JP7335125B2 - Method for manufacturing optical member - Google Patents

Method for manufacturing optical member Download PDF

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JP7335125B2
JP7335125B2 JP2019188478A JP2019188478A JP7335125B2 JP 7335125 B2 JP7335125 B2 JP 7335125B2 JP 2019188478 A JP2019188478 A JP 2019188478A JP 2019188478 A JP2019188478 A JP 2019188478A JP 7335125 B2 JP7335125 B2 JP 7335125B2
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laminated structure
rotary blade
cutting
face
laminated
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JP2021062447A (en
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丈行 芦田
幹士 藤井
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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Priority to JP2019188478A priority Critical patent/JP7335125B2/en
Priority to TW109133667A priority patent/TW202128320A/en
Priority to KR1020200131243A priority patent/KR20210044708A/en
Priority to CN202011093671.9A priority patent/CN112666647A/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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0016—Abrading

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

Description

本発明は、光学部材の製造方法に関する。 The present invention relates to a method for manufacturing an optical member.

光学部材の一種である偏光板は、液晶ディスプレイ、有機ＥＬディスプレイ、スマートフォン、スマートウォッチ、又は車両の計器パネル等の画像表示装置に用いられる。偏光板は、偏光子フィルム及び保護フィルム等の複数の光学フィルムの積層体である。画像表示装置の精密化又は小型化に伴い、偏光板の形状及び寸法には、高い精度が求められる。例えば、下記特許文献１は、互い積層された複数の積層体からなる積層構造体の端面（切断面）を回転刃で切削することにより、各積層体の形状及び寸法の精度を高める方法を開示している。 A polarizing plate, which is a type of optical member, is used in image display devices such as liquid crystal displays, organic EL displays, smartphones, smart watches, and instrument panels of vehicles. A polarizing plate is a laminate of a plurality of optical films such as a polarizer film and a protective film. As the image display device becomes more precise or smaller, the shape and dimensions of the polarizing plate are required to have high accuracy. For example, Patent Literature 1 below discloses a method for increasing the accuracy of the shape and dimensions of each laminate by cutting the end face (cut surface) of a laminate structure composed of a plurality of laminates laminated to each other with a rotary blade. are doing.

特開２００４‐１４８４１９号公報JP-A-2004-148419

画像表示装置の種類及び用途は多様であるため、画像表示装置の設計上の要求に応じて、偏光板の受光面が異形に加工されることがある。異形とは、全ての角が直角である完全な四辺形とは異なる形状を意味する。例えば、偏光板の形状を画像表示装置の構造に合わせるために、長方形状の偏光板の四つ角が面取りされたり、切欠き部（ノッチ）が偏光板の端部に形成されたり、偏光板の端部全体が曲線へ加工されたりする。 Since the types and uses of image display devices are diverse, the light-receiving surface of the polarizing plate may be processed into an irregular shape according to the design requirements of the image display device. A variant means a shape that differs from a perfect quadrilateral in which all the angles are right angles. For example, in order to match the shape of the polarizing plate to the structure of the image display device, the four corners of the rectangular polarizing plate may be chamfered, notches may be formed at the edges of the polarizing plate, or the edges of the polarizing plate may be The whole part is processed into a curve.

上記の積層構造体が回転刃によって異形に加工される場合、積層体の積層方向において積層構造体がクランプで固定された状態で、回転刃が積層構造体の端面に押し当てられ、端面が切削される。積層構造体を構成する各積層体を高い精度で異形に加工するためは、積層構造体の端面全体を平面へ加工する場合に比べて、積層構造体の端面に対する回転刃の相対的位置及び相対的移動速度をより精密に制御する必要がある。しかしながら、積層構造体の端面が切削される過程において、回転刃が積層構造体の端面へ及ぼす力に因り、積層構造体の端面のうち回転刃が接する部分においてモーメントが生じ易い。回転刃が及ぼす力又はモーメントに因り、積層構造体の一部又は全体が、所定の位置からずれたり、積層構造体の一部又は全体が、積層体の積層方向に略平行な回転軸線の周りに回転して、積層構造体が捩じれたりする。上記のような積層構造体の位置ずれ又は捩じれに因り、積層構造体の端面に対する回転刃の相対的位置及び相対的移動速度を精密に制御することが困難になる。以上の理由により、回転刃を用いた従来の切削方法では、積層構造体の端面を精密に切削することは困難であり、異形を有する各積層体の形状及び寸法の精度を高めることは困難である。偏光板以外の光学部材も、その用途に応じて異形に加工される。したがって、上記の技術的課題は偏光板以外の光学部材の製造においても起こり得る。 When the above laminated structure is processed into an irregular shape by a rotary blade, the rotary blade is pressed against the end face of the laminated structure while the laminated structure is fixed with a clamp in the lamination direction of the laminated structure, and the end face is cut. be done. In order to process each laminated body constituting the laminated structure into an irregular shape with high accuracy, the relative position and relative position of the rotary blade with respect to the end face of the laminated structure are required compared to the case where the entire end face of the laminated structure is processed into a flat surface. It is necessary to control target movement speed more precisely. However, in the process of cutting the end face of the laminated structure, a moment is likely to be generated in the portion of the end face of the laminated structure with which the rotary blade contacts due to the force exerted by the rotary blade on the end face of the laminated structure. Due to the force or moment exerted by the rotary blade, part or all of the laminated structure is displaced from a predetermined position, or part or all of the laminated structure is rotated around a rotation axis substantially parallel to the lamination direction of the laminated body. , and the laminated structure is twisted. Due to the positional deviation or twist of the laminated structure as described above, it becomes difficult to precisely control the relative position and relative moving speed of the rotary blade with respect to the end surface of the laminated structure. For the above reasons, it is difficult to precisely cut the end face of the laminate structure by the conventional cutting method using a rotary blade, and it is difficult to improve the accuracy of the shape and dimensions of each laminate having an irregular shape. be. Optical members other than polarizing plates are also processed into irregular shapes according to their uses. Therefore, the technical problems described above may also occur in the manufacture of optical members other than polarizing plates.

本発明の目的は、形状及び寸法の精度に優れた光学部材の製造方法を提供することである。 SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing an optical member having excellent shape and dimensional accuracy.

本発明の一側面に係る光学部材の製造方法は、積層構造体を一対の回転刃で切削する切削工程を備え、積層構造体は、互いに積層された複数の積層体を含み、積層体は、互いに積層された複数の光学フィルムを含み、積層構造体は、対向する二つの端面を有し、積層構造体の対向する二つの端面は、積層体の積層方向に略平行であり、積層構造体の上面及び下面は、積層方向に略垂直であり、積層構造体は、積層構造体の上面及び下面に接するクランプによって挟持されており、回転刃は、積層方向に沿って延びており、回転刃の側面は、積層構造体の端面に略平行であり、回転刃の回転軸線は、回転刃の側面に略平行であり、一方の回転刃の側面は、積層構造体の一方の端面に接し、他方の回転刃の側面は、積層構造体の他方の端面に接し、積層構造体の対向する二つの端面は、少なくとも一方の端面の少なくとも一部が平面とならないように、一対の回転刃で略同時に切削される。 A method for manufacturing an optical member according to one aspect of the present invention includes a cutting step of cutting a laminated structure with a pair of rotary blades, the laminated structure includes a plurality of laminated bodies laminated together, and the laminated body comprises: comprising a plurality of optical films laminated to each other, the laminated structure having two opposite end surfaces, the two opposite end surfaces of the laminated structure being substantially parallel to the lamination direction of the laminated structure, and The upper and lower surfaces of the are substantially perpendicular to the lamination direction, the laminated structure is clamped by clamps in contact with the upper and lower surfaces of the laminated structure, the rotary blade extends along the lamination direction, and the rotary blade The side surface of is substantially parallel to the end surface of the laminated structure, the rotation axis of the rotary blade is substantially parallel to the side surface of the rotary blade, the side surface of one rotary blade is in contact with one end surface of the laminated structure, The side surface of the other rotary blade is in contact with the other end face of the laminated structure, and the two opposing end faces of the laminated structure are roughly divided by a pair of rotary blades so that at least a part of at least one end face is not flat. cut at the same time.

積層構造体の対向する二つの端面は、積層構造体の上面及び下面其々の長手方向に略平行であってよい。 The two opposing end surfaces of the laminated structure may be substantially parallel to the longitudinal direction of each of the upper and lower surfaces of the laminated structure.

積層構造体の全ての端面を回転刃で切削する過程において、一対の回転刃が設置される位置は変わってよく、積層構造体の全ての端面を回転刃で切削する過程において終始、クランプは積層方向に略平行な回転軸線に対して旋回しなくてよい。 In the process of cutting all the end faces of the laminated structure with the rotary blades, the positions at which the pair of rotary blades are installed may be changed, and the clamps are kept on the laminated structure throughout the process of cutting all the end faces of the laminated structure with the rotary blades. It does not have to pivot about an axis of rotation that is substantially parallel to the direction.

切削工程において、一対の回転刃は、積層構造体の対向する二つの端面に沿って移動してよい。 In the cutting step, the pair of rotary blades may move along two opposing end faces of the laminated structure.

切削工程において、一対の回転刃の間隔は変動してよく、切削工程において、クランプは積層構造体の対向する二つの端面に略平行な方向に沿って移動してよい。 During the cutting process, the spacing between the pair of rotary blades may vary, and during the cutting process, the clamp may move along a direction substantially parallel to the two opposing end surfaces of the laminated structure.

本発明の一側面に係る光学部材の製造方法は、切削工程前に実施される加工工程を更に備えてよく、加工工程前の積層構造体の上面及び下面其々は、全ての角が直角である四辺形であってよく、加工工程において、積層構造体の上面及び下面其々が四辺形と異なる形状になるように、積層構造体が加工されてよい。 The method for manufacturing an optical member according to one aspect of the present invention may further include a processing step that is performed before the cutting step. It may be a certain quadrilateral, and the laminated structure may be processed in a processing step such that each of the upper and lower surfaces of the laminated structure has a shape different from the quadrilateral.

切削工程に用いられる積層構造体の上面及び下面其々は、全ての角が直角である四辺形であってよく、切削工程において、積層構造体の上面及び下面其々が四辺形と異なる形状になるように、積層構造体の対向する二つの端面が、一対の回転刃で略同時に切削されてよい。 Each of the upper and lower surfaces of the laminated structure used in the cutting step may be a quadrilateral with all corners being right angles, and in the cutting step, each of the upper and lower surfaces of the laminated structure may be formed into a shape different from a quadrilateral. The two opposing end surfaces of the laminated structure may be cut substantially simultaneously with a pair of rotary blades so that the two end surfaces are cut at the same time.

