WO2016072359A1 - Method for manufacturing polarization plate sheet - Google Patents
Method for manufacturing polarization plate sheet Download PDFInfo
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- WO2016072359A1 WO2016072359A1 PCT/JP2015/080677 JP2015080677W WO2016072359A1 WO 2016072359 A1 WO2016072359 A1 WO 2016072359A1 JP 2015080677 W JP2015080677 W JP 2015080677W WO 2016072359 A1 WO2016072359 A1 WO 2016072359A1
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- WIPO (PCT)
- Prior art keywords
- polarizing plate
- plate sheet
- protective film
- adhesive layer
- film
- Prior art date
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- 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
- G02B5/3041—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 comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—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 comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
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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
- B32B38/04—Punching, slitting or perforating
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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
- 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
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- 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
- G02B5/3041—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 comprising multiple thin layers, e.g. multilayer stacks
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
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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
- B32B38/04—Punching, slitting or perforating
- B32B2038/045—Slitting
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
Definitions
- the present invention relates to a method for producing a polarizing plate sheet with reduced undulation defects, which is preferably used in an image display device such as a liquid crystal display device.
- a polarizing plate used in an image display device such as a liquid crystal display device generally has a laminated structure in which a protective film is bonded to one or both sides of a polarizer via an adhesive layer, and a long polarizer and Using a long protective film, it is produced as a long product (polarizing plate roll) by a roll-to-roll method [for example, JP 2009-134190 A (Patent Document 1)].
- the obtained long polarizing plate is cut into a sheet of a predetermined size according to the screen size of the image display device, and is laminated to an image display element such as a liquid crystal cell using an adhesive layer or the like. Embedded in an image display device.
- Patent Document 1 as a method for suppressing a problem called reverse curling and wave curling that occurs in a polarizing plate, a long polarizer and a long protective film are laminated with an adhesive interposed therebetween. It is described that an adhesive is polymerized and cured while the laminate is in close contact with a convex curved surface formed in an arc shape along the longitudinal direction of the laminate.
- an object of the present invention is to provide a method for producing a polarizing plate sheet having a reduced number or height of undulating defects.
- a rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof, and having a long side and a short side, wherein at least one of the long sides is 1
- a method for producing a polarizing plate sheet comprising:
- the first polarizing plate sheet includes the polarizer, a first protective film laminated on one surface of the polarizer through a first adhesive layer, and a second adhesive on the other surface.
- the first polarizing plate sheet has the following (a) and (b): (A) a protective film laminated on the protective film; (B) The adhesive layer according to any one of [1] to [7], further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on the outer surface thereof. Manufacturing method.
- the present invention it is possible to provide a polarizing plate sheet having a reduced number or height of undulating defects.
- the present invention is capable of reducing wavy defects to a sufficient extent even for polarizing plate sheets having four or more or wavy defects whose height exceeds 2 mm. Can provide a method.
- the manufacturing method of the polarizing plate sheet according to the present invention includes the following steps: (1) A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides is 1 A step of preparing a first polarizing plate sheet having at least one wavy defect, and (2) slit removing an end portion including the long side having the wavy defect in the first polarizing plate sheet; A step of obtaining a polarizing plate sheet, including.
- each step will be described.
- the first polarizing plate sheet has a undulating defect, and is likely to be accompanied by the above-described problem of bubble mixing and accompanying visibility deterioration. Specifically, it is a polarizing plate sheet that has one or more undulation defects on at least one of the long sides. As a result of further occurrence of undulation defects, the first polarizing plate sheet has undulation defects whose height exceeds 2 mm on at least any one long side, or at least four on at least any one long side. It may be a polarizing plate sheet having undulating defects, and the first polarizing plate sheet has four or more undulating defects on at least one of the long sides, and these undulating defects. Any one or more of the above may be a waving defect whose height exceeds 2 mm.
- the height of the undulating defect is the height from the flat table to the top of the undulating defect when the first polarizing plate sheet is placed on the flat table.
- the first polarizing plate sheet is displayed as an image.
- the surface to be bonded to the element (for example, a liquid crystal cell) is placed on a flat table with the surface facing up.
- the height of the undulation defect is measured at the side (end) of the first polarizing plate sheet.
- the number of undulating defects is substantially the number of undulating defects. Specifically, when the first polarizing plate sheet is placed on a flat table, the height is 0 from the flat table. It is the number of undulating defects that are 5 mm or more. The number of wavy defects is also measured at the side (edge) of the first polarizing plate sheet.
