない方がブロッキングを抑制できる。一方、本発明のようにハードコート層付光学積層体が柔らかい粘着剤層を含む場合には、粘着剤層の弾性回復の影響の方が大きいので、刃数が多い方がブロッキングを抑制できる。なお、本明細書において「ブロッキング」とは、ワークにおける粘着剤層付光学積層体同士が端面の粘着剤で接着する現象をいい、端面に付着する粘着剤の削りカスが粘着剤層付光学積層体同士の接着に寄与することとなる。切削手段の刃角度（図示例における切削刃のねじれ角θ）は、好ましくは４５°〜７５°であり、より好ましくは４５°〜６０°である。このような刃角度であれば、粘着剤の削りカスが切削刃から容易に排出され得るので、結果として、ブロッキングが抑制され得る。切削刃の逃がし面は、好ましくは、粗面化処理されている。粗面化処理としては、任意の適切な処理が採用され得る。代表例としては、ブラスト処理が挙げられる。逃がし面に粗面化処理を施すことにより、切削刃への粘着剤の付着が抑制され、結果として、ブロッキングが抑制され得る。刃数と逃がし面の粗面化処理と刃角度の調整とを適切に組み合わせることにより、上記の相乗的な効果により、ブロッキングがさらに抑制され得る。すなわち、エンドミルが上記のような構成であれば、ブロッキングを良好に抑制することができる。   Specifically, as shown in FIG. 5, the cutting means 20 is configured as a rotating shaft 21 extending in the stacking direction (vertical direction) of the workpiece 1 and an outermost diameter of a main body that rotates around the rotating shaft 21. A cutting blade 22. In the illustrated example, the cutting blade 22 is configured as an outermost diameter twisted along the rotation shaft 21. The cutting blade 22 includes a cutting edge 22a, a rake surface 22b, and a relief surface 22c. The number of blades of the cutting blade 22 can be appropriately set according to the purpose. Although the cutting blade in the illustrated example has a configuration of three sheets, the number of blades may be one continuous, two, four, or five or more. Good. Preferably, the number of blades is two or more. If the number of blades is two or more, the adhesion of the shaving residue of the adhesive to the escape surface 22c is suppressed, and as a result, blocking can be suppressed. This is a tendency opposite to that of cutting of an optical laminate including a normal pressure-sensitive adhesive layer. That is, in the cutting of an optical laminated body including a normal pressure-sensitive adhesive layer, if the number of blades is large, the scraps accumulate on the rake face 22b and often cause cutting defects. On the other hand, when the optical layered body with an adhesive layer includes a soft adhesive layer as in the present invention, the elastic recovery of the optical layered body with an adhesive layer (adhesive layer thereof) is suppressed when the number of blades is large. Adhesion of the adhesive scraps to the escape surface 22c is suppressed. As a result, the contact between the scraped residue of the pressure-sensitive adhesive and the optical laminate with the adhesive layer (adhesive layer thereof) is suppressed, and as a result, blocking due to the scraped residue can be suppressed. More specifically, it is as follows: In general, the smaller the number of blades, the better the scraping performance of the adhesive scrap on the rake face, while the greater the cutting resistance per blade, Since the elastic recovery of the pressure-sensitive adhesive layer is increased, the shavings of the pressure-sensitive adhesive easily adhere to the escape surface. In the cutting of an optical layered body including a normal pressure-sensitive adhesive layer, the influence of the scraping property of the pressure-sensitive adhesive on the rake face is larger, so that blocking with a smaller number of blades can suppress blocking. On the other hand, when the optical layered body with a hard coat layer includes a soft pressure-sensitive adhesive layer as in the present invention, the effect of elastic recovery of the pressure-sensitive adhesive layer is larger, so that the one with a larger number of blades can suppress blocking. In the present specification, “blocking” refers to a phenomenon in which the optical laminates with the pressure-sensitive adhesive layer in the workpiece are bonded to each other with the pressure-sensitive adhesive on the end surface. It will contribute to the adhesion between the bodies. The blade angle of the cutting means (the twist angle θ of the cutting blade in the illustrated example) is preferably 45 ° to 75 °, more preferably 45 ° to 60 °. With such a blade angle, the shaving residue of the adhesive can be easily discharged from the cutting blade, and as a result, blocking can be suppressed. The relief surface of the cutting blade is preferably roughened. Any appropriate process can be adopted as the roughening process. A typical example is blasting. By applying a roughening treatment to the relief surface, adhesion of the adhesive to the cutting blade is suppressed, and as a result, blocking can be suppressed. By appropriately combining the number of blades, the roughening treatment of the relief surface, and the adjustment of the blade angle, blocking can be further suppressed by the above synergistic effect. That is, if an end mill is the above structures, blocking can be suppressed favorably.