積層体は、少なくとも一つの粘着剤層を含んでよい。 The laminate may comprise at least one adhesive layer.

回転刃は、エンドミルであってよい。 The rotary blade may be an end mill.

本発明によれば、形状及び寸法の精度に優れた光学部材の製造方法が提供される。 According to the present invention, there is provided a method for manufacturing an optical member with excellent precision in shape and dimensions.

図１は、積層構造体、クランプ、及び回転刃の模式的な側面図である。FIG. 1 is a schematic side view of a laminated structure, clamps and rotary blades. 図２は、図１に示される積層構造体を構成する各積層体の断面図であり、図２に示される断面は積層体の積層方向に略平行である。FIG. 2 is a cross-sectional view of each laminate constituting the laminate structure shown in FIG. 1, and the cross section shown in FIG. 2 is substantially parallel to the stacking direction of the laminate. 図３中の（ａ）は、角部が面取りされた積層構造体の上面と、切削工程において積層構造体の端面に当接される回転刃を示す模式図であり、図３中の（ｂ）は、角部が面取りされる前の積層構造体の上面の模式図である。(a) in FIG. 3 is a schematic diagram showing the upper surface of a laminated structure with chamfered corners and a rotary blade that comes into contact with the end surface of the laminated structure in a cutting step; ) is a schematic view of the top surface of the laminated structure before the corners are chamfered. 図４は、切削工程における積層構造体の上面と、切削工程において積層構造体の端面に当接される回転刃を示す模式図である。FIG. 4 is a schematic diagram showing the upper surface of the laminated structure in the cutting process and the rotary blade that abuts on the end surface of the laminated structure in the cutting process. 図５中の（ａ）は、切欠き部が形成された積層構造体の上面と、切削工程において積層構造体の端面に当接される回転刃を示す模式図であり、図５中の（ｂ）は一対の端面其々の全体が曲面に加工された積層構造体の上面と、切削工程において積層構造体の端面に当接される回転刃を示す模式図である。(a) in FIG. 5 is a schematic diagram showing the upper surface of a laminated structure having a notch formed therein and a rotary blade that abuts against the end surface of the laminated structure in a cutting step. b) is a schematic view showing the upper surface of a laminated structure having a pair of end faces that are entirely curved, and a rotary blade that abuts against the end face of the laminated structure in a cutting step. 図６は、一つの端面の全体が曲面に加工された積層構造体の上面と、切削工程において積層構造体の端面に当接される回転刃を示す模式図である。FIG. 6 is a schematic diagram showing an upper surface of a laminated structure having one end face entirely curved, and a rotary blade that abuts against the end face of the laminated structure in a cutting step. 図７中の（ａ）は、積層構造体の積層方向に略平行な回転軸線の周りに回転した積層構造体の上面図であり、図７中の（ｂ）は、捩じれた積層構造体の上面図である。(a) in FIG. 7 is a top view of the laminated structure rotated around a rotation axis substantially parallel to the lamination direction of the laminated structure, and (b) in FIG. 7 is a twisted laminated structure. It is a top view.

以下、図面を参照しながら、本発明の好適な実施形態が説明される。図面において、同等の構成要素には同等の符号が付される。本発明は下記実施形態に限定されるものではない。各図に示すＸ，Ｙ及びＺは、互いに直交する３つの座標軸を意味する。各図中のＸＹＺ座標軸其々が示す方向は各図に共通する。 Preferred embodiments of the present invention will be described below with reference to the drawings. In the drawings, similar components are provided with similar reference numerals. The present invention is not limited to the following embodiments. X, Y and Z shown in each figure mean three coordinate axes orthogonal to each other. The directions indicated by the XYZ coordinate axes in each figure are common to each figure.

本実施形態に係る光学部材の製造方法は、例えば、偏光板（反射型偏光板を含む。）、位相差フィルム、輝度向上フィルム、防眩機能付フィルム、表面反射防止機能付フィルム、反射フィルム、半透過反射フィルム、又は視野角補償フィルムの製造方法であってよい。 The method for producing an optical member according to the present embodiment includes, for example, a polarizing plate (including a reflective polarizing plate), a retardation film, a brightness enhancement film, a film with antiglare function, a film with surface antireflection function, a reflective film, It may be a method for producing a transflective film or a viewing angle compensation film.

本実施形態に係る光学部材の製造方法の概要は、図１～図４に示される。本実施形態に係る光学部材の製造方法は、積層構造体２を一対の回転刃（第一回転刃ｂ１及び第二回転刃ｂ２）で切削する切削工程を備える。切削工程では、積層構造体２の対向する二つの端面（第一端面ｆ１及び第二端面ｆ２）は、少なくとも一方の端面の少なくとも一部が平面とならないように、一対の回転刃で略同時に（並行して）切削される。換言すれば、切削工程後の積層構造体２の上面及び下面其々は、全ての角が直角である完全な四辺形とは異なる形状である。全ての角が直角である完全な四辺形とは異なる形状は、「異形」と表記される。異形の具体的形状は限定されない。切削後の少なくとも一方の端面が平面ではない限りにおいて、同時に切削された一方の端面の形状及び寸法は、同時に切削された他方の端面の形状及び寸法と同じであってよく、同時に切削された一方の端面の形状及び寸法は、同時に切削された他方の端面の形状及び寸法と異なってもよい。切削後の端面の一部分が平面でなく、切削後の端面の他の部分は平面であってもよい。積層構造体２及び切削工程の詳細は、以下の通りである。 An overview of the method for manufacturing an optical member according to this embodiment is shown in FIGS. 1 to 4. FIG. The method for manufacturing an optical member according to this embodiment includes a cutting step of cutting the laminated structure 2 with a pair of rotary blades (first rotary blade b1 and second rotary blade b2). In the cutting step, two opposing end surfaces (first end surface f1 and second end surface f2) of the laminated structure 2 are cut substantially simultaneously by a pair of rotary blades ( in parallel). In other words, each of the upper and lower surfaces of the laminated structure 2 after the cutting process has a shape different from a complete quadrilateral in which all corners are right angles. Shapes that differ from perfect quadrilaterals with all right angles are denoted as "variants". The specific shape of the variant is not limited. As long as at least one end face after cutting is not flat, the shape and dimensions of one end face cut at the same time may be the same as the shape and dimensions of the other end face cut at the same time. may differ from the shape and dimensions of the other end face cut at the same time. A portion of the end surface after cutting may not be flat, and the other portion of the end surface after cutting may be flat. Details of the laminated structure 2 and the cutting process are as follows.

積層構造体２は、互いに積層された複数の積層体４を含み、各積層体４は、互いに積層された複数の光学フィルムを含む。積層構造体２における積層体４の積層方向（Ｚ軸方向）は、各積層体４における光学フィルムの積層方向と同じである。光学フィルムとは、光学部材を構成するフィルム状（層状）の部材を意味する。光学フィルムは、例えば、偏光子フィルム、保護フィルム、粘着剤層、離型フィルム、光学補償層、ハードコート層、タッチセンサー層、帯電防止層及び防汚層からなる群より選ばれる少なくとも一種のフィルム（層）であってよい。積層構造体２の積層構造は限定されない。 Laminate structure 2 includes a plurality of laminates 4 laminated to each other, each laminate 4 including a plurality of optical films laminated to each other. The stacking direction (Z-axis direction) of the laminates 4 in the laminate structure 2 is the same as the stacking direction of the optical films in each laminate 4 . An optical film means a film-like (layered) member constituting an optical member. The optical film is, for example, at least one film selected from the group consisting of a polarizer film, a protective film, an adhesive layer, a release film, an optical compensation layer, a hard coat layer, a touch sensor layer, an antistatic layer and an antifouling layer. (layer). The laminated structure of the laminated structure 2 is not limited.

図１、３及び４に示される積層構造体２の形状は、略直方体である。積層構造体２は、第一端面ｆ１、第二端面ｆ２、第三端面ｆ３及び第四端面ｆ４を有している。第一端面ｆ１及び第二端面ｆ２は互いに対向し、且つ略平行である。第三端面ｆ３及び第四端面ｆ４は互いに対向し、且つ略平行である。第一端面ｆ１及び第二端面ｆ２其々は、積層構造体２の上面ｔｆ及び下面ｕｆ其々の長手方向（Ｙ軸方向）に略平行である。第三端面ｆ３及び第四端面ｆ４は、積層構造体２の上面ｔｆ及び下面ｕｆ其々の短手方向（Ｘ軸方向）其々に略平行である。第一端面ｆ１、第二端面ｆ２、第三端面ｆ３及び第四端面ｆ４其々は、積層体４の積層方向（Ｚ軸方向）に略平行である。積層構造体２の上面ｔｆ及び下面ｕｆ其々は、積層方向（Ｚ軸方向）に略垂直である。対向する第一端面ｆ１及び第二端面ｆ２其々の形状及び寸法は、互いに略同じである。対向する第三端面ｆ３及び第四端面ｆ４其々の形状及び寸法は、互いに略同じである。対向する上面ｔｆ及び下面ｕｆ其々の形状及び寸法は、互いに略同じである。第一研磨パッド１２ａは積層構造体２の上面ｔｆに接し、第二研磨パッド１２ｂは積層構造体２の下面ｕｆに接している。第一研磨パッド１２ａ及び第二研磨パッド１２ｂから構成されるクランプ１２によって、積層構造体２は積層方向（Ｚ軸方向）において挟持及び固定される。切削工程において研磨される積層構造体２の各端面は、第一研磨パッド１２ａ及び第二研磨パッド１２ｂの間から外側へはみ出している。 The shape of the laminated structure 2 shown in FIGS. 1, 3 and 4 is substantially rectangular parallelepiped. The laminated structure 2 has a first end face f1, a second end face f2, a third end face f3 and a fourth end face f4. The first end face f1 and the second end face f2 are opposed to each other and substantially parallel. The third end face f3 and the fourth end face f4 face each other and are substantially parallel. The first end face f1 and the second end face f2 are substantially parallel to the longitudinal direction (Y-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, respectively. The third end surface f3 and the fourth end surface f4 are substantially parallel to the lateral direction (X-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, respectively. The first end face f1, the second end face f2, the third end face f3, and the fourth end face f4 are substantially parallel to the lamination direction (Z-axis direction) of the laminated body 4, respectively. Each of the upper surface tf and the lower surface uf of the laminated structure 2 is substantially perpendicular to the lamination direction (Z-axis direction). The shape and dimensions of the first end face f1 and the second end face f2 that face each other are substantially the same. The shapes and dimensions of the opposing third end face f3 and fourth end face f4 are substantially the same. The shape and dimensions of the upper surface tf and the lower surface uf facing each other are substantially the same. The first polishing pad 12 a is in contact with the upper surface tf of the laminated structure 2 , and the second polishing pad 12 b is in contact with the lower surface uf of the laminated structure 2 . The laminated structure 2 is clamped and fixed in the lamination direction (Z-axis direction) by the clamp 12 composed of the first polishing pad 12a and the second polishing pad 12b. Each end surface of the laminated structure 2 that is polished in the cutting step protrudes outward from between the first polishing pad 12a and the second polishing pad 12b.