- the first polarizing plate sheet has a rectangular shape having a long side and a short side, and is typically a rectangle.
- the lengths of the long side and the short side are not particularly limited, but the long side of the first polarizing plate sheet is usually 700 mm or more and the short side is 400 mm or more.
- the size of the first polarizing plate sheet is larger, the waviness defect is more prominent in the height and number of waviness. If the size (long side and / or short side) is too small, the problem of undulation defects itself is less likely to occur.
- the first polarizing plate sheet is a polarizing plate in which the above-described wavy defects are generated in the process of storing and transporting under some conditions after cutting the polarizing plate manufactured as a long product. it can.
- the first polarizing plate having a wavy defect whose height exceeds 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side.
- the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side may have a wavy defect also on two short sides.
- the wavy defects that occur on the two short sides tend to be smaller in height and / or number than the wavy defects that occur on the long sides, and the wavy defects on the short sides are Compared to this, there is a tendency that the problem of air bubbles is less likely to occur. Therefore, in order to suppress the problem of mixing of bubbles and the accompanying deterioration in visibility, it is important to reduce the undulation defect that occurs on the long side.
- the layer configuration of the first polarizing plate sheet is not particularly limited as long as it includes a polarizer and a protective film laminated and bonded on at least one surface thereof, and the protective film is laminated and bonded on both surfaces of the polarizer. May be.
- the protective film is usually laminated and bonded onto the polarizer via an adhesive layer.
- the first polarizing plate sheet may have a layer (or film) other than the polarizer and the protective film.
- a polarizing plate produced as a long product and a polarizing plate sheet obtained by cutting the polarizing plate have a pressure-sensitive adhesive layer for bonding to an image display element (for example, a liquid crystal cell) on the outer surface of the polarizing plate in advance.
- an image display element for example, a liquid crystal cell
- the first polarizing plate sheet can also include such an adhesive layer.
- a separate film (separator) for protecting the surface (outer surface) is usually laminated on the outer surface of the adhesive layer.
- a polarizing plate produced as a long product is usually stored or distributed as a polarizing plate roll formed by winding the polarizing plate.
- the protective film is used.
- a protective film surface protective film
- a polarizing plate sheet obtained by cutting the polarizing plate generally has a protective film.
- the first polarizing plate sheet may include a protective film laminated on the protective film.
- the protective film of the first polarizing plate sheet has a hard coat layer, an antiglare layer, an antireflection layer, an antistatic layer, an antifouling layer on the outer surface (the surface opposite to the polarizer).
- a surface treatment layer (coating layer) may be provided.
- the 1st polarizing plate sheet can contain the layer or film which has optical functions other than a polarizer.
- One example is a retardation film.
- a first polarizing plate sheet 1 shown in FIG. 1 includes a polarizer 10; a first protective film 20 that is bonded to one surface of the polarizer 10; a first film that is bonded to the other surface of the polarizer 10. 2 protective film 30; adhesive layer 40 laminated on the outer surface of the second protective film 30; separate film 50 laminated on the outer surface of the adhesive layer 40; a protective film 60 laminated on the outer surface of the first protective film 20 Including.
- the layer configuration having the pressure-sensitive adhesive layer 40 and the separate film 50, the layer configuration having the protective film 60, or the pressure-sensitive adhesive layer 40 is an example of a preferable layer structure of the first polarizing plate sheet.
- the pressure-sensitive adhesive layer 40 may be directly laminated on the polarizer 10 by omitting one of the first protective film 20 and the second protective film 30.
- the polarizer 10 is an optical film having a property of absorbing linearly polarized light having a vibration plane parallel to the optical axis and transmitting linearly polarized light having a vibration plane perpendicular to the optical axis.
- the polarizer 10 is uniaxially stretched and has two colors. It can be a polyvinyl alcohol-based resin film in which a functional dye is adsorbed and oriented.
- the dichroic dye iodine or a dichroic organic dye is used.
- the polyvinyl alcohol-based resin constituting the polarizer 10 includes polyvinyl alcohol, which is a saponified product of polyvinyl acetate, and a copolymer of vinyl acetate and other monomers copolymerizable therewith (for example, ethylene and unsaturated carboxylic acid). It may be a vinyl alcohol copolymer which is a saponified product.
- the thickness of the polarizer 10 is usually about 5 to 40 ⁇ m.