ワーク１の切削加工（非直線加工）の一例について説明する。まず、図６（ａ）に示すように、図３の面取り部４ａが形成される部分が面取り加工され、次いで、図６（ｂ）に示すように、面取り部４ｂが形成される部分が面取り加工される。最後に、図６（ｃ）に示すように、凹部（曲線部を含む凹部）４ｃが切削形成される。曲線部の半径は、好ましくは５ｍｍ以下であり、より好ましくは４ｍｍ以下であり、さらに好ましくは３ｍｍ以下である。本発明の実施形態によれば、このような半径が小さい曲線部を形成する場合であっても、クラックを良好に抑制することができる。なお、面取り部４ａおよび４ｂ、ならびに凹部４ｃの形成順序（切削順序）は限定されない。さらに、上記のような非直線加工は、直線加工と連続して行ってもよく（例えば、図示例とは異なりワークの全周を連続的に切削加工してもよく）、所定の直線加工を行った後に行ってもよく、直線加工の前に行ってもよい。   An example of cutting (non-linear processing) of the workpiece 1 will be described. First, as shown in FIG. 6A, the portion where the chamfered portion 4a in FIG. 3 is formed is chamfered, and then, as shown in FIG. 6B, the portion where the chamfered portion 4b is formed is chamfered. Processed. Finally, as shown in FIG. 6C, a concave portion (a concave portion including a curved portion) 4c is formed by cutting. The radius of the curved portion is preferably 5 mm or less, more preferably 4 mm or less, and further preferably 3 mm or less. According to the embodiment of the present invention, cracks can be satisfactorily suppressed even when such a curved portion having a small radius is formed. In addition, the formation order (cutting order) of the chamfered parts 4a and 4b and the recessed part 4c is not limited. Further, the non-linear machining as described above may be performed continuously with the linear machining (for example, unlike the illustrated example, the entire circumference of the workpiece may be continuously machined), and a predetermined linear machining is performed. You may carry out after performing, and you may carry out before a linear process.

切削加工の条件は、所望の形状に応じて適切に設定され得る。例えば、切削手段（エンドミル）２０の直径は、好ましくは３ｍｍ〜２０ｍｍである。切削手段の回転数は、好ましくは１０００ｒｐｍ〜６００００ｒｐｍであり、より好ましくは１００００ｒｐｍ〜４００００ｒｐｍである。第２切削手段の送り速度は、好ましくは５００ｍｍ／分〜１００００ｍｍ／分であり、より好ましくは５００ｍｍ／分〜２５００ｍｍ／分である。切削箇所の切削回数は、１回削り、２回削り、３回削りまたはそれ以上であり得る。なお、図示例では面取り部４ａ、面取り部４ｂおよび凹部４ｃをこの順に形成しているが、これらは任意の適切な順序で形成されればよい。   The cutting conditions can be appropriately set according to a desired shape. For example, the diameter of the cutting means (end mill) 20 is preferably 3 mm to 20 mm. The rotation speed of the cutting means is preferably 1000 rpm to 60000 rpm, more preferably 10,000 rpm to 40000 rpm. The feed rate of the second cutting means is preferably 500 mm / min to 10000 mm / min, more preferably 500 mm / min to 2500 mm / min. The number of cuts at the cut location can be one round, two rounds, three rounds or more. In the illustrated example, the chamfered portion 4a, the chamfered portion 4b, and the recessed portion 4c are formed in this order, but these may be formed in any appropriate order.

以上のようにして、切削加工された粘着剤層付光学積層体が得られ得る。   As described above, an optical layered body with a pressure-sensitive adhesive layer that has been cut can be obtained.