図１に示されるように、積層構造体２は、第一保護シート６ａ、複数の積層体４及び第二保護シート６ｂから構成されている。複数の積層体４は、第一保護シート６ａ及び第二保護シート６ｂの間において積層されている。隣り合う一対の積層体４は、互いに接着されておらず、分離可能である。第一保護シート６ａ及び積層体４も、互いに接着されておらず、分離可能である。第二保護シート６ｂ及び積層体４も、互いに接着されておらず、分離可能である。第一保護シート６ａ及び第二保護シート６ｂ其々は、ポリスチレン等の樹脂であってよい。 As shown in FIG. 1, the laminate structure 2 is composed of a first protective sheet 6a, a plurality of laminates 4, and a second protective sheet 6b. A plurality of laminates 4 are laminated between the first protective sheet 6a and the second protective sheet 6b. A pair of adjacent laminates 4 are not adhered to each other and can be separated. The first protective sheet 6a and the laminate 4 are also not adhered to each other and can be separated. The second protective sheet 6b and the laminate 4 are also not adhered to each other and can be separated. Each of the first protective sheet 6a and the second protective sheet 6b may be made of resin such as polystyrene.

図２に示されるように、各積層体４は、積層された複数の光学フィルム８ａ、８ｂ、８ｃ、８ｄ、８ｅ、１０ａ及び１０ｂを含む。積層体４の積層構造は限定されない。積層体４の積層構造は、完成後の光学部材の積層構造と同じであってよい。例えば、光学部材が偏光板である場合、積層体４の積層構造は、偏光板の積層構造と同じであってよい。つまり、積層体４其々が偏光板であってよい。例えば、光学フィルム８ａは、偏光子フィルムであってよい。光学フィルム８ｂは、第一保護フィルムであってよい。光学フィルム８ｃは、第二保護フィルムであってよい。光学フィルム１０ａは、第一粘着剤層であってよく、光学フィルム１０ｂは、第二粘着剤層であってよい。つまり積層構造体２は、光学フィルムとして粘着剤層を含んでよい。光学フィルム８ｄは、第一離型フィルムであってよい。光学フィルム８ｅは、第二離型フィルムであってよい。第一保護フィルム（８ｂ）は、偏光子フィルム（８ａ）の一方の表面に直接形成されていてよい。第一保護フィルム（８ｂ）は、紫外線硬化樹脂等の接着剤を介して偏光子フィルム（８ａ）の一方の表面に貼合されていてもよい。第二保護フィルム（８ｃ）は、偏光子フィルム（８ａ）の他方の表面に直接形成されていてよい。第二保護フィルム（８ｃ）は、紫外線硬化樹脂等の接着剤を介して偏光子フィルム（８ａ）の他方の表面に貼合されていてもよい。 As shown in FIG. 2, each stack 4 includes a plurality of laminated optical films 8a, 8b, 8c, 8d, 8e, 10a and 10b. The laminated structure of the laminated body 4 is not limited. The laminate structure of the laminate 4 may be the same as the laminate structure of the completed optical member. For example, when the optical member is a polarizing plate, the laminated structure of the laminate 4 may be the same as that of the polarizing plate. That is, each of the laminates 4 may be a polarizing plate. For example, the optical film 8a may be a polarizer film. The optical film 8b may be a first protective film. The optical film 8c may be a second protective film. The optical film 10a may be the first adhesive layer, and the optical film 10b may be the second adhesive layer. That is, the laminated structure 2 may contain an adhesive layer as an optical film. The optical film 8d may be a first release film. The optical film 8e may be a second release film. The first protective film (8b) may be formed directly on one surface of the polarizer film (8a). The first protective film (8b) may be attached to one surface of the polarizer film (8a) via an adhesive such as an ultraviolet curable resin. The second protective film (8c) may be formed directly on the other surface of the polarizer film (8a). The second protective film (8c) may be attached to the other surface of the polarizer film (8a) via an adhesive such as an ultraviolet curable resin.

偏光子フィルムは、延伸、染色及び架橋等の工程によって作製されたフィルム状のポリビニルアルコール（ＰＶＡ）系樹脂であってよい。偏光子フィルムの厚みは、例えば、１μｍ以上５０μｍ以下であってよい。偏光子フィルムの縦幅及び横幅其々は、例えば、３０ｍｍ以上６００ｍｍ以下であってよい。積層体４の厚みは、例えば、１０μｍ以上１２００μｍ以下であってよい。 The polarizer film may be a film-like polyvinyl alcohol (PVA) resin produced by processes such as stretching, dyeing and crosslinking. The thickness of the polarizer film may be, for example, 1 μm or more and 50 μm or less. Each of the vertical width and horizontal width of the polarizer film may be, for example, 30 mm or more and 600 mm or less. The thickness of the laminate 4 may be, for example, 10 μm or more and 1200 μm or less.

第一保護フィルム及び第二保護フィルムは、透光性を有する熱可塑性樹脂であればよい。第一保護フィルム及び第二保護フィルム其々を構成する樹脂は、例えば、鎖状ポリオレフィン系樹脂、環状オレフィンポリマー系樹脂（ＣＯＰ系樹脂）、セルロースエステル系樹脂（トリアセチルセルロース等）、ポリエステル系樹脂、ポリカーボネート系樹脂、（メタ）アクリル系樹脂、ポリスチレン系樹脂、又はこれらの混合物若しくは共重合体であってよい。第一保護フィルムの組成は、第二保護フィルムの組成と同じであってよい。第一保護フィルムの組成は、第二保護フィルムの組成と異なっていてもよい。第一保護フィルムの厚みは、例えば、５μｍ以上９０μｍ以下であってよい。第二保護フィルムの厚みも、例えば、５μｍ以上９０μｍ以下であってよい。 The first protective film and the second protective film may be a thermoplastic resin having translucency. Resins constituting the first protective film and the second protective film are, for example, linear polyolefin-based resins, cyclic olefin polymer-based resins (COP-based resins), cellulose ester-based resins (such as triacetyl cellulose), and polyester-based resins. , polycarbonate-based resins, (meth)acrylic-based resins, polystyrene-based resins, or mixtures or copolymers thereof. The composition of the first protective film may be the same as the composition of the second protective film. The composition of the first protective film may differ from the composition of the second protective film. The thickness of the first protective film may be, for example, 5 μm or more and 90 μm or less. The thickness of the second protective film may also be, for example, 5 μm or more and 90 μm or less.

第一粘着剤層及び第二粘着剤層其々は、粘着剤からなる層であってよい。第一粘着剤層及び第二粘着剤層其々は、光学用透明粘着（Ｏｐｔｉｃａｌｌｙ Ｃｌｅａｒ Ａｄｈｅｓｉｖｅ； ＯＣＡ）フィルムであってよい。例えば、第一粘着剤層及び第二粘着剤層其々は、アクリル系感圧型粘着剤、ゴム系感圧型粘着剤、シリコーン系感圧型粘着剤、又はウレタン系感圧型粘着剤などの粘着剤から構成されていてよい。第一粘着剤層の組成は、第二粘着剤層の組成と異なっていてもよい。第一粘着剤層の厚みは、例えば、２μｍ以上５００μｍ以下であってよい。第二粘着剤層の厚みも、例えば、２μｍ以上５００μｍ以下であってよい。 Each of the first adhesive layer and the second adhesive layer may be a layer made of an adhesive. Each of the first adhesive layer and the second adhesive layer may be an Optically Clear Adhesive (OCA) film. For example, each of the first pressure-sensitive adhesive layer and the second pressure-sensitive adhesive layer is made of an adhesive such as an acrylic pressure-sensitive adhesive, a rubber-based pressure-sensitive adhesive, a silicone-based pressure-sensitive adhesive, or a urethane-based pressure-sensitive adhesive. may be configured. The composition of the first adhesive layer may differ from the composition of the second adhesive layer. The thickness of the first adhesive layer may be, for example, 2 μm or more and 500 μm or less. The thickness of the second pressure-sensitive adhesive layer may also be, for example, 2 μm or more and 500 μm or less.

第一離型フィルム及び第二離型フィルム其々を構成する樹脂は、第一保護フィルム又は第二保護フィルムを構成する上記の樹脂と同じであってよい。第一離型フィルムの組成は、第二離型フィルムの組成と同じであってよい。第一離型フィルムの組成は、第二離型フィルムの組成と異なっていてもよい。第一離型フィルムの厚みは、例えば、５μｍ以上２００μｍ以下であってよい。第二離型フィルムの厚みも、例えば、５μｍ以上２００μｍ以下であってよい。 The resin constituting the first release film and the second release film may be the same as the resin constituting the first protective film or the second protective film. The composition of the first release film may be the same as the composition of the second release film. The composition of the first release film may differ from the composition of the second release film. The thickness of the first release film may be, for example, 5 μm or more and 200 μm or less. The thickness of the second release film may also be, for example, 5 μm or more and 200 μm or less.

第一回転刃ｂ１及び第二回転刃ｂ２其々は、積層体４の積層方向（Ｚ軸方向）に沿って延びている。第一回転刃ｂ１の側面ｓ１は、積層構造体２の各端面に対して略平行である。第二回転刃ｂ２の側面ｓ２も、積層構造体２の各端面に対して略平行である。第一回転刃ｂ１の回転軸線ａ１は、第一回転刃ｂ１の側面ｓ１に略平行である。第二回転刃ｂ２の回転軸線ａ２は、第二回転刃ｂ２の側面ｓ２に略平行である。 The first rotary blade b1 and the second rotary blade b2 each extend along the stacking direction (Z-axis direction) of the stack 4 . A side surface s1 of the first rotary blade b1 is substantially parallel to each end surface of the laminated structure 2 . The side surface s2 of the second rotary blade b2 is also substantially parallel to each end surface of the laminated structure 2 . The rotation axis a1 of the first rotary blade b1 is substantially parallel to the side surface s1 of the first rotary blade b1. The rotation axis a2 of the second rotary blade b2 is substantially parallel to the side surface s2 of the second rotary blade b2.