- the polarizer 10 includes a step of uniaxially stretching a polyvinyl alcohol-based resin film, a step of dyeing the polyvinyl alcohol-based resin film with a dichroic dye and adsorbing the dichroic dye, and polyvinyl alcohol on which the dichroic dye is adsorbed. It can manufacture by the method of including the process of wash
- the dichroic dye can be dyed by immersing the film in an aqueous solution containing the dichroic dye, and the treatment with the boric acid aqueous solution can be performed by immersing the film in the boric acid aqueous solution.
- the uniaxial stretching of the polyvinyl alcohol-based resin film can be performed before, simultaneously with, or after the dyeing of the dichroic dye.
- this uniaxial stretching may be performed before boric acid treatment or during boric acid treatment. Moreover, you may uniaxially stretch in these several steps.
- the first and second protective films 20 and 30 can be a thermoplastic resin film having translucency (preferably optically transparent).
- thermoplastic resins include polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.) and cyclic polyolefin resins (norbornene resins, etc.); polyester resins (polyethylene terephthalate resins, etc.); ) Acrylic resin (methyl methacrylate resin etc.); Cellulosic resin (cellulose acetate resin such as triacetyl cellulose [TAC], diacetyl cellulose etc.); Polycarbonate resin; Polyvinyl alcohol resin; Polyvinyl acetate resin Polyarylate resins; polystyrene resins; polyethersulfone resins; polysulfone resins; polyamide resins; polyimide resins; and mixtures and copolymers thereof.
- polyolefin resins such as chain polyolefin resins (polypropylene resins,
- the thickness of the first and second protective films 20 and 30 is, for example, about 5 to 200 ⁇ m, preferably 10 to 150 ⁇ m, and more preferably 15 to 100 ⁇ m.
- (meth) acryl means at least one selected from acryl and methacryl.
- the 1st protective film 20 and the 2nd protective film 30 may be comprised with the same kind of thermoplastic resin, and may be comprised with a different kind of thermoplastic resin, but are comprised with a different kind of thermoplastic resin.
- the moisture permeability of the protective films bonded to both surfaces is different from each other, such as in the case where the moisture film absorbs moisture, the undulation defect is particularly likely to occur due to the difference in hygroscopicity. Therefore, the present invention is particularly advantageous in such a case.
- the difference in moisture permeability of the protective films bonded on both sides is 30 g / (m 2 ⁇ 24 hr) or more, further 50 g / (m 2 ⁇ 24 hr) or more, and even more 100 g / (m 2 Even if it is 24 hr) or more, and more particularly 300 g / (m 2 ⁇ 24 hr) or more, it is possible to obtain a polarizing plate sheet that is less likely to cause undulation defects and is less likely to cause problems of air bubbles and associated visibility degradation. it can.
- the difference in the water vapor transmission rate of the protective film bonded to both surfaces is 900 g / (m 2 ⁇ 24 hr) or less.
- the moisture permeability is a moisture permeability at a temperature of 40 ° C. and a relative humidity of 90%, and is measured by a cup method defined in JIS Z 0208.
- Examples of combinations of protective films having a difference in moisture permeability of 30 g / (m 2 ⁇ 24 hr) at a temperature of 40 ° C. and a relative humidity of 90% include, for example, a cellulose resin film (TAC film, etc.) and a cyclic polyolefin resin , A combination of a cellulose resin film (TAC film or the like) and a (meth) acrylic resin film, a combination of a cyclic polyolefin resin and a (meth) acrylic resin film, or the like.
- the thermoplastic resin which comprises the protective film bonded on both surfaces is the same kind, a difference may arise in a water vapor transmission rate by the presence or absence of a surface treatment layer laminated
- the polarizer 10, the first protective film 20, and the second protective film 30 can be bonded via an adhesive layer.
- an adhesive layer a water-based adhesive, that is, an adhesive component dissolved or dispersed in water, or an active energy ray-curable adhesive can be used.
- the adhesive component of the water-based adhesive can be, for example, a polyvinyl alcohol resin or a urethane resin.
- the active energy ray-curable adhesive can be, for example, a curable composition containing an active energy ray-curable compound such as an epoxy compound or a (meth) acrylic compound and a polymerization initiator.
- the active energy ray-curable adhesive can be a solventless adhesive, but can also contain an organic solvent. If a solventless type adhesive is used, a drying process for removing the solvent becomes unnecessary.