以下、実施例により本発明を具体的に説明するが、本発明はこれらの実施例には限定されない。実施例における評価項目は以下のとおりである。   EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to these Examples. Evaluation items in the examples are as follows.

（１）破断強度
実施例および比較例で用いた光学機能フィルムの破断強度を、ＪＩＳ Ｋ ７１６１に準拠して測定した。具体的には、フィルムを縦１００ｍｍおよび横１０ｍｍに切り出して測定試料とし、精密万能試験機（島津製作所社製、製品名「オートグラフ」）を用いて当該測定試料を破断するまで引っ張り、破断強度を測定した。なお、測定試料の引張条件は、３００ｍｍ／ｍｉｎとした。
（２）貯蔵弾性率
実施例および比較例で用いた粘着剤について、動的粘弾性測定から貯蔵弾性率を求めた。動的粘弾性測定は、レオメーター（動的粘弾性測定装置）（ＴＡ Ｉｎｓｔｒｕｍｅｎｔｓ社製、製品名「ＡＲＥＳ」）を用いて下記の条件で行った。
試料形状 １ｍｍ積層
温度範囲 −７０℃〜１５０℃
昇温速度 ５℃／ｍｉｎ
測定周波数 １Ｈｚ
測定治具 パラレルプレート（上下２枚の平板に試料を挟む）
（３）クラック
実施例および比較例で得られた粘着剤層付光学積層体（ワークを構成するすべての粘着剤層付光学積層体）について、−４０℃〜８５℃で２００サイクルのヒートショック試験を行い、凹部（曲線部を含む凹部）のクラックの発生状況を目視により確認し、以下の基準で評価した。なお、クラックの長さは、光学顕微鏡で拡大したものを測定した。
なし：最も長いクラックの長さが１００μｍ以下
発生：最も長いクラックの長さが１００μｍを超える
（４）加工精度
実施例２、比較例１、参考例１および２で得られた粘着剤層付光学積層体について、長辺および短辺の寸法をノギスにより測定し加工精度を評価した。
（５）ブロッキング
実施例２、比較例１、参考例１および２で得られた粘着剤層付光学積層体について、切削加工終了後のワークの状態で、先端に両面テープを付した棒を粘着剤層付光学積層体の中心部に付着させて持ち上げ、下記の基準で評価した。
◎：粘着剤層付光学積層体を１枚ずつ持ち上げることができた
○：粘着剤層付光学積層体が複数枚持ち上がる場合もあるが、揺すると１枚ずつにばらすことができた
×：粘着剤層付光学積層体が複数枚持ち上がり、揺すっても１枚ずつにばらすことができなかった (1) Breaking strength The breaking strength of the optical functional film used in the examples and comparative examples was measured according to JIS K 7161. Specifically, a film is cut into a length of 100 mm and a width of 10 mm to obtain a measurement sample, and the measurement sample is pulled until it breaks using a precision universal testing machine (manufactured by Shimadzu Corporation, product name “Autograph”). Was measured. The tensile condition of the measurement sample was 300 mm / min.
(2) Storage elastic modulus About the adhesive used in the Example and the comparative example, the storage elastic modulus was calculated | required from the dynamic viscoelasticity measurement. The dynamic viscoelasticity measurement was performed under the following conditions using a rheometer (dynamic viscoelasticity measuring apparatus) (product name “ARES” manufactured by TA Instruments).
Sample shape 1mm lamination Temperature range -70 ° C to 150 ° C
Temperature increase rate 5 ℃ / min
Measurement frequency 1Hz
Measuring jig Parallel plate (sample is sandwiched between two flat plates)
(3) Crack About the optical layered product with pressure-sensitive adhesive layer (all optical layered products with pressure-sensitive adhesive layer constituting the workpiece) obtained in Examples and Comparative Examples, heat shock test of 200 cycles at −40 ° C. to 85 ° C. The occurrence of cracks in the recesses (concave portions including the curved portion) was visually confirmed and evaluated according to the following criteria. In addition, the length of the crack measured with the optical microscope.
None: The longest crack has a length of 100 μm or less. Occurrence: The longest crack has a length of more than 100 μm. (4) Processing accuracy Optical with pressure-sensitive adhesive layer obtained in Example 2, Comparative Example 1, Reference Examples 1 and 2 About the laminated body, the dimension of the long side and the short side was measured with calipers, and the processing accuracy was evaluated.
(5) Blocking For the optical laminate with adhesive layer obtained in Example 2, Comparative Example 1 and Reference Examples 1 and 2, sticking a stick with a double-sided tape on the tip in the state of the workpiece after cutting processing It was made to adhere to the center part of the optical laminated body with an agent layer, lifted up, and evaluated by the following criteria.
A: The optical laminate with the adhesive layer could be lifted one by one. ○: Multiple optical laminates with the adhesive layer could be lifted up, but they could be separated one by one when shaken. Multiple optical laminates with adhesive layers were lifted and could not be separated one by one even when shaken