第一回転刃ｂ１は、その側面ｓ１に形成された刃（エッジ）を有している。回転軸線ａ１の周りに回転する第一回転刃ｂ１の側面ｓ１を積層構造体２の端面に押し当てることにより、積層構造体２の端面が切削される。第二回転刃ｂ２も、その側面ｓ２に形成された刃（エッジ）を有している。回転軸線ａ２の周りに回転する第二回転刃ｂ２の側面ｓ２を積層構造体２の端面に押し当てることにより、積層構造体２の端面が切削される。積層体４の積層方向（Ｚ軸方向）における各回転刃の幅は、積層方向における積層構造体２の幅以上であってよい。 The first rotary blade b1 has a blade (edge) formed on its side surface s1. The end face of the laminated structure 2 is cut by pressing the side face s1 of the first rotary blade b1 rotating around the rotation axis a1 against the end face of the laminated structure 2 . The second rotary blade b2 also has a blade (edge) formed on its side surface s2. The end face of the laminated structure 2 is cut by pressing the side face s2 of the second rotary blade b2 that rotates around the rotation axis a2 against the end face of the laminated structure 2 . The width of each rotary blade in the stacking direction (Z-axis direction) of the stack 4 may be equal to or greater than the width of the stack structure 2 in the stacking direction.

第一回転刃ｂ１及び第二回転刃ｂ２其々は、エンドミル（ｅｎｄｍｉｌｌ）であってよい。ただし、第一回転刃ｂ１及び第二回転刃ｂ２其々は、エンドミルに限定されない。例えば、第一回転刃ｂ１及び第二回転刃ｂ２其々は、側面にカンナ刃が配置された回転刃であってもよい。 Each of the first rotary blade b1 and the second rotary blade b2 may be an endmill. However, the first rotary blade b1 and the second rotary blade b2 are not limited to end mills. For example, each of the first rotary blade b1 and the second rotary blade b2 may be a rotary blade having planer blades arranged on its side surface.

切削工程では、積層構造体２の上面ｔｆ及び下面ｕｆ其々の長手方向（Ｙ軸方向）に略平行である第一端面ｆ１及び第二端面ｆ２其々が、以下の方法によって切削される。 In the cutting step, the first end face f1 and the second end face f2 that are substantially parallel to the longitudinal direction (Y-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2 are cut by the following method.

図３中の（ａ）に示されるように、第一回転刃ｂ１の側面ｓ１は、積層構造体２の第一端面ｆ１に接しながら、第一端面ｆ１の全体を切削する。第二回転刃ｂ２の側面ｓ２は、第一端面ｆ１と対向する第二端面ｆ２に接しながら、第二端面ｆ２の全体を切削する。 As shown in FIG. 3A, the side surface s1 of the first rotary blade b1 cuts the entire first end surface f1 of the laminated structure 2 while being in contact with the first end surface f1. The side surface s2 of the second rotary blade b2 cuts the entire second end surface f2 while being in contact with the second end surface f2 facing the first end surface f1.

切削工程では、第一回転刃ｂ１による第一端面ｆ１の切削と、第二回転刃ｂ２による第二端面ｆ２の切削が略同時に行われ、切削工程後においては、第一端面ｆ１の両端に位置する角部、及び第二端面ｆ２の両端に位置する角部がそれぞれ面取りされており、第一端面ｆ１の両端、及び第二端面ｆ２の両端は、曲面である。換言すれば、切削工程を経た積層構造体２の上面ｔｆ及び下面ｕｆは、完全な長方形ではなく、４つの角部が曲率を有する異形である。 In the cutting step, the cutting of the first end face f1 by the first rotary blade b1 and the cutting of the second end face f2 by the second rotary blade b2 are performed substantially simultaneously, and after the cutting step, at both ends of the first end face f1 and corners located at both ends of the second end face f2 are chamfered, and both ends of the first end face f1 and both ends of the second end face f2 are curved surfaces. In other words, the top surface tf and the bottom surface uf of the laminated structure 2 that have undergone the cutting process are not perfect rectangles, but irregular shapes having four curved corners.

第一端面ｆ１及び第二端面ｆ２は互い対向しているため、第一回転刃ｂ１が第一端面ｆ１へ及ぼす圧力と、第二回転刃ｂ２が第二端面ｆ２へ及ぼす圧力が釣り合い易く、第一回転刃ｂ１が第一端面ｆ１へ及ぼすモーメントと、第二回転刃ｂ２が第二端面ｆ２へ及ぼすモーメントが互いに相殺され易い。したがって、積層構造体２の一部又は全体が、積層体４の積層方向（Ｚ軸方向）に略垂直な方向（ＸＹ面方向）においてずれ難い。同様の理由から、積層構造体２の一部又は全体が、積層体４の積層方向（Ｚ軸方向）に略平行な回転軸線ａ１２（クランプの中軸線）の周りに回転し難い。つまり、対向する第一端面ｆ１及び第二端面ｆ２を略同時に切削することにより、積層構造体２の位置ずれ及び捩じれが抑制される。したがって、積層構造体２の各端面に対する各回転刃の相対的位置及び相対的移動速度を精密に制御することが可能であり、第一端面ｆ１及び第二端面ｆ２其々を高い精度で切削することができる。以上のメカニズムにより、積層構造体２及び積層体４其々の形状及び寸法の精度が高まる。つまり、積層構造体２の上面ｔｆ、下面ｕｆ及び各積層体４が、高い精度で異形へ加工される。例えば、面取りされていない部分における第一端面ｆ１と第二端面ｆ２との間隔が均一に制御される。また第一端面ｆ１の平坦部分と第三端面ｆ３の平坦部分との交差角、第一端面ｆ１の平坦部分と第四端面ｆ４の平坦部分との交差角、第二端面ｆ２の平坦部分と第三端面ｆ３の平坦部分との交差角、及び、第二端面ｆ２の平坦部分と第四端面ｆ４の平坦部分との交差角が均一に制御される。例えば、積層構造体２を構成する積層体４の数が１００枚であり、積層方向（Ｚ軸方向）における積層構造体２の厚みに占める粘着剤層の厚みの合計の割合が１７％であり、各積層体４の厚みが１９０μｍであり、切削工程前の各積層体４の長辺の長さ（Ｙ方向における積層体４の幅）が１５５ｍｍであり、切削工程前の各積層体４の短辺の長さ（Ｘ方向における積層体４の幅）が７５ｍｍである場合、切削工程後の積層体４の短辺の長さの設計値からのずれ幅は、最大で０．００８ｍｍ程度であり、交差角の９０°からのずれ幅は、最大で０．１６°程度である。一方、第一端面ｆ１及び第二端面ｆ２が同時に切削されず、第一端面ｆ１及び第二端面ｆ２が一つの回転刃で別々に切削される場合、積層体４の短辺の長さの設計値からのずれ幅は、最大で０．０４４ｍｍ程度であり、交差角の９０°からのずれ幅は、０．２９°程度である。 Since the first end surface f1 and the second end surface f2 face each other, the pressure exerted by the first rotary blade b1 on the first end surface f1 and the pressure exerted by the second rotary blade b2 on the second end surface f2 are easily balanced. The moment exerted by the single rotary blade b1 on the first end surface f1 and the moment exerted by the second rotary blade b2 on the second end surface f2 tend to cancel each other out. Therefore, part or all of the laminated structure 2 is less likely to shift in the direction (XY plane direction) substantially perpendicular to the lamination direction (Z-axis direction) of the laminated body 4 . For the same reason, part or all of the laminated structure 2 is less likely to rotate around the rotation axis a12 (center axis of the clamp) substantially parallel to the lamination direction (Z-axis direction) of the laminated body 4 . That is, by cutting the first end face f1 and the second end face f2 facing each other substantially at the same time, displacement and twisting of the laminated structure 2 are suppressed. Therefore, it is possible to precisely control the relative position and relative movement speed of each rotary blade with respect to each end face of the laminated structure 2, and to cut each of the first end face f1 and the second end face f2 with high accuracy. be able to. By the mechanism described above, the accuracy of the shape and dimension of each of the laminated structure 2 and the laminated body 4 is enhanced. That is, the upper surface tf and the lower surface uf of the laminated structure 2 and each laminated body 4 are processed into irregular shapes with high accuracy. For example, the interval between the first end face f1 and the second end face f2 in the non-chamfered portion is uniformly controlled. Further, the intersection angle between the flat portion of the first end surface f1 and the flat portion of the third end surface f3, the intersection angle between the flat portion of the first end surface f1 and the flat portion of the fourth end surface f4, the flat portion of the second end surface f2 and the third The intersection angle between the flat portion of the third end face f3 and the intersection angle between the flat portion of the second end face f2 and the flat portion of the fourth end face f4 are uniformly controlled. For example, the number of laminates 4 constituting the laminate structure 2 is 100, and the ratio of the total thickness of the adhesive layers to the thickness of the laminate structure 2 in the lamination direction (Z-axis direction) is 17%. , the thickness of each laminate 4 is 190 μm, the length of the long side of each laminate 4 (the width of the laminate 4 in the Y direction) before the cutting process is 155 mm, and the thickness of each laminate 4 before the cutting process is When the length of the short side (the width of the laminate 4 in the X direction) is 75 mm, the maximum deviation of the length of the short side of the laminate 4 after the cutting process from the design value is about 0.008 mm. , and the maximum deviation of the intersection angle from 90° is about 0.16°. On the other hand, when the first end face f1 and the second end face f2 are not cut at the same time and the first end face f1 and the second end face f2 are cut separately with one rotary blade, the length of the short side of the laminate 4 The deviation width from the value is about 0.044 mm at maximum, and the deviation width from the crossing angle of 90° is about 0.29°.