- the active energy ray-curable adhesive When an active energy ray-curable adhesive is used, after bonding a protective film through an adhesive layer, the active energy rays such as visible light, ultraviolet rays, X-rays, electron beams, etc., preferably ultraviolet rays are irradiated and bonded.
- the agent layer is cured. Therefore, in this case, the adhesive layer in the first polarizing plate sheet is made of a cured product of an active energy ray-curable adhesive.
- the 1st adhesive layer which bonds 1 protective film 20, and the 2nd adhesive layer which bonds 2nd protective film 30 may be formed from the same kind of adhesives, and are formed from a different kind of adhesives. However, it is preferably formed from the same kind of adhesive from the viewpoint of production efficiency.
- the present invention is particularly advantageous.
- an adhesive which comprises the adhesive layer 40 for bonding to an image display element for example, a (meth) acrylic adhesive, a urethane adhesive, a silicone adhesive, a polyester adhesive, Examples thereof include a polyamide-based adhesive, a polyether-based adhesive, a fluorine-based adhesive, and a rubber-based adhesive.
- a (meth) acrylic pressure-sensitive adhesive is preferably used from the viewpoints of transparency, adhesive strength, reliability, reworkability, and the like.
- the thickness of the pressure-sensitive adhesive layer 40 is usually 2 to 40 ⁇ m.
- the separate film 50 and the protect film 60 are provided for the purpose of temporarily protecting the adhesive layer 40 and the first protective film 20 when the polarizing plate is stored, transported, or inspected.
- the separate film 50 that protects the pressure-sensitive adhesive layer 40 is peeled and removed immediately before the second polarizing plate sheet described below is put to practical use (for example, bonded to an image display element such as a liquid crystal cell).
- the protective film 60 is usually peeled and removed together with the pressure-sensitive adhesive layer after the second polarizing plate sheet is put into practical use (for example, bonded to an image display element such as a liquid crystal cell).
- the separate film 50 is usually composed of a thermoplastic resin film having a release treatment on one side, and the release treatment surface is bonded to the pressure-sensitive adhesive layer 40.
- the protect film 60 is usually configured by providing an adhesive layer on one side of a thermoplastic resin film.
- the thermoplastic resin constituting the separate film 50 and the protect film 60 may be, for example, a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, or a polyester resin such as polyethylene terephthalate or polyethylene naphthalate. it can.
- the description of the pressure-sensitive adhesive layer 40 described above is cited.
- the layer configuration of the first polarizing plate sheet is not limited to the example shown in FIG. 1, and may be the following layer configuration, for example.
- An example of the above [b] is a configuration in which the second protective film 30 is omitted, and a preferred specific example thereof is that the pressure-sensitive adhesive layer 40 is directly laminated on the surface of the polarizer 10 opposite to the first protective film 20.
- the protective film 60 / first protective film 20 / polarizer 10 / adhesive layer 40 / separate film 50 are layered.
- a preferred specific example of the above [c] is a protective film 60 / first protective film 20 / polarizer 10 / retardation film (second protective film 30) / adhesive layer 40 / separate film 50 layer structure. It is.
- a preferred specific example of the above [d] is a protective film 60 / first protective film 20 / polarizer 10 / second protective film 30 / retardation film / adhesive layer 40 / separate film 50 layer structure. is there. In this case, the 2nd protective film 30 and retardation film can be bonded through an adhesive layer, for example.
- the retardation film is an optical film having optical anisotropy such as uniaxial or biaxial, and can be, for example, a stretched film of a thermoplastic resin.
- the thermoplastic resin can be the one exemplified above for the first and second protective films 20 and 30, as well as polyvinylidene fluoride / polymethyl methacrylate copolymer, liquid crystal polyester, acetyl cellulose, ethylene-vinyl acetate.
- a saponified copolymer, polyvinyl chloride, or the like can also be used.
- the draw ratio is usually about 1.01 to 6 times.
- Step of obtaining a second polarizing plate sheet This step is a process of obtaining a long side end portion of the first polarizing plate sheet having one or more wavy defects on at least one of the long sides (the wavy defect is removed). This is a step of obtaining a second polarizing plate sheet with reduced waviness defects by slit-removing the end portion including the long side.
- Conventionally known cutting (cutting) means such as a shear cutter can be used for the slit.