＜実施例１＞
偏光子として、長尺状のポリビニルアルコール（ＰＶＡ）系樹脂フィルムにヨウ素を含有させ、長手方向（ＭＤ方向）に一軸延伸して得られたフィルム（厚み１２μｍ）を用いた。この偏光子の片側に第３の粘着剤層（厚み５μｍ）を形成し、第３の粘着剤層を介して、長尺状の光学機能フィルム（ＨＣ−ＴＡＣフィルム）を互いの長手方向を揃えるようにして貼り合わせた。なお、ＨＣ−ＴＡＣフィルムは、トリアセチルセルロース（ＴＡＣ）フィルム（２５μｍ）にハードコート（ＨＣ）層（２μｍ）が形成されたフィルムであり、ＴＡＣフィルムが偏光子側となるようにして貼り合わせた。得られた偏光子／ＴＡＣフィルム／ＨＣ層の積層体のハードコート層側に第１の粘着剤層を形成し、および、偏光子側に第２の粘着剤層を形成し、それぞれの粘着剤層にセパレーターを貼り合わせ、長尺状の粘着剤層付光学積層体（粘着剤層付偏光板）を得た。第１の粘着剤層の貯蔵弾性率は１．２×１０５（Ｐａ）であり、厚みは１００μｍであった。第２の粘着剤層の貯蔵弾性率は２．７×１０５（Ｐａ）であり、厚みは１５μｍであった。ＨＣ−ＴＡＣフィルムの破断強度は２６Ｎであった。 <Example 1>
As a polarizer, a film (thickness 12 μm) obtained by adding iodine to a long polyvinyl alcohol (PVA) resin film and uniaxially stretching in the longitudinal direction (MD direction) was used. A third pressure-sensitive adhesive layer (thickness of 5 μm) is formed on one side of the polarizer, and the longitudinal optical function films (HC-TAC film) are aligned with each other in the longitudinal direction via the third pressure-sensitive adhesive layer. In this way, they were bonded together. The HC-TAC film is a film in which a hard coat (HC) layer (2 μm) is formed on a triacetyl cellulose (TAC) film (25 μm), and the TAC film is bonded so that the TAC film is on the polarizer side. . A first pressure-sensitive adhesive layer is formed on the hard coat layer side of the obtained polarizer / TAC film / HC layer laminate, and a second pressure-sensitive adhesive layer is formed on the polarizer side. A separator was bonded to the layer to obtain a long optical laminate with an adhesive layer (polarizing plate with an adhesive layer). The storage modulus of the first pressure-sensitive adhesive layer was 1.2 × 10 5 (Pa) and the thickness was 100 μm. The storage adhesive modulus of the second pressure-sensitive adhesive layer was 2.7 × 10 5 (Pa), and the thickness was 15 μm. The breaking strength of the HC-TAC film was 26N.