積層方向（Ｚ軸方向）に垂直な方向（ＸＹ面方向）において、第一端面ｆ１及び第二端面ｆ２其々の幅は、第三端面ｆ３及び第四端面ｆ４其々の幅よりも大きい。積層方向（Ｚ軸方向）に垂直な方向（ＸＹ面方向）における端面の幅が大きいほど、回転刃が端面へモーメントを及ぼし易い。したがって、仮に幅が広い第一端面ｆ１及び第二端面ｆ２其々が、一つの回転刃のみを用いて非同時に切削される場合、図７中の（ａ）に示されるように、回転刃（ｂ１）が積層構造体２へ及ぼす力Ｆにより、積層構造体２の全体が、積層方向（Ｚ軸方向）に略平行な回転軸線ａ１２（クランプ１２の中心軸線）の周りに回転して、積層構造体２が所定の位置からずれ易く、図７中の（ｂ）に示されるように、積層構造体２を構成する各積層体４が、積層方向（Ｚ軸方向）に略平行な回転軸線ａ１２（クランプ１２の中心軸線）の周りに回転して、積層構造体２が捩じれ易い。特に、積層方向（Ｚ軸方向）における積層構造体２の中央部は特に回転し易く、積層構造体２を構成する積層体４の枚数が多いほど、積層構造体２の位置ずれ及び捩じれが起き易い。特に各積層体４が光学フィルム１０ａ及び１０ｂとして第一粘着剤層及び第二粘着剤層等の粘着剤層を含む場合、粘着剤層は他の光学フィルムによりも軟らかいため、積層構造体２は捩じれ易い。その結果、切削工程において、第一端面ｆ１及び第二端面ｆ２其々の形状を精密に制御することが困難であり、積層構造体２の上面ｔｆ、下面ｕｆ及び各積層体４を、高い精度で異形へ加工することが困難である。一方、本実施形態の場合、上記のメカニズムにより、幅が大きい第一端面ｆ１及び第二端面ｆ２の切削中における積層構造体２の位置ずれ及び捩じれを抑制することができる。 In the direction (XY plane direction) perpendicular to the stacking direction (Z-axis direction), the width of each of the first end face f1 and the second end face f2 is greater than the width of each of the third end face f3 and the fourth end face f4. The larger the width of the end face in the direction (XY plane direction) perpendicular to the stacking direction (Z-axis direction), the easier it is for the rotary blade to exert a moment on the end face. Therefore, if each of the wide first end face f1 and second end face f2 is cut non-simultaneously using only one rotary blade, the rotary blade ( Due to the force F exerted by b1) on the laminated structure 2, the entire laminated structure 2 rotates around the rotation axis a12 (the central axis of the clamp 12) substantially parallel to the lamination direction (Z-axis direction), and lamination is performed. The structure 2 tends to shift from its predetermined position, and as shown in FIG. 7B, each laminate 4 constituting the laminate structure 2 has a rotation axis substantially parallel to the lamination direction (Z-axis direction). Rotating around a12 (the central axis of the clamp 12), the laminated structure 2 is likely to be twisted. In particular, the central portion of the laminated structure 2 in the lamination direction (Z-axis direction) is particularly prone to rotation. easy. In particular, when each laminate 4 includes adhesive layers such as a first adhesive layer and a second adhesive layer as the optical films 10a and 10b, the adhesive layers are softer than other optical films, so the laminated structure 2 Easy to twist. As a result, it is difficult to precisely control the shapes of the first end face f1 and the second end face f2 in the cutting step, and the upper surface tf and the lower surface uf of the laminated structure 2 and each laminated body 4 can be cut with high accuracy. It is difficult to process it into an irregular shape. On the other hand, in the case of the present embodiment, it is possible to suppress displacement and twisting of the laminated structure 2 during cutting of the first end face f1 and the second end face f2 having a large width by the above mechanism.

上記のメカニズムにより、積層構造体２の位置ずれ及び捩じれが抑制されるので、本実施形態によれば、積層構造体２を構成する積層体４の数を増やすことができる。一括して切削される積層体４の数の増加により、切削工程の所要時間が短縮され、光学部材の生産性が向上する。更に、本実施形態によれば、積層構造体２を構成する各積層体４が粘着剤層を含む場合であっても、積層構造体２の位置ずれ及び捩じれを容易に抑制することができる。 Since the above mechanism suppresses the positional displacement and twisting of the laminated structure 2, according to the present embodiment, the number of laminated bodies 4 constituting the laminated structure 2 can be increased. By increasing the number of laminated bodies 4 that are cut together, the time required for the cutting process is shortened, and the productivity of optical members is improved. Furthermore, according to this embodiment, even when each laminate 4 constituting the laminate structure 2 includes an adhesive layer, the laminate structure 2 can be easily prevented from being displaced and twisted.

図３中の（ａ）に示されるように、第一回転刃ｂ１から延びる点線及び矢印は、切削工程における第一回転刃ｂ１の移動経路及び移動方向を示す。第一回転刃ｂ１の移動経路及び移動方向は、積層構造体２に対して相対的であってよい。つまり第一回転刃ｂ１自体が移動してよく、積層構造体２自体が移動してもよい。図３中の（ａ）に示されるように、第二回転刃ｂ２から延びる点線及び矢印は、切削工程における第二回転刃ｂ２の移動経路及び移動方向を示す。第二回転刃ｂ２の移動経路及び移動方向は、積層構造体２に対して相対的であってよい。つまり第二回転刃ｂ２自体が移動してよく、積層構造体２自体が移動してもよい。第一回転刃ｂ１及び第二回転刃ｂ２其々から延びる点線及び矢印が示すように、切削工程において、第一回転刃ｂ１及び第二回転刃ｂ２は、対向する第一端面ｆ１及び第二端面ｆ２に沿って並進してよい。第一回転刃ｂ１及び第二回転刃ｂ２が並行して移動することにより、第一端面ｆ１及び第二端面ｆ２其々に作用するモーメントが互いに相殺され易く、積層構造体２の回転及び捩じれが抑制され易い。同様の理由から、第一回転刃ｂ１が第一端面ｆ１に及ぼす圧力は、第二回転刃ｂ２が第二端面ｆ２に及ぼす圧力と略等しくてよく、第一端面ｆ１に略平行な方向における第一回転刃ｂ１の移動速度は、第二端面ｆ２に略平行な方向における第二回転刃ｂ２の移動速度とほぼ同じであってよい。第一端面ｆ１及び第二端面ｆ２が切削される過程では、第一回転刃ｂ１及び第二回転刃ｂ２の間隔は自在に変動してよい。第一回転刃ｂ１及び第二回転刃ｂ２の間隔を制御することにより、第一端面ｆ１及び第二端面ｆ２其々が平面でない形状へ精密に加工される。第一端面ｆ１及び第二端面ｆ２が切削される過程では、クランプ１２の位置は固定されていてよい。第一端面ｆ１及び第二端面ｆ２が切削される過程では、第一端面ｆ１及び第二端面ｆ２に略平行な方向（Ｙ軸方向）における第一回転刃ｂ１及び第二回転刃ｂ２其々の位置が固定されてよく、クランプ１２が、第一端面ｆ１及び第二端面ｆ２に略平行な方向（Ｙ軸方向）に沿って移動してもよい。つまり、クランプ１２に挟持された積層構造体２が、第一回転刃ｂ１及び第二回転刃ｂ２の間を通過してよい。 As shown in (a) of FIG. 3, the dotted line and arrow extending from the first rotary blade b1 indicate the moving path and moving direction of the first rotary blade b1 in the cutting process. The moving path and moving direction of the first rotary blade b1 may be relative to the laminated structure 2 . That is, the first rotary blade b1 itself may move, and the laminated structure 2 itself may move. As shown in FIG. 3(a), the dotted line and arrows extending from the second rotary blade b2 indicate the moving path and moving direction of the second rotary blade b2 in the cutting process. The moving path and moving direction of the second rotary blade b2 may be relative to the laminated structure 2 . That is, the second rotary blade b2 itself may move, and the laminated structure 2 itself may move. As indicated by the dotted lines and arrows extending from the first rotary blade b1 and the second rotary blade b2, respectively, in the cutting process, the first rotary blade b1 and the second rotary blade b2 have a first end surface f1 and a second end surface f1 facing each other. It may translate along f2. By moving the first rotary blade b1 and the second rotary blade b2 in parallel, the moments acting on the first end surface f1 and the second end surface f2 are likely to cancel each other, and the rotation and twisting of the laminated structure 2 are prevented. easily suppressed. For the same reason, the pressure exerted by the first rotary blade b1 on the first end face f1 may be substantially equal to the pressure exerted by the second rotary blade b2 on the second end face f2, and the pressure in the direction substantially parallel to the first end face f1 The moving speed of the single-rotation blade b1 may be substantially the same as the moving speed of the second rotary blade b2 in the direction substantially parallel to the second end surface f2. During the process of cutting the first end face f1 and the second end face f2, the distance between the first rotary blade b1 and the second rotary blade b2 may be freely changed. By controlling the distance between the first rotary blade b1 and the second rotary blade b2, each of the first end face f1 and the second end face f2 is precisely machined into a non-flat shape. The position of the clamp 12 may be fixed during the process of cutting the first end face f1 and the second end face f2. In the process of cutting the first end face f1 and the second end face f2, each of the first rotary blade b1 and the second rotary blade b2 in a direction (Y-axis direction) substantially parallel to the first end face f1 and the second end face f2 The position may be fixed, and the clamp 12 may move along a direction (Y-axis direction) substantially parallel to the first end face f1 and the second end face f2. That is, the laminated structure 2 clamped by the clamp 12 may pass between the first rotary blade b1 and the second rotary blade b2.

光学部材の製造方法は、切削工程前に実施される加工工程を更に備えてよい。図３中の（ｂ）に示されるように、加工工程前の積層構造体２’の上面ｔｆ’及び下面其々は、全ての角が直角である四辺形であってよく、加工工程において、積層構造体２’の上面ｔｆ’及び下面其々が異形になるように、積層構造体２’が加工されてよい。加工工程は、例えば、積層構造体２’の打ち抜き又は切断であってよい。加工工程に用いる切断手段は、刃物又はレーザー（例えば、ＣＯ２ガスレーザー、又はエキシマレーザー）であってよい。 The method for manufacturing an optical member may further include a processing step that is performed before the cutting step. As shown in (b) of FIG. 3, each of the upper surface tf' and the lower surface of the laminated structure 2' before the processing step may be a quadrilateral having all right angles, and in the processing step, The laminated structure 2' may be processed such that the upper surface tf' and the lower surface of the laminated structure 2' are deformed. The processing step may be, for example, punching or cutting the laminated structure 2'. The cutting means used in the processing step may be a knife or a laser (eg CO2 gas laser or excimer laser).