- the first polarizing plate sheet has a protective film 60 laminated on the protective film, and / or a pressure-sensitive adhesive layer 40 laminated on the polarizer 10 or the protective film, and a separate film 50 laminated on the outer surface thereof.
- the first polarizing plate sheet having a wavy defect at the end may be accompanied by an appearance defect in which the color of the end becomes dark.
- This poor appearance is caused by a shift in the interface between the thermoplastic resin film constituting the protective film 60 and the pressure-sensitive adhesive layer or the interface between the separate film 50 and the pressure-sensitive adhesive layer 40 due to the stress at the time when the wavy defect occurs. This is thought to be due to the rough surface of the layer.
- the surface of the pressure-sensitive adhesive layer 40 is rough, there is a possibility that an appearance defect may remain even after being bonded to an image display element such as a liquid crystal cell.
- a slit is removed by this step so as to remove the defective appearance portion, a polarizing plate sheet having good appearance quality can be obtained even in terms of color.
- ⁇ Slit removal is performed on the long side end portion having the undulation defect.
- the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side. Therefore, typically, slit removal is performed on both long side end portions.
- the width W1 at the end of the long side to be slit-removed is reduced in the case of a polarizing plate sheet having a wavy defect having a height exceeding 2 mm or four or more wavy defects in at least one of the long sides. From the viewpoint of effect, it is preferably 65 mm or more per one end. It should be noted that as long as the first polarizing plate sheet is the above-described normal size (long side 700 mm or more and short side 400 mm or more), the long side end portion is preferably 65 mm or more regardless of the size. By removing with the slit width W1, it is possible to obtain a good undulating defect reduction effect.
- the slit width W1 is more preferably 70 mm or more, more preferably 80 mm or more, still more preferably 100 mm or more, and particularly preferably 140 mm, per one end. That's it.
- the wavy defects that can occur in the two short sides tend to be smaller in height and / or number than the wavy defects that occur in the long side, and the wavy defects in the short side
- the undulation defect has occurred.
- the short side edge part one end part or both end parts
- the slit width W2 at the short side end can be, for example, 35 mm or more, preferably 40 mm or more, more preferably 45 mm or more, per one end.
- the second polarizing plate is reduced in size from the first polarizing plate sheet by removing one or both of the short side ends.
- Leaf bodies may be obtained.
- the long side edge and the short side edge of the 46-inch size (long side 1031 mm ⁇ short side 585 mm) first polarizing plate sheet are slit to remove a 39 inch size (long side).
- the slit may be removed to obtain a second polarizing plate sheet having a size of 32 inches (long side 700 mm ⁇ short side 400 mm).
- the long side end is 65 mm or more per one end.
- the slit width W1 is removed, only one of the two long side ends may be removed by slit, or both of the long side ends may be removed by slit.
- only one of the two short side ends may be slit removed, or both short side ends may be slit removed.
- the polarizing plate sheet is placed on a flat table with the separate film 50 side facing upward, and the number of wavy defects on the two long sides of the polarizing plate sheet (the height is 0 from the flat table as described above). , And the height of the undulating defect from the plane table was measured.
- Table 1 shows the number and height of undulating defects on the long side having more undulating defects among the two long sides. The height of the undulating defect shown in Table 1 is the highest height of the undulating defect when having a plurality of undulating defects.
- first polarizing plate sheet A long polarizing plate having the layer structure shown in FIG. 1 was prepared.
- This polarizing plate is composed of a protective film 60 having a thickness of 53 ⁇ m (consisting of a (meth) acrylic pressure-sensitive adhesive layer and a polyethylene terephthalate film) / first protective film 20 having a thickness of 60 ⁇ m (TAC film) / a polarizer having a thickness of 25 ⁇ m.
- first protective film 20 and the second protective film 30 are an active energy ray-curable adhesive (a UV curable adhesive containing a curable compound that is a cationic polymerizable epoxy compound and a photocationic polymerization initiator).
- the moisture permeability of the first protective film 20 and the second protective film 30 at 40 ° C. and 90% relative humidity was 560 g / (m 2 ⁇ 24 hr) and 5 g / (m 2 ⁇ 24 hr), respectively.
- Example 2 The first polarized light of 46 inch size (long side: 1031 mm ⁇ short side: 585 mm) having a long side of 3.5 mm and a number of wavy defects of 4 mm obtained in the same manner as in Experimental Example 1 above. Use a shear cutter to slit the two long side edges of the plate sheet body by 85.5 mm per one end, and slit the two short side edges by 47.5 mm per one end. Thus, a second polarizing plate sheet reduced in size to 39 inches (long side 860 mm ⁇ short side 490 mm) was obtained.