上記のようにして得られた粘着剤層付偏光板を５．７インチサイズ（縦１４０ｍｍおよび横６５ｍｍ程度）に打ち抜き、打ち抜いた偏光板を複数枚重ねてワーク（総厚み約１０ｍｍ）とした。得られたワークをクランプ（治具）で挟んだ状態で、エンドミル加工により、ワークの外周の２つの隅部に面取り部を形成し、面取り部が形成された外周面の中央部に凹部（曲線部を含む凹部）を形成し、図３に示すような切削加工された粘着剤層付偏光板を得た。曲線部の半径は２．５ｍｍであった。ここで、エンドミルの刃数は３枚であり、刃角度（ねじれ角）は４５°であった。また、エンドミルの送り速度は１５００ｍｍ／分であり、回転数は３００００ｒｐｍであった。   The pressure-sensitive adhesive layer-attached polarizing plate obtained as described above was punched into a size of 5.7 inches (length: about 140 mm and width: about 65 mm), and a plurality of punched polarizing plates were stacked to form a workpiece (total thickness: about 10 mm). With the obtained workpiece sandwiched between clamps (jigs), chamfered portions are formed at the two corners of the outer periphery of the workpiece by end milling, and a concave portion (curved line) is formed at the center of the outer peripheral surface where the chamfered portion is formed. The recessed part containing a part) was formed, and the polarizing plate with an adhesive layer cut as shown in FIG. 3 was obtained. The radius of the curved part was 2.5 mm. Here, the number of blades of the end mill was 3, and the blade angle (twist angle) was 45 °. Moreover, the feed rate of the end mill was 1500 mm / min, and the rotation speed was 30000 rpm.

最終的に得られた切削加工された粘着剤層付偏光板を、上記クラックの評価に供した。結果を表１に示す。   The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the crack evaluation. The results are shown in Table 1.

＜実施例２＞
第１の粘着剤層の厚みを１５０μｍとしたこと以外は実施例１と同様にして粘着剤層付偏光板を作製した。この粘着剤層付偏光板を実施例１と同様にして切削加工した。最終的に得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。さらに、加工精度およびブロッキングの評価も行った。結果を表２に示す。 <Example 2>
A polarizing plate with a pressure-sensitive adhesive layer was produced in the same manner as in Example 1 except that the thickness of the first pressure-sensitive adhesive layer was 150 μm. This pressure-sensitive adhesive layer-attached polarizing plate was cut in the same manner as in Example 1. The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1. Furthermore, processing accuracy and blocking were also evaluated. The results are shown in Table 2.

＜実施例３＞
第１の粘着剤層の貯蔵弾性率を１．６×１０５（Ｐａ）としたこと、および、曲線部の半径を４．０ｍｍとしたこと以外は実施例１と同様にして粘着剤層付偏光板を作製した。この粘着剤層付偏光板を実施例１と同様にして切削加工した。最終的に得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。 <Example 3>
A pressure-sensitive adhesive layer is attached in the same manner as in Example 1 except that the storage elastic modulus of the first pressure-sensitive adhesive layer is 1.6 × 10 5 (Pa) and the radius of the curved portion is 4.0 mm. A polarizing plate was produced. This pressure-sensitive adhesive layer-attached polarizing plate was cut in the same manner as in Example 1. The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1.

＜実施例４＞
第１の粘着剤層の厚みを１５０μｍとしたこと以外は実施例３と同様にして粘着剤層付偏光板を作製した。この粘着剤層付偏光板を実施例１と同様にして切削加工した。最終的に得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。 <Example 4>
A polarizing plate with a pressure-sensitive adhesive layer was produced in the same manner as in Example 3 except that the thickness of the first pressure-sensitive adhesive layer was 150 μm. This pressure-sensitive adhesive layer-attached polarizing plate was cut in the same manner as in Example 1. The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1.

＜実施例５＞
偏光子の厚みを５μｍとしたこと、および、ＨＣ−ＴＡＣフィルムの代わりにＨＣ−ＣＯＰフィルムを用いたこと以外は実施例１と同様にして粘着剤層付偏光板を作製した。なお、ＨＣ−ＣＯＰフィルムは、シクロオレフィン（ＣＯＰ）フィルム（２５μｍ）にハードコート（ＨＣ）層（２μｍ）が形成されたフィルムであり、破断強度は９Ｎであった。この粘着剤層付偏光板を実施例１と同様にして切削加工した。最終的に得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。 <Example 5>
A polarizing plate with an adhesive layer was produced in the same manner as in Example 1 except that the thickness of the polarizer was 5 μm and that an HC-COP film was used instead of the HC-TAC film. The HC-COP film was a film in which a hard coat (HC) layer (2 μm) was formed on a cycloolefin (COP) film (25 μm), and the breaking strength was 9N. This pressure-sensitive adhesive layer-attached polarizing plate was cut in the same manner as in Example 1. The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1.