光学部材の製造方法は、上記の加工工程を備えなくてもよい。光学部材の製造方法が上記の加工工程を備えない場合、図３中の（ｂ）に示されるように、切削工程に用いられる積層構造体２’の上面ｔｆ’及び下面其々は、全ての角が直角である四辺形であってよく、切削工程において、積層構造体２’の上面ｔｆ’及び下面其々が異形になるように、積層構造体２’の対向する二つの端面（第一端面ｆ１’及び第二端面ｆ２’）が、一対の回転刃（第一回転刃ｂ１及び第二回転刃ｂ２）で略同時に（並行して）切削されてよい。 The method for manufacturing an optical member may not include the above processing steps. When the method for manufacturing an optical member does not include the above processing steps, as shown in FIG. It may be a quadrilateral with right-angled corners, and in the cutting process, two opposing end faces (first The end face f1' and the second end face f2') may be cut substantially simultaneously (in parallel) by a pair of rotary blades (first rotary blade b1 and second rotary blade b2).

積層構造体２の上面ｔｆ及び下面ｕｆ其々の短手方向（Ｘ軸方向）に略平行である第三端面ｆ３及び第四端面ｆ４は、第一端面ｆ１及び第二端面ｆ２と同様に、一対の回転刃（第一回転刃ｂ１及び第二回転刃ｂ２）で略同時に（並行して）切削されてよい。第三端面ｆ３及び第四端面ｆ４其々が、第一回転刃ｂ１又は第二回転刃ｂ２を用いて、非同時に切削されてもよい。 The third end surface f3 and the fourth end surface f4, which are substantially parallel to the lateral direction (X-axis direction) of the upper surface tf and the lower surface uf of the laminated structure 2, are similar to the first end surface f1 and the second end surface f2. A pair of rotary blades (first rotary blade b1 and second rotary blade b2) may cut substantially simultaneously (in parallel). The third end surface f3 and the fourth end surface f4 may be cut non-simultaneously using the first rotary blade b1 or the second rotary blade b2.

積層構造体２の全ての端面（第一端面ｆ１、第二端面ｆ２、第三端面ｆ３及び第四端面ｆ４）を上記の回転刃で切削する一連の過程において終始、クランプ１２は積層方向（Ｚ軸方向）に略平行な回転軸線ａ１２（クランプ１２の中心軸線）に対して旋回しないことが好ましい。つまり、積層構造体２の端面の切削を開始した時点から、全ての端面の切削が完了する時点まで、クランプ１２は旋回しないことが好ましい。積層構造体２のいずれの端面も全く切削されていない時点においては、クランプ１２が旋回してもよい。積層構造体２の全ての端面の切削が完了した後では、クランプ１２が旋回してもよい。仮に積層構造体２の全ての端面を回転刃で切削する一連の過程中に、クランプ１２が旋回した場合、図７中の（ｂ）に示されるように、クランプ１２に連動して、積層構造体２を構成する各積層体４が、積層方向（Ｚ軸方向）に略平行な回転軸線ａ１２（クランプ１２の中心軸線）の周りに回転して、積層構造体２が捩じれ易い。一方、積層構造体２の全ての端面を回転刃で切削する過程において終始、クランプ１２が旋回しない場合、積層構造体２の捩じれが抑制される。その結果、積層構造体２の全ての端面の形状を精密に制御し易く、積層構造体２の上面ｔｆ、下面ｕｆ及び各積層体４を、高い精度で異形へ加工し易い。 In a series of processes for cutting all the end faces (first end face f1, second end face f2, third end face f3 and fourth end face f4) of the laminated structure 2 with the above rotary blade, the clamp 12 is kept in the lamination direction (Z It is preferable not to rotate about the rotational axis a12 (the central axis of the clamp 12) substantially parallel to the axial direction). In other words, it is preferable that the clamp 12 does not rotate from the time when cutting of the end faces of the laminated structure 2 is started to the time when cutting of all the end faces is completed. At times when none of the end faces of the laminated structure 2 have been cut, the clamp 12 may be pivoted. After cutting all the end faces of the laminated structure 2 is completed, the clamp 12 may be pivoted. If the clamp 12 turns during a series of processes of cutting all the end surfaces of the laminated structure 2 with a rotary blade, as shown in FIG. Each laminated body 4 constituting the body 2 rotates around the rotation axis a12 (the central axis of the clamp 12) substantially parallel to the lamination direction (Z-axis direction), and the laminated structure 2 is easily twisted. On the other hand, if the clamp 12 does not rotate throughout the process of cutting all the end faces of the laminated structure 2 with the rotary blade, twisting of the laminated structure 2 is suppressed. As a result, it is easy to precisely control the shape of all the end faces of the laminated structure 2, and it is easy to process the upper surface tf and the lower surface uf of the laminated structure 2 and each laminated body 4 into irregular shapes with high accuracy.

積層構造体２の全ての端面を回転刃で切削する過程において終始、クランプ１２が旋回せず、積層構造体２の全ての端面を回転刃で切削する過程において、第一回転刃ｂ１及び第二回転刃ｂ２其々が設置される位置は自在に変わってよい。例えば、図４に示されるように、第一回転刃ｂ１が第四端面ｆ４の一端（位置ｐ２）へ設置され、位置ｐ２から位置ｐ１へ移動する第一回転刃ｂ１によって、第四端面ｆ４が切削されてよい。第四端面ｆ４の切削後、第一回転刃ｂ１が第四端面ｆ４の一端（位置ｐ１）へ設置され、第二回転刃ｂ２が第四端面ｆ４の他端（位置ｐ２）へ設置され、第一回転刃ｂ１による第一端面ｆ１の切削と、第二回転刃ｂ２による第二端面ｆ２の切削が略同時に行われてよい。第一端面ｆ１及び第二端面ｆ２の同時切削後、第二回転刃ｂ２が第三端面ｆ３の一端（位置ｐ３）へ設置され、位置ｐ３から位置ｐ４へ移動する第二回転刃ｂ２によって、第三端面ｆ３が切削されてよい。ただし、対向する二つの端面が、少なくとも一方の端面の少なくとも一部が平面とならないように、一対の回転刃で略同時に切削される限り、第一端面ｆ１、第二端面ｆ２、第三端面ｆ３及び第四端面ｆ４の切削の順序は限定されず、各端面と各端面を切削する回転刃の組み合わせも限定されない。 During the process of cutting all the end faces of the laminated structure 2 with the rotary blades, the clamp 12 does not turn all the time, and in the process of cutting all the end faces of the laminated structure 2 with the rotary blades, the first rotary blade b1 and the second The positions at which the rotary blades b2 are installed may be freely changed. For example, as shown in FIG. 4, the first rotary blade b1 is installed at one end (position p2) of the fourth end face f4, and the fourth end face f4 is rotated by the first rotary blade b1 moving from position p2 to position p1. May be cut. After cutting the fourth end face f4, the first rotary blade b1 is installed at one end (position p1) of the fourth end face f4, the second rotary blade b2 is installed at the other end (position p2) of the fourth end face f4, and the The cutting of the first end face f1 by the one-rotational blade b1 and the cutting of the second end face f2 by the second rotary blade b2 may be performed substantially simultaneously. After the simultaneous cutting of the first end face f1 and the second end face f2, the second rotary blade b2 is installed at one end (position p3) of the third end face f3, and the second rotary blade b2 moves from the position p3 to the position p4. The third end surface f3 may be cut. However, the first end face f1, the second end face f2, and the third end face f3 are cut substantially simultaneously by a pair of rotary blades so that at least a portion of at least one of the end faces is not flat. And the order of cutting the fourth end face f4 is not limited, and the combination of each end face and the rotary blades for cutting each end face is also not limited.

積層構造体２の全ての端面を回転刃で切削する過程において終始、クランプ１２が自在に旋回してもよく、且つ第一回転刃ｂ１及び第二回転刃ｂ２其々が設置される位置も自在に変わってよい。積層構造体２の全ての端面を回転刃で切削する過程において終始、クランプ１２が自在に旋回してもよく、且つ第一回転刃ｂ１及び第二回転刃ｂ２其々が設置される位置は固定されていてもよい。 Throughout the process of cutting all the end surfaces of the laminated structure 2 with the rotary blades, the clamp 12 may be freely rotated, and the positions at which the first rotary blade b1 and the second rotary blade b2 are respectively installed are also free. can be changed to Throughout the process of cutting all the end surfaces of the laminated structure 2 with the rotary blade, the clamp 12 may be freely rotated, and the positions at which the first rotary blade b1 and the second rotary blade b2 are respectively installed are fixed. may have been

光学部材の製造方法は、積層体４の積層方向において積層構造体２を貫通する穴を形成する工程をさらに備えてよい。上記の切削工程前に、積層構造体２又は２’を貫通する穴が形成されてよい。上記の切削工程後に、積層構造体２を貫通する穴が形成されてもよい。積層構造体２又は２’を貫通する穴を形成する手段は、打ち抜き装置、ドリル等の回転刃、又はレーザーであってよい。レーザーは、例えば、ＣＯ２ガスレーザー、又はエキシマレーザーであってよい。積層構造体２又は２’を貫通する穴の内壁が、上記の第一回転刃ｂ１又は第二回転刃ｂ２で切削されてよい。 The method for manufacturing the optical member may further include a step of forming a hole penetrating through the laminated structure 2 in the lamination direction of the laminated body 4 . A hole may be formed through the laminated structure 2 or 2' before the cutting step described above. A hole penetrating through the laminated structure 2 may be formed after the above cutting step. The means for forming holes through the laminate structure 2 or 2' may be a punching device, a rotary blade such as a drill, or a laser. The laser may be, for example, a CO2 gas laser, or an excimer laser. The inner wall of the hole penetrating the laminated structure 2 or 2' may be cut by the first rotary blade b1 or the second rotary blade b2.

以上の工程を経た積層構造体２が、一つの積層光学フィルムとして用いられてよい。以上の工程を経た積層構造体２を構成する各積層体４が光学部材として用いられてよい。 The laminated structure 2 that has undergone the above steps may be used as one laminated optical film. Each laminate 4 constituting the laminate structure 2 that has undergone the above steps may be used as an optical member.