- first polarizing plate sheet 10 polarizer, 20 first protective film, 30 second protective film, 40 adhesive layer, 50 separate film, 60 protective film.
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Abstract
Description
[1]偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか1つの長辺において1個以上の波打ち欠陥を有する第1偏光板枚葉体を用意する工程と、
前記第1偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部をスリット除去して、第2偏光板枚葉体を得る工程と、
を含む、偏光板枚葉体の製造方法。 This invention provides the manufacturing method of the polarizing plate sheet shown below.
[1] A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof, and having a long side and a short side, wherein at least one of the long sides is 1 Preparing a first polarizing plate sheet having one or more wavy defects;
Slit removing the end including the long side having the undulation defect in the first polarizing plate sheet to obtain a second polarizing plate sheet;
A method for producing a polarizing plate sheet comprising:
(a)前記保護フィルム上に積層されるプロテクトフィルム、
(b)前記偏光子上又は前記保護フィルム上に積層される粘着剤層と、その外面に積層されるセパレートフィルム
の少なくともいずれか一方をさらに含む、[1]~[7]のいずれかに記載の製造方法。 [8] The first polarizing plate sheet has the following (a) and (b):
(A) a protective film laminated on the protective film;
(B) The adhesive layer according to any one of [1] to [7], further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on the outer surface thereof. Manufacturing method.
(1)偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか1つの長辺において1個以上の波打ち欠陥を有する第1偏光板枚葉体を用意する工程、並びに
(2)第1偏光板枚葉体における上記波打ち欠陥を有する長辺を含む端部をスリット除去して、第2偏光板枚葉体を得る工程、
を含む。以下、各工程について説明する。 The manufacturing method of the polarizing plate sheet according to the present invention includes the following steps:
(1) A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides is 1 A step of preparing a first polarizing plate sheet having at least one wavy defect, and (2) slit removing an end portion including the long side having the wavy defect in the first polarizing plate sheet; A step of obtaining a polarizing plate sheet,
including. Hereinafter, each step will be described.
第1偏光板枚葉体は、波打ち欠陥が進行しており、上述したような気泡混入やそれに伴う視認性低下の問題を伴いやすい偏光板枚葉体であり、具体的には、少なくともいずれか1つの長辺において1個以上の波打ち欠陥を有する偏光板枚葉体である。第1偏光板枚葉体は、波打ち欠陥がさらに生じた結果、少なくともいずれか1つの長辺において高さが2mmを超える波打ち欠陥を有するか、又は少なくともいずれか1つの長辺において4個以上の波打ち欠陥を有する偏光板枚葉体であってもよく、第1偏光板枚葉体は、少なくともいずれか1つの長辺において4個以上の波打ち欠陥を有しており、かつ、これらの波打ち欠陥のいずれか1つ以上が、高さが2mmを超える波打ち欠陥であってもよい。 (1) Step of preparing first polarizing plate sheet The first polarizing plate sheet has a undulating defect, and is likely to be accompanied by the above-described problem of bubble mixing and accompanying visibility deterioration. Specifically, it is a polarizing plate sheet that has one or more undulation defects on at least one of the long sides. As a result of further occurrence of undulation defects, the first polarizing plate sheet has undulation defects whose height exceeds 2 mm on at least any one long side, or at least four on at least any one long side. It may be a polarizing plate sheet having undulating defects, and the first polarizing plate sheet has four or more undulating defects on at least one of the long sides, and these undulating defects. Any one or more of the above may be a waving defect whose height exceeds 2 mm.
〔b〕第1保護フィルム20及び第2保護フィルム30のいずれか一方を省略した構成、
〔c〕第2保護フィルム30として位相差フィルムのような光学補償フィルムを用いる構成、
〔d〕第1保護フィルム20及び第2保護フィルム30に加えて、位相差フィルムのような光学補償フィルムを有する構成。 [A] Configuration in which any one or more of the pressure-
[B] a configuration in which one of the first
[C] a configuration using an optical compensation film such as a retardation film as the second
[D] A configuration having an optical compensation film such as a retardation film in addition to the first
本工程は、少なくともいずれか1つの長辺において1個以上の波打ち欠陥を有する第1偏光板枚葉体の長辺端部(当該波打ち欠陥を有する長辺を含む端部)をスリット除去して、当該波打ち欠陥が低減された第2偏光板枚葉体を得る工程である。スリットには、シアーカッター等の従来公知の裁断(切断)手段を用いることができる。 (2) Step of obtaining a second polarizing plate sheet This step is a process of obtaining a long side end portion of the first polarizing plate sheet having one or more wavy defects on at least one of the long sides (the wavy defect is removed). This is a step of obtaining a second polarizing plate sheet with reduced waviness defects by slit-removing the end portion including the long side. Conventionally known cutting (cutting) means such as a shear cutter can be used for the slit.