＜実施例６＞
第１の粘着剤層の厚みを１５０μｍとしたこと、および、曲線部の半径を４．０ｍｍとしたこと以外は実施例５と同様にして粘着剤層付偏光板を作製した。この粘着剤層付偏光板を実施例１と同様にして切削加工した。最終的に得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。 <Example 6>
A polarizing plate with a pressure-sensitive adhesive layer was produced in the same manner as in Example 5 except that the thickness of the first pressure-sensitive adhesive layer was 150 μm and the radius of the curved portion was 4.0 mm. This pressure-sensitive adhesive layer-attached polarizing plate was cut in the same manner as in Example 1. The finally obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1.

＜比較例１〜４＞
偏光子の厚み、光学機能フィルム（したがって、その破断強度）、第１の粘着剤層の厚み、第１の粘着剤層の貯蔵弾性率、および／または、凹部の曲線部の半径を表１に示すように変更したこと以外は実施例１と同様にして、切削加工された粘着剤層付偏光板を作製した。得られた切削加工された粘着剤層付偏光板を上記クラックの評価に供した。結果を表１に示す。比較例１については、加工精度およびブロッキングの評価も行った。結果を表２に示す。 <Comparative Examples 1-4>
Table 1 shows the thickness of the polarizer, the optical functional film (and therefore its breaking strength), the thickness of the first pressure-sensitive adhesive layer, the storage elastic modulus of the first pressure-sensitive adhesive layer, and / or the radius of the curved portion of the recess. A cut polarizing plate with an adhesive layer was produced in the same manner as in Example 1 except that the changes were made as shown. The obtained polarizing plate with a pressure-sensitive adhesive layer was subjected to the evaluation of the crack. The results are shown in Table 1. For Comparative Example 1, processing accuracy and blocking were also evaluated. The results are shown in Table 2.

Figure 2019184912
Figure 2019184912

＜参考例１：ブロッキングの検討＞
エンドミルの刃数を１枚としたこと以外は実施例２と同様にして、切削加工された粘着剤層付偏光板を作製した。得られた粘着剤層付偏光板を上記の加工精度およびブロッキングの評価に供した。結果を表２に示す。 <Reference Example 1: Examination of blocking>
A cut polarizing plate with an adhesive layer was produced in the same manner as in Example 2 except that the number of blades of the end mill was one. The obtained polarizing plate with the pressure-sensitive adhesive layer was subjected to the above processing accuracy and blocking evaluation. The results are shown in Table 2.

＜参考例２：ブロッキングの検討＞
エンドミルの刃数を１枚としたこと以外は比較例１と同様にして、切削加工された粘着剤層付偏光板を作製した。得られた粘着剤層付偏光板を上記の加工精度およびブロッキングの評価に供した。結果を表２に示す。 <Reference Example 2: Examination of blocking>
A cut polarizing plate with an adhesive layer was produced in the same manner as in Comparative Example 1 except that the number of end mill blades was one. The obtained polarizing plate with the pressure-sensitive adhesive layer was subjected to the above processing accuracy and blocking evaluation. The results are shown in Table 2.