本発明は必ずしも上述された実施形態に限定されるものではない。本発明の趣旨を逸脱しない範囲において、本発明の種々の変更が可能である。下記の変更例も本発明に含まれる。 The invention is not necessarily limited to the embodiments described above. Various modifications of the present invention are possible without departing from the gist of the present invention. The following modifications are also included in the present invention.

積層構造体の対向する二つの端面のうち少なくとも一方の端面の少なくとも一部が平面とならないように、対向する二つの端面が略同時に切削される限り、切削工程後の各端面の形状は限定されない。切削工程後の端面の一部分のみが平面とならないように、対向する二つの端面が一対の回転刃で略同時に切削されてよい。切削工程後の端面の全体が平面とならないように、対向二つの端面が一対の回転刃で略同時に切削されてもよい。積層構造体が、対向する二つの端面を有する柱体であり、対向する二つの端面が積層体の積層方向に略平行である限り、切削工程前の積層構造体の形状は限定されない。切削工程前の積層構造体において対向する二つの端面は、平行でなくてもよい。切削工程前の積層構造体において対向する二つの端面の少なくとも一面は、完全な平面でなくてもよい。 The shape of each end face after the cutting step is not limited as long as the two opposing end faces are cut substantially simultaneously so that at least a portion of at least one of the two opposing end faces of the laminated structure is not flat. . Two opposing end faces may be cut substantially simultaneously with a pair of rotary blades so that only a portion of the end faces after the cutting step is not flat. The two opposing end faces may be cut substantially simultaneously with a pair of rotary blades so that the entire end face after the cutting step is not flat. The shape of the laminated structure before the cutting step is not limited as long as the laminated structure is a column having two opposing end faces and the two opposing end faces are substantially parallel to the stacking direction of the laminated structure. The two opposing end faces in the laminated structure before the cutting step may not be parallel. At least one of the two opposing end faces in the laminated structure before the cutting step may not be completely flat.

図５中の（ａ）に示されるように、幅が狭い第三端面ｆ３及び第四端面ｆ４が、第一回転刃ｂ１又は第二回転刃ｂ２で略同時に切削されてよく、積層体４の積層方向（Ｚ軸方向）に延びる切欠き部５０（窪み）が、切削後の第四端面ｆ４に形成されてよい。図５中の（ａ）の場合、積層体４の積層方向（Ｚ軸方向）から見られる切欠き部５０の形状は、略長方形である。ただし、切欠き部５０の形状は限定されない。例えば、積層体４の積層方向（Ｚ軸方向）から見られる切欠き部５０の形状は、長方形以外の四角形、三角形、その他の多角形、半円、半楕円、又はその他の曲線であってよい。図５中の（ａ）に示される積層構造体２の四つの角部が、上記実施形態と同様の方法で面取りされてもよい。切欠き部は、第三端面ｆ３及び第四端面ｆ４の両面に形成されてよい。第三端面ｆ３に形成された切欠き部の形状及び寸法が、第四端面ｆ４に形成された切欠き部の形状及び寸法と同じであってよい。第三端面ｆ３に形成された切欠き部の形状及び寸法が、第四端面ｆ４に形成された切欠き部の形状及び寸法と異なってもよい。幅が広い第一端面ｆ１及び第二端面ｆ２の同時切削により、積層体４の積層方向（Ｚ軸方向）に延びる切欠き部が、切削後の第一端面ｆ１及び第二端面ｆ２のうち少なくとも一方の端面に形成されてもよい。積層体４の積層方向（Ｚ軸方向）に延びる切欠き部が、切削後の第一端面ｆ１及び第二端面ｆ２の両面に形成されてもよい。 As shown in (a) in FIG. 5 , the narrow third end surface f3 and fourth end surface f4 may be cut substantially simultaneously by the first rotary blade b1 or the second rotary blade b2, and the laminate 4 A notch 50 (recess) extending in the stacking direction (Z-axis direction) may be formed in the cut fourth end surface f4. In the case of (a) in FIG. 5, the shape of the notch 50 seen from the stacking direction (Z-axis direction) of the stack 4 is substantially rectangular. However, the shape of the notch 50 is not limited. For example, the shape of the notch 50 viewed from the stacking direction (Z-axis direction) of the laminate 4 may be a quadrangle other than a rectangle, a triangle, other polygons, a semicircle, a semiellipse, or other curves. . The four corners of the laminated structure 2 shown in (a) of FIG. 5 may be chamfered by the same method as in the above embodiment. The notch may be formed on both sides of the third end face f3 and the fourth end face f4. The shape and dimensions of the notch formed in the third end face f3 may be the same as the shape and dimensions of the notch formed in the fourth end face f4. The shape and dimensions of the notch formed in the third end face f3 may differ from the shape and dimensions of the notch formed in the fourth end face f4. By simultaneously cutting the wide first end face f1 and second end face f2, the notch portion extending in the stacking direction (Z-axis direction) of the laminate 4 is at least one of the first end face f1 and the second end face f2 after cutting. It may be formed on one end surface. Notch portions extending in the stacking direction (Z-axis direction) of the laminate 4 may be formed on both the first end surface f1 and the second end surface f2 after cutting.

図５中の（ｂ）に示されるように、幅が広い第一端面ｆ１及び第二端面ｆ２が、第一回転刃ｂ１又は第二回転刃ｂ２で略同時に切削されてよく、切削工程後の第一端面ｆ１及び第二端面ｆ２其々の全体が、曲面（凸面）であってよい。切削工程後の第一端面ｆ１及び第二端面ｆ２其々の全体が、凹面であってもよい。切削工程後の第一端面ｆ１の全体が、凸面であってよく、切削工程後の第二端面ｆ２の全体が、凹面であってもよい。 As shown in (b) in FIG. 5, the wide first end face f1 and second end face f2 may be cut substantially simultaneously with the first rotary blade b1 or the second rotary blade b2, and after the cutting process The entirety of the first end face f1 and the second end face f2 may be curved surfaces (convex surfaces). The entirety of each of the first end face f1 and the second end face f2 after the cutting step may be concave. The entire first end surface f1 after the cutting step may be convex, and the entire second end surface f2 after the cutting step may be concave.

図６に示されるように、幅が広い第一端面ｆ１及び第二端面ｆ２が、第一回転刃ｂ１又は第二回転刃ｂ２で略同時に切削されてよく、切削工程後の第一端面ｆ１は平面であってよく、切削工程後の第二端面ｆ２の全体は、曲面（凸面）であってよい。切削工程後の第二端面ｆ２の全体が、凹面であってもよい。 As shown in FIG. 6, the wide first end face f1 and the second end face f2 may be cut substantially simultaneously by the first rotary blade b1 or the second rotary blade b2, and the first end face f1 after the cutting step is It may be a flat surface, and the entire second end face f2 after the cutting step may be a curved surface (convex surface). The entire second end surface f2 after the cutting step may be a concave surface.

切削工程では、第一回転刃ｂ１又は第二回転刃ｂ２に加えて更に別の回転刃が用いられてよい。つまり、切削工程では、三つの以上の回転刃が用いられてよい。 In the cutting step, another rotary blade may be used in addition to the first rotary blade b1 or the second rotary blade b2. That is, three or more rotary blades may be used in the cutting process.

本発明に係る製造方法によって得られる光学部材は、例えば、液晶ディスプレイ、有機ＥＬディスプレイ、スマートフォン、スマートウォッチ、又は車両の計器パネル等の画像表示装置に用いられてよい。 The optical member obtained by the manufacturing method according to the present invention may be used, for example, in image display devices such as liquid crystal displays, organic EL displays, smart phones, smart watches, and vehicle instrument panels.

２…積層構造体、４…積層体、６ａ…第一保護シート、６ｂ…第二保護シート、８ａ，８ｂ，８ｃ，８ｄ，８ｅ…光学フィルム、１０ａ，１０ｂ…光学フィルム（粘着剤層）、１２…クランプ、１２ａ…第一研磨パッド、１２ｂ…第二研磨パッド、ａ１…第一回転刃の回転軸線、ａ１２…積層体の積層方向に略平行な回転軸線、ａ２…第二回転刃の回転軸線、ｂ１…第一回転刃、ｂ２…第二回転刃、ｆ１…第一端面、ｆ２…第二端面、ｆ３…第三端面、ｆ４…第四端面、ｔｆ…上面、ｕｆ…下面。 2 Laminate structure 4 Laminate 6a First protective sheet 6b Second protective sheet 8a, 8b, 8c, 8d, 8e Optical film 10a, 10b Optical film (adhesive layer) DESCRIPTION OF SYMBOLS 12...Clamp 12a...First polishing pad 12b...Second polishing pad a1...Rotational axis of the first rotary blade a12...Rotational axis substantially parallel to the stacking direction of the laminate a2...Rotation of the second rotary blade Axis line, b1... First rotary blade, b2... Second rotary blade, f1... First end face, f2... Second end face, f3... Third end face, f4... Fourth end face, tf... Upper surface, uf... Lower surface.

Claims (11)