セパレートフィルム50側を上向きにして、偏光板枚葉体を平面台に載置し、偏光板枚葉体の2つの長辺における波打ち欠陥の数(上述のように、高さが平面台から0.5mm以上である波打ち欠陥に限る。)、及び波打ち欠陥の平面台からの高さをそれぞれ測定した。表1には、2つの長辺のうち、より多くの波打ち欠陥を有する長辺における波打ち欠陥の数及び高さを記載している。表1に記載の波打ち欠陥の高さは、複数の波打ち欠陥を有する場合には、最も高い波打ち欠陥の高さである。 (Number and height of undulating defects)
The polarizing plate sheet is placed on a flat table with the
〔1〕第1偏光板枚葉体の作製
図1に示される層構成を有する長尺状の偏光板を用意した。この偏光板の層構成は、厚み53μmのプロテクトフィルム60((メタ)アクリル系粘着剤層とポリエチレンテレフタレートフィルムとからなる)/厚み60μmの第1保護フィルム20(TACフィルム)/厚み25μmの偏光子10(ヨウ素が吸着配向している一軸延伸ポリビニルアルコールフィルム)/厚み52μmの第2保護フィルム30(環状ポリオレフィン系樹脂からなる位相差フィルム)/厚み20μmの粘着剤層40((メタ)アクリル系粘着剤層)/厚み38μmのセパレートフィルム50(片面に離型処理が施されたポリエチレンテレフタレートフィルム)である。第1保護フィルム20及び第2保護フィルム30はともに、活性エネルギー線硬化性接着剤(カチオン重合性のエポキシ系化合物である硬化性化合物と光カチオン重合開始剤とを含む紫外線硬化性接着剤である(株)ADEKA製の「KR-70T」)の硬化物からなる接着剤層を介して偏光子10に貼合されている。また、第1保護フィルム20及び第2保護フィルム30の40℃、相対湿度90%における透湿度は、それぞれ、560g/(m2・24hr)、5g/(m2・24hr)であった。 <Experimental example 1>
[1] Production of first polarizing plate sheet A long polarizing plate having the layer structure shown in FIG. 1 was prepared. This polarizing plate is composed of a
上で得られた第1偏光板枚葉体における、波打ち高さが3.5mmであり、波打ち欠陥の数が5個である長辺端部を、シアーカッターを用いて10mmの幅でスリット除去し、スリット後の第2偏光板枚葉体の長辺における波打ち欠陥の高さ及び数を測定した。この操作をトータルのスリット幅(スリット幅W1)が170mmになるまで繰り返し、スリット幅W1と波打ち欠陥低減効果との関係について調べた。結果を表1に示す。 [2] Fabrication of second polarizing plate sheet (removal of slits at end of long side)
In the first polarizing plate sheet obtained above, the long edge of the corrugated height of 3.5 mm and the number of corrugated defects of 5 is removed with a shear cutter to a width of 10 mm. Then, the height and number of undulation defects on the long side of the second polarizing plate sheet after the slit were measured. This operation was repeated until the total slit width (slit width W1) reached 170 mm, and the relationship between the slit width W1 and the wavy defect reduction effect was examined. The results are shown in Table 1.