Figure 2019184912
Figure 2019184912

＜評価＞
表１から明らかなように、本発明の実施例によれば、切削加工された粘着剤層付光学積層体の製造方法において、粘着剤層付光学積層体に含まれる粘着剤層のうち少なくとも１つの貯蔵弾性率を所定範囲とし、かつ、厚みを所定値以上とすることにより、光学フィルムのクラック（特に、凹部の曲線部のクラック）を顕著に抑制することができる。結果として、粘着剤層付光学積層体全体のクラックを抑制することができる。さらに、表２から明らかなように、貯蔵弾性率が小さい（柔らかい）粘着剤層を含む粘着剤層付光学積層体の切削加工においては、エンドミルの刃数が多い方がブロッキングを抑制することができ、一方、貯蔵弾性率が大きい（硬い）粘着剤層を含む粘着剤層付光学積層体の切削加工においては、エンドミルの刃数が少ない方がブロッキングを抑制することができる。 <Evaluation>
As apparent from Table 1, according to the example of the present invention, in the method for producing a cut optical laminate with an adhesive layer, at least one of the adhesive layers included in the optical laminate with an adhesive layer. By making one storage elastic modulus into a predetermined range and making thickness into a predetermined value or more, the crack (especially the crack of the curved part of a recessed part) of an optical film can be suppressed notably. As a result, the crack of the whole optical laminated body with an adhesive layer can be suppressed. Furthermore, as is clear from Table 2, in the cutting process of the optical layered body with the pressure-sensitive adhesive layer including the (soft) pressure-sensitive adhesive layer having a low storage elastic modulus, blocking is suppressed when the number of end mill blades is large. On the other hand, in the cutting process of the optical layered body with the pressure-sensitive adhesive layer including the pressure-sensitive adhesive layer having a large storage modulus (hard), blocking can be suppressed with a smaller number of end mill blades.

本発明の製造方法は、切削加工（特に、非直線加工）が必要とされる粘着剤層付光学積層体の製造に好適に用いられ得る。本発明の製造方法により得られる粘着剤層付光学積層体は、自動車のインストゥルメントパネルやスマートウォッチに代表される異形の画像表示部に好適に用いられ得る。   The production method of the present invention can be suitably used for the production of an optical laminate with an adhesive layer that requires cutting (particularly non-linear machining). The optical layered body with the pressure-sensitive adhesive layer obtained by the production method of the present invention can be suitably used for a deformed image display unit typified by an automobile instrument panel or a smart watch.

１ ワーク
２０ 切削手段
１００ 粘着剤層付光学積層体
１０１ 粘着剤層付光学積層体
１１０ 光学フィルム
１３０ 第１の粘着剤層
１５０ 第２の粘着剤層
１７０ 光学機能フィルム
１８０ 第３の粘着剤層
DESCRIPTION OF SYMBOLS 1 Work 20 Cutting means 100 Optical laminated body 101 with an adhesive layer Optical laminated body 110 with an adhesive layer Optical film 130 1st adhesive layer 150 2nd adhesive layer 170 Optical function film 180 3rd adhesive layer

Claims (10)