積層構造体を一対の回転刃で切削する切削工程を備え、
前記積層構造体は、互いに積層された複数の積層体を含み、
前記積層体は、互いに積層された複数の光学フィルムを含み、
前記積層構造体は、対向する二つの端面を有し、
前記積層構造体の対向する二つの前記端面は、前記積層体の積層方向に略平行であり、
前記積層構造体の上面及び下面は、前記積層方向に略垂直であり、
前記積層構造体は、前記積層構造体の前記上面及び前記下面に接するクランプによって挟持されており、
前記回転刃は、前記積層方向に沿って延びており、
前記回転刃の側面は、前記積層構造体の前記端面に略平行であり、
前記回転刃の回転軸線は、前記回転刃の側面に略平行であり、
一方の前記回転刃の前記側面は、前記積層構造体の一方の前記端面に接し、
他方の前記回転刃の前記側面は、前記積層構造体の他方の前記端面に接し、
前記積層構造体の対向する二つの前記端面は、少なくとも一方の前記端面の少なくとも一部が平面とならないように、一対の前記回転刃で略同時に切削され、
前記積層構造体の全ての端面を前記回転刃で切削する過程において、一対の前記回転刃が設置される位置は変わり、
前記積層構造体の全ての端面を前記回転刃で切削する過程において終始、前記クランプは前記積層方向に略平行な回転軸線に対して旋回しない、
光学部材の製造方法。 Equipped with a cutting process for cutting the laminated structure with a pair of rotary blades,
The laminated structure includes a plurality of laminated bodies laminated together,
The laminate comprises a plurality of optical films laminated together,
The laminated structure has two opposing end surfaces,
The two opposing end faces of the laminated structure are substantially parallel to the lamination direction of the laminated structure,
The upper and lower surfaces of the laminated structure are substantially perpendicular to the lamination direction,
The laminated structure is held by clamps in contact with the upper surface and the lower surface of the laminated structure,
The rotary blade extends along the stacking direction,
The side surface of the rotary blade is substantially parallel to the end surface of the laminated structure,
A rotation axis of the rotary blade is substantially parallel to a side surface of the rotary blade,
the side surface of one of the rotating blades is in contact with one of the end surfaces of the laminated structure,
the side surface of the other rotary blade is in contact with the other end surface of the laminated structure,
The two opposing end surfaces of the laminated structure are cut substantially simultaneously with a pair of rotary blades so that at least a portion of at least one of the end surfaces is not flat ,
In the process of cutting all the end faces of the laminated structure with the rotary blades, the positions at which the pair of rotary blades are installed are changed,
Throughout the process of cutting all the end surfaces of the laminated structure with the rotary blade, the clamp does not rotate about a rotation axis substantially parallel to the lamination direction,
A method for manufacturing an optical member. 積層構造体を一対の回転刃で切削する切削工程を備え、
前記積層構造体は、互いに積層された複数の積層体を含み、
前記積層体は、互いに積層された複数の光学フィルムを含み、
前記積層構造体は、対向する二つの端面を有し、
前記積層構造体の対向する二つの前記端面は、前記積層体の積層方向に略平行であり、
前記積層構造体の上面及び下面は、前記積層方向に略垂直であり、
前記積層構造体は、前記積層構造体の前記上面及び前記下面に接するクランプによって挟持されており、
前記回転刃は、前記積層方向に沿って延びており、
前記回転刃の側面は、前記積層構造体の前記端面に略平行であり、
前記回転刃の回転軸線は、前記回転刃の側面に略平行であり、
一方の前記回転刃の前記側面は、前記積層構造体の一方の前記端面に接し、
他方の前記回転刃の前記側面は、前記積層構造体の他方の前記端面に接し、
前記積層構造体の対向する二つの前記端面は、少なくとも一方の前記端面の少なくとも一部が平面とならないように、一対の前記回転刃で略同時に切削され、
二つの前記端面が一対の前記回転刃で略同時に切削されることにより、前記積層体の前記積層方向に延びる切欠き部が、二つの前記端面のうち少なくとも一方の前記端面に形成され、
前記切欠き部が、窪みである、
光学部材の製造方法。 Equipped with a cutting process for cutting the laminated structure with a pair of rotary blades,
The laminated structure includes a plurality of laminated bodies laminated together,
The laminate comprises a plurality of optical films laminated together,
The laminated structure has two opposing end surfaces,
The two opposing end faces of the laminated structure are substantially parallel to the lamination direction of the laminated structure,
The upper and lower surfaces of the laminated structure are substantially perpendicular to the lamination direction,
The laminated structure is held by clamps in contact with the upper surface and the lower surface of the laminated structure,
The rotary blade extends along the stacking direction,
The side surface of the rotary blade is substantially parallel to the end surface of the laminated structure,
A rotation axis of the rotary blade is substantially parallel to a side surface of the rotary blade,
the side surface of one of the rotating blades is in contact with one of the end surfaces of the laminated structure,
the side surface of the other rotary blade is in contact with the other end surface of the laminated structure,
The two opposing end surfaces of the laminated structure are cut substantially simultaneously with a pair of rotary blades so that at least a portion of at least one of the end surfaces is not flat ,
The two end faces are substantially simultaneously cut by the pair of rotary blades to form a notch portion extending in the stacking direction of the laminate in at least one of the two end faces,
The notch is a depression,
A method for manufacturing an optical member. 積層構造体を一対の回転刃で切削する切削工程を備え、
前記積層構造体は、互いに積層された複数の積層体を含み、
前記積層体は、互いに積層された複数の光学フィルムを含み、
前記積層構造体は、対向する二つの端面を有し、
前記積層構造体の対向する二つの前記端面は、前記積層体の積層方向に略平行であり、
前記積層構造体の上面及び下面は、前記積層方向に略垂直であり、
前記積層構造体は、前記積層構造体の前記上面及び前記下面に接するクランプによって挟持されており、
前記回転刃は、前記積層方向に沿って延びており、
前記回転刃の側面は、前記積層構造体の前記端面に略平行であり、
前記回転刃の回転軸線は、前記回転刃の側面に略平行であり、
一方の前記回転刃の前記側面は、前記積層構造体の一方の前記端面に接し、
他方の前記回転刃の前記側面は、前記積層構造体の他方の前記端面に接し、
前記積層構造体の対向する二つの前記端面は、少なくとも一方の前記端面の少なくとも一部が平面とならないように、一対の前記回転刃で略同時に切削され、
切削後の二つの前記端面のうち少なくとも一方の前記端面の全体が、曲面である、
光学部材の製造方法。 Equipped with a cutting process for cutting the laminated structure with a pair of rotary blades,
The laminated structure includes a plurality of laminated bodies laminated together,
The laminate comprises a plurality of optical films laminated together,
The laminated structure has two opposing end surfaces,
The two opposing end faces of the laminated structure are substantially parallel to the lamination direction of the laminated structure,
The upper and lower surfaces of the laminated structure are substantially perpendicular to the lamination direction,
The laminated structure is held by clamps in contact with the upper surface and the lower surface of the laminated structure,
The rotary blade extends along the stacking direction,
The side surface of the rotary blade is substantially parallel to the end surface of the laminated structure,
A rotation axis of the rotary blade is substantially parallel to a side surface of the rotary blade,
the side surface of one of the rotating blades is in contact with one of the end surfaces of the laminated structure,
the side surface of the other rotary blade is in contact with the other end surface of the laminated structure,
The two opposing end surfaces of the laminated structure are cut substantially simultaneously with a pair of rotary blades so that at least a portion of at least one of the end surfaces is not flat ,
At least one of the two end faces after cutting is entirely curved,
A method for manufacturing an optical member. 前記積層構造体の対向する二つの前記端面は、前記積層構造体の前記上面及び前記下面其々の長手方向に略平行である、
請求項１～３のいずれか一項に記載の光学部材の製造方法。 The two opposing end surfaces of the laminated structure are substantially parallel to the longitudinal directions of the upper surface and the lower surface of the laminated structure.
A method for manufacturing an optical member according to any one of claims 1 to 3 . 前記積層構造体の全ての端面を前記回転刃で切削する過程において、一対の前記回転刃が設置される位置は変わり、
前記積層構造体の全ての端面を前記回転刃で切削する過程において終始、前記クランプは前記積層方向に略平行な回転軸線に対して旋回しない、
請求項２又は３に記載の光学部材の製造方法。 In the process of cutting all the end faces of the laminated structure with the rotary blades, the positions at which the pair of rotary blades are installed are changed,
Throughout the process of cutting all the end surfaces of the laminated structure with the rotary blade, the clamp does not rotate about a rotation axis substantially parallel to the lamination direction,
4. A method for manufacturing an optical member according to claim 2 or 3 . 前記切削工程において、前記一対の前記回転刃は、前記積層構造体の対向する二つの前記端面に沿って移動する、
請求項１～５のいずれか一項に記載の光学部材の製造方法。 In the cutting step, the pair of rotary blades move along the two opposing end surfaces of the laminated structure.
A method for manufacturing an optical member according to any one of claims 1 to 5 . 前記切削工程において、一対の前記回転刃の間隔は変動し、
前記切削工程において、前記クランプは前記積層構造体の対向する二つの前記端面に略平行な方向に沿って移動する、
請求項１～６のいずれか一項に記載の光学部材の製造方法。 In the cutting step, the spacing between the pair of rotary blades varies,
In the cutting step, the clamp moves along a direction substantially parallel to the two opposing end surfaces of the laminated structure.
A method for manufacturing an optical member according to any one of claims 1 to 6 . 前記切削工程前に実施される加工工程を更に備え、
前記加工工程前の前記積層構造体の前記上面及び前記下面其々は、全ての角が直角である四辺形であり、
前記加工工程において、前記積層構造体の前記上面及び前記下面其々が前記四辺形と異なる形状になるように、前記積層構造体が加工される、
請求項１～７のいずれか一項に記載の光学部材の製造方法。 Further comprising a processing step performed before the cutting step,
each of the upper surface and the lower surface of the laminated structure before the processing step is a quadrilateral having all right angles;
In the processing step, the laminated structure is processed such that the upper surface and the lower surface of the laminated structure each have a shape different from the quadrilateral,
A method for manufacturing an optical member according to any one of claims 1 to 7 . 前記切削工程に用いられる前記積層構造体の前記上面及び前記下面其々は、全ての角が直角である四辺形であり、
前記切削工程において、前記積層構造体の前記上面及び前記下面其々が前記四辺形と異なる形状になるように、前記積層構造体の対向する二つの前記端面が、一対の前記回転刃で略同時に切削される、
請求項１～７のいずれか一項に記載の光学部材の製造方法。 each of the upper surface and the lower surface of the laminated structure used in the cutting step is a quadrilateral having all right angles;
In the cutting step, the two opposing end surfaces of the laminated structure are cut substantially simultaneously by the pair of rotary blades so that the upper surface and the lower surface of the laminated structure each have a shape different from the quadrilateral. be cut,
A method for manufacturing an optical member according to any one of claims 1 to 7 . 前記積層体は、少なくとも一つの粘着剤層を含む、
請求項１～９のいずれか一項に記載の光学部材の製造方法。 The laminate comprises at least one adhesive layer,
A method for manufacturing an optical member according to any one of claims 1 to 9 . 前記回転刃は、エンドミルである、
請求項１～１０のいずれか一項に記載の光学部材の製造方法。
The rotary blade is an end mill,
A method for manufacturing an optical member according to any one of claims 1 to 10 .
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JP2012203209A (en) 2011-03-25 2012-10-22 Sumitomo Chemical Co Ltd Method for manufacturing end face processed polarizing plate
JP2019018308A (en) 2017-07-20 2019-02-07 住友化学株式会社 Cutting device and polarizer manufacturing method

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JP2005157066A (en) 2003-11-27 2005-06-16 Nitto Denko Corp Method for cutting laminated sheet, laminated sheet, optical device, and image display device
JP2012203209A (en) 2011-03-25 2012-10-22 Sumitomo Chemical Co Ltd Method for manufacturing end face processed polarizing plate
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