上記実験例1と同様にして得られた波打ち高さが3.5mmであり、波打ち欠陥の数が4個である長辺を有する46インチサイズ(長辺1031mm×短辺585mm)の第1偏光板枚葉体における2つの長辺端部を、シアーカッターを用いて、片端部あたり85.5mmずつスリット除去するとともに、2つの短辺端部を、片端部あたり47.5mmずつスリット除去することによって、39インチサイズ(長辺860mm×短辺490mm)にサイズダウンされた第2偏光板枚葉体を得た。この第2偏光板枚葉体について、波打ち高さが3.5mmであり、波打ち欠陥の数が4個である第1偏光板枚葉体の長辺に相当する長辺における波打ち欠陥の高さ及び数を測定した。結果を表2に示す。 <Experimental example 2>
The first polarized light of 46 inch size (long side: 1031 mm × short side: 585 mm) having a long side of 3.5 mm and a number of wavy defects of 4 mm obtained in the same manner as in Experimental Example 1 above. Use a shear cutter to slit the two long side edges of the plate sheet body by 85.5 mm per one end, and slit the two short side edges by 47.5 mm per one end. Thus, a second polarizing plate sheet reduced in size to 39 inches (long side 860 mm × short side 490 mm) was obtained. About this 2nd polarizing plate sheet, the height of the undulation defect in the long side corresponding to the long side of the 1st polarizing plate sheet whose wave height is 3.5mm and the number of undulation defects is four. And the number was measured. The results are shown in Table 2.
Claims (8)
- 偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか1つの長辺において1個以上の波打ち欠陥を有する第1偏光板枚葉体を用意する工程と、
前記第1偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部をスリット除去して、第2偏光板枚葉体を得る工程と、
を含む、偏光板枚葉体の製造方法。 A polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides has at least one Preparing a first polarizing plate sheet having undulation defects;
Slit removing the end including the long side having the undulation defect in the first polarizing plate sheet to obtain a second polarizing plate sheet;
A method for producing a polarizing plate sheet comprising: - 前記第1偏光板枚葉体を用意する工程において、前記少なくともいずれか1つの長辺において有する波打ち欠陥が4個以上である、請求項1に記載の製造方法。 The manufacturing method according to claim 1, wherein, in the step of preparing the first polarizing plate sheet, there are four or more undulating defects on at least one of the long sides.
- 前記第1偏光板枚葉体を用意する工程において、前記少なくともいずれか1つの長辺において有する波打ち欠陥の高さが2mmを超える、請求項1又は2に記載の製造方法。 The manufacturing method according to claim 1 or 2, wherein, in the step of preparing the first polarizing plate sheet, a height of a wavy defect on at least one of the long sides exceeds 2 mm.
- 前記第2偏光板枚葉体を得る工程において、前記第1偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部を65mm以上の幅でスリット除去する、請求項1~3のいずれか1項に記載の製造方法。 4. The step of obtaining the second polarizing plate sheet includes slit-removing an end including a long side having the wavy defect in the first polarizing plate sheet with a width of 65 mm or more. The production method according to claim 1.
- 前記第1偏光板枚葉体は、前記偏光子と、その一方の面上に第1接着剤層を介して積層される第1保護フィルムと、他方の面上に第2接着剤層を介して積層される第2保護フィルムと、を含む、請求項1~4のいずれか1項に記載の製造方法。 The first polarizing plate sheet includes the polarizer, a first protective film laminated on one surface of the polarizer through a first adhesive layer, and a second adhesive layer on the other surface. The manufacturing method according to any one of claims 1 to 4, further comprising a second protective film laminated in a stacked manner.
- 前記第1保護フィルムと前記第2保護フィルムとは、温度40℃、相対湿度90%での透湿度が30g/(m2・24hr)以上異なる、請求項5に記載の製造方法。 The manufacturing method according to claim 5, wherein the first protective film and the second protective film differ in moisture permeability at a temperature of 40 ° C. and a relative humidity of 90% by 30 g / (m 2 · 24 hr) or more.
- 前記第1接着剤層及び前記第2接着剤層の少なくともいずれか一方は、活性エネルギー線硬化性接着剤の硬化物からなる、請求項5又は6に記載の製造方法。 The manufacturing method according to claim 5 or 6, wherein at least one of the first adhesive layer and the second adhesive layer is made of a cured product of an active energy ray-curable adhesive.
- 前記第1偏光板枚葉体は、下記(a)及び(b):
(a)前記保護フィルム上に積層されるプロテクトフィルム、
(b)前記偏光子上又は前記保護フィルム上に積層される粘着剤層と、その外面に積層されるセパレートフィルム
の少なくともいずれか一方をさらに含む、請求項1~7のいずれか1項に記載の製造方法。 The first polarizing plate sheet has the following (a) and (b):
(A) a protective film laminated on the protective film;
(B) The adhesive layer according to any one of claims 1 to 7, further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on an outer surface thereof. Manufacturing method.
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