粘着剤層付光学積層体を複数枚重ねてワークを形成すること、および
該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること、
を含み、
該粘着剤層付光学積層体が、光学フィルムと、該光学フィルムの一方の側に配置された第１の粘着剤層と、該第１の粘着剤層の該光学フィルムと反対側に配置された第１のセパレーターと、該光学フィルムの他方の側に配置された第２の粘着剤層と、該第２の粘着剤層の該光学フィルムと反対側に配置された第２のセパレーターと、を含み、
該第１の粘着剤層および該第２の粘着剤層の少なくとも１つの２５℃における貯蔵弾性率Ｇ’が１．０×１０５（Ｐａ）〜２．５×１０５（Ｐａ）であり、かつ、該少なくとも１つの粘着剤層の厚みが５０μｍ以上である、
切削加工された粘着剤層付光学積層体の製造方法。 Forming a workpiece by stacking a plurality of optical laminates with an adhesive layer, and a rotating shaft extending in the stacking direction of the workpiece and a cutting blade configured as an outermost diameter of a main body rotating around the rotating shaft Cutting the outer peripheral surface of the workpiece by bringing the cutting blade of the cutting means into contact with the outer peripheral surface of the workpiece;
Including
The optical layered body with the pressure-sensitive adhesive layer is disposed on the side opposite to the optical film of the optical film, the first pressure-sensitive adhesive layer disposed on one side of the optical film, and the first pressure-sensitive adhesive layer. A first separator, a second pressure-sensitive adhesive layer disposed on the other side of the optical film, a second separator disposed on the opposite side of the second pressure-sensitive adhesive layer from the optical film, Including
The storage elastic modulus G ′ at 25 ° C. of at least one of the first pressure-sensitive adhesive layer and the second pressure-sensitive adhesive layer is 1.0 × 10 5 (Pa) to 2.5 × 10 5 (Pa), And the thickness of the at least one pressure-sensitive adhesive layer is 50 μm or more,
A method for producing a cut optical laminated body with an adhesive layer. 粘着剤層付光学積層体を複数枚重ねてワークを形成すること、および
該ワークの積層方向に延びる回転軸と該回転軸を中心として回転する本体の最外径として構成された切削刃とを有する切削手段の該切削刃を該ワークの外周面に当接させて、該ワークの外周面を切削すること、
を含み、
該粘着剤層付光学積層体が、光学フィルムと、該光学フィルムの一方の側に該光学フィルム側から順に配置された第３の粘着剤層、光学機能フィルム、第１の粘着剤層および第１のセパレーターと、該光学フィルムの他方の側に該光学フィルム側から順に配置された第２の粘着剤層および第２のセパレーターと、を含み、
該第１の粘着剤層、前記第２の粘着剤層および該第３の粘着剤層の少なくとも１つの２５℃における貯蔵弾性率Ｇ’が１．０×１０５（Ｐａ）〜２．５×１０５（Ｐａ）であり、かつ、該少なくとも１つの粘着剤層の厚みが５０μｍ以上である、
切削加工された粘着剤層付光学積層体の製造方法。 Forming a workpiece by stacking a plurality of optical laminates with an adhesive layer, and a rotating shaft extending in the stacking direction of the workpiece and a cutting blade configured as an outermost diameter of a main body rotating around the rotating shaft Cutting the outer peripheral surface of the workpiece by bringing the cutting blade of the cutting means into contact with the outer peripheral surface of the workpiece;
Including
The optical laminate with the pressure-sensitive adhesive layer is an optical film, a third pressure-sensitive adhesive layer, an optical functional film, a first pressure-sensitive adhesive layer, 1 separator, and a second pressure-sensitive adhesive layer and a second separator arranged in order from the optical film side on the other side of the optical film,
The storage elastic modulus G ′ at 25 ° C. of at least one of the first pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer, and the third pressure-sensitive adhesive layer is 1.0 × 10 5 (Pa) to 2.5 ×. 10 5 (Pa), and the thickness of the at least one pressure-sensitive adhesive layer is 50 μm or more,
A method for producing a cut optical laminated body with an adhesive layer. 前記ワークの外周面を非直線的に切削することを含む、請求項１または２に記載の製造方法。   The manufacturing method of Claim 1 or 2 including cutting the outer peripheral surface of the said workpiece | work non-linearly. 前記切削手段がエンドミルである、請求項１から３のいずれかに記載の製造方法。   The manufacturing method according to claim 1, wherein the cutting means is an end mill. 前記光学フィルムが偏光子または偏光板である、請求項１から４のいずれかに記載の製造方法。   The manufacturing method in any one of Claim 1 to 4 whose said optical film is a polarizer or a polarizing plate. 前記光学機能フィルムが、セルロース系樹脂、シクロオレフィン系樹脂およびアクリル系樹脂から選択される少なくとも１つを含む、請求項２から５のいずれかに記載の製造方法。   The manufacturing method according to claim 2, wherein the optical functional film includes at least one selected from a cellulose resin, a cycloolefin resin, and an acrylic resin. 前記光学機能フィルムの破断強度が３５Ｎ以下である、請求項２から６のいずれかに記載の製造方法。   The manufacturing method in any one of Claim 2 to 6 whose breaking strength of the said optical function film is 35 N or less. 前記切削手段が、前記切削刃を２枚以上有する、請求項１から７のいずれかに記載の製造方法。   The manufacturing method according to claim 1, wherein the cutting means has two or more cutting blades. 前記非直線的な切削が、前記粘着剤層付光学積層体を平面視した場合に曲線部を含む凹部を形成することを含む、請求項３から８のいずれかに記載の製造方法。   The manufacturing method according to claim 3, wherein the non-linear cutting includes forming a concave portion including a curved portion when the optical layered body with an adhesive layer is viewed in plan. 前記曲線部の半径が５ｍｍ以下である、請求項９に記載の製造方法。
The manufacturing method of Claim 9 whose radius of the said curved part is 5 mm or less.